OA-l SECTION OA

GENERAL INFORMATION
VEHICLE SPECIFICATIONS IDENTIFICATION OF VEHICLE STANDARD TIGHTENING TORQUE . VEHICLE LlFTING POINTS CAUTIONS PRE-DELlVERY INSPECTION . . . . . . OA- 2 OA- 4 OA- 7 OA- 8 OA-10 OA-12

OA2

VEHICLE SPECIFICATIONS
llom l. Olmenslon Overallcngln Ovarall wldlh OvaraY hlghl W_base Tread. (mm) (mm) (mm)
(mm) 3,340

Slandard Valve.

110m
Inlllke

SIAndard Open - 12 (BTOC) CIos<! - 36 Open(A BOC) 45 ( B80C) Closo100'(A TOC) InLake 015 iOO2

e.lIau.t
Valve c"'arane Cotd HOI (mm)

1.400 1.395 2.335

Elcha..el 020 '002

(mm)

Fronr (mm) Rea, (mm) MonimumglOtnl c!ea,ance (mm)

1.220 1,200
160
6, Fuel $yalom

Intako 0,25'0,02 ExhaUSi O,30>002

2. Welghl V""dewo~1 G,oss vehlcla woighl 3. Perfonnanco Maxlmum .pead (kmIh) (tan 8) G,adabilrty Minirnum lurning radius, (mm) Len RlgIrt (mm) 4. Englno EngIMtype Bar. x Slro~e No. of Cy1inde' P'SlOndlsplacernonl Compression ratio Fac.l.ad gaso~ne (mm)
(ce)

(kg) (kg)

620

895

Cart>uretO< Fuelpump Fuel

2 ea.... 00"" d",tt

o.uphragm Iypc
Fillor llemonl

,~I(),

Ga>aoIy 01fUe! ""'" 143

7, LubtlcaUon s'Istom

(1)

eo

0.382
43
4.4

Type ollubllcahon Oilpump

00I1il1o,
Capa.ily o, oi' (Ir>e 001F'14te<) (1)

I
I

Splash ond 'o,co leed Trochold pump type f\.ter ere"""'1

2,5
(2.7)

68,5><72.0
3 CyindolS
7Q6 9,3

8. Coollng ,yslem
Type of cool"9 sy51em Walerpump ThetmOllal (1) Capoc,ty01cooIanl Coolanl Waxpalet
Axial

"ow

M'lJ(1mum po_
Maximtm 10rqve

(psItpm) (kg. nVrpm)

4115.500 6,012.500

5. Ignition .y.tem Type 01'on'llon systom Ignilion limng Firing ordo, Type o, ignltion plug Fullltansi,tor BTOC.8'/950,pm 1-3-2 RNIIYC

('I'pm)

OA3

110m
9, Trllnsmission
1st

Standard 4speed

lIem 14, Suspension Systtm

Standard

5 speed

3,616
2210

3818
2.210

fronl

2nd
3rd 4th

Re.,

l.Iaq""'rson

SltUI

1423 0971
3.583

1.423 0971
0.837

lsoIatOO l1aiIing Ink. lorsoon bean

Gastype GOltspnng

51h
Rea, lO. Ctutch Type 01 elutch
plate

3.583

Shock absorbe, Sprlftg Stabll1zer. Frenl Aear

Torsioo bar Lateral roo

15,
Ory. songfe

EI.ctlle.t

avat.m

d.aph,agm F""'IOgdoncnsron
11, arake (mm)

Sallery
Ailemalo' Start.ng molo<
Slartlng

(V. AH) (VA)

12-28

170x 110~3 2

12-50
Magnellc shJt 0,8
,1

moIor pawer

lkW)

Fronl Roo, 12. Axle

Dlsc
O'\lrn

16. Tire Front 135 SR 12 1155170 R 12) 135 SR 12 (155170 R 12)

Type ol Iront axJe

Type 01 'ea! a~1o 13. Steering systcm Type 01 steerlrlg

Sa' ()<nItype
Integral 8lde lyp8

Rear

Recka P,OIon
( ) ( ) (mm)

Steefing anglo. runor

Outar Tos-ln

Sleering wheel dlamOIOf(mm)

42 35 365
1 2

Camber
casrer

()
()

3O~1
;; 35'il 12 S

KIIlgpt, anglo

()

OA-4

IDENTlFICATION OF VEHICLE
Chassls Number
Ccntcr ot eowt panel KLV3S11 BBMC 000001

ID Plate
R.ght sIde o' cowl panol

111 III lIll

1111 11 11 1111

FIG.OA-l
IdentIficaban number 01 englne is 811he followinglocation.

'FIG OA- 2

Loeabon 01cng no 10 number. F8C - 000001 Rlghl bololV end 01 cylinder block

FIG. OA- 3 lOCATION OF ENGIN ID NUMBER

OA-5
Metrlc Fasteners Mosl 01 Ihe Iasteoers used lor Ihis vehlcle ore melrlc. When roplacing any fasloners, II is mosllmpOrtant Ihat replacomenl laslenors be Ihe corree! dlamelar. Ihread 11.1.6 Fastener strength Identification M2 M22 Metric Bollle Necked Fastener Metrlc Narrow Necked Fastener
Nomr\81

PlII:~
(mm)

Plleh
(mm)

Sil.

035

O'
04S
045 O 4S

Mos! commonly used melric faslener slfenglh property dasses are 4T, ano radialllne wilh tho etass Identiucaucn embossed on 1110head 01 each bol!. Some melrlc nuts l'Iill be marked with punch mar!< slrenglh Ideo~focallOnon Ihe nul lace. Fog. OA - 5 shows!he dHereol slfenglh markings.

rr

M25
M3xO.5

~3S
t.'...; >.0.7

06 07
0.75

11.01.5
M5xO.8 11.6 11.7

When replacing melrle lasleners, be carelul to use bolls and nuts 01thesame Slrengthorgreaterlhen Ihaoriginal las!eners(the same number marking or higher). It is IikoW1seImportanl 10 select replacemonl Iasleners 01 the COfrect sae Wilh some special excepllon Ihe pitch 01common sized one is as shown in Ihe righl table. CAUTION Tho standard lastonors adopted in thls vohiele aro botlle necked upto nominal diameter M8, and narrow necked from MIO and more.
1.5

08

"'8
"'10 11.12 MI4 M16 M18

125 15 1.75 2

...18 , 1 MIO> 125 MI2 , 125 MI4 ~ 15 MI6 , 15 M18 , 15 125 125 1.5 1.5 1.5 1.5

25
25
"'22 25

"'20

~120, 15

M22 > 1 5 M24 ~ 2 M27> 2

In Ihe table, the rellltlon between nominal size and pitch is classifled lnto the bottle neeked and narrow necked, Upon roplacing Ihe lastener, its pileh should be conlirmed even though il is the same klnd 01 metrie lastener.

1124 1127 M30 M33 MJ6 M39

3 3

2 2
2

35
35
4 4

~130, 2
M33'
M39

2 3

2
2

M36 > 3

2 ~

OA-6

Metrle BoI1-ldenllllCaUon eass numbers 01 marks oorrespond lo. Bold Slrenglh -Increasing nurnbers represenl increa5'ng slrenglh. FIG. OA - 4 SOLT STRENGTH MARKINGS

OA-7

STANDARD TIGHTENING TORQUE

Each fastonor should be dghtQned lO lile lOIqUe specified In each secbon of lhIs men<lal. If no descnpl>oo 01 speclflcation ts provided, retor 10 the folJowngUghtsnlnglorque charl fer Iheapplicable lorque foreach fastener, Wl1en

a tastener 01 grealer slronglh Ihan !he original one 1$ used, however, use Ihe terque specifled for Ihe onglnal fastener.
UTION ' S for the flange bolls and nuts, tighlen Ihem al 1M lorque 10% highor

Ihan Ihe one shOwn In !he

b~bel~ ha lable befow shall be adopled only 10 Ihe bol!s aOOnuls 01 metalend lighl alloy.

Sltenglh

~~

~
(TOtque)

~
SIIenglh 7T

C<>nven~ona4l T BoIIS
4

BolIs

10 20
40

20

15

30 60

5
6

40

eo
80 180
4()()

70 150
350

120 280
500

8 10

100
220

350 500 18

550 800

700
1100

1000 1600

1300 - 1900 800 - 1300

_--

2000

2800
2500

1700

FIG OA - 5 TA8LE OF TIOHTENING TORQUE

OA-S

VEHICLE LlFTING POINTS

t
2 3 2. Ro.r 5vppol1rnpgO.ilion
3 FfOnl'.fl11re 4 Rear 101u1ro
I F,O", SUppor1olgposrtion

5. Trailingann

FIG. OA- S VEHICLE LlFTING POINTS

When IIIIIn9up and down lile vehlclobody. the 8rrow markadposhons shouldbe sUpJ()rted as shownIn lhe lig.OA-S. FIQ. OA 7 ano Fig. OA- 8 areforpositions tosupport WlIII2posl ~fters.and Fig. OA-9 an<!OA- IOarewith garagejack. CAUTtON When using 2 posllifters. a.pplypads on Ihe poslllons as Shown in the tlgure(same for both right and left) and lift the body unlil Ihe 411resare IIfled a liltle off Ihe ground. Work can be slarted only afler this conflrmallon. Before apptylng pad lo underbody, always lake car balance Ihroughoul service Inlo conslderallon. Car balance on holst may change depending upon what part lo be re moved. Makesure to lock lilter alter car ts holsled up.

When the front or rear 01 vehlde l. Illtad fO( work. supporttIle vehcle body withthe$810tystand underthe chassislrame. CAUTlON PUI1he slopping blocks at Ihe Ironl and back sidas of both wheels of which tires are cooteet ing on Ihe glOund.

OA-10

CAUTIONS

<D

Protection of Iha vehicfe Always be sure 10 use fender, seat covers to protect painted surface ond &0315 Irom dirt.

@ Electricel systom
Be sure 10 dlsconnect tIle connectors wilh holding the Iock parto Push the oonnectors unbl the eonnec tors are secured completely.

Jaol< installauon
At work with lifted vehicle by jack, be sure to install sa!ety stand on tIle spec,fied poston

Be sure that the w'flng namess 15 also lObe banded

securcly,

Spedal tools Be sure lo use tha spaaal tooIs ,\'here tIle work requires such 10015. 00 not use otller tools to prevent any posSlble Clamage to me vehicle

Upon measunng or .nspectltlQ !he oonnectDtS

tesrer, put me tOSIrod "to !he connectors frcm w re harness side.

",t1l

0) Oibng
Apply Ihe specihed orease and oi! befare inslalbng sorne parts which need lo be oiled.

When installing WtrC harnoss. clamp.lnot lo contaet to the oarts or rotailon. v.bratlOn. or high tempera ture.

OA12

PAEDELlVEAY INSPECTION
'Oacwoo Publlc Vehicle' gels Ihoroughlyand Slrtcdy inspecled al Ihe lactory belore delivery HoY/avar.dIJe lo Ihe vanees d'slnbubon passages. a predelivery Inspeclion should be lhroughiy takon on 1110 mainlam lhe besl quallllcation .'

* Prodelivery inspeclion lisl *

Sloaring cperation, clearance Parking brake lever cfearance

..

Broke pedal clearance and lhe cfearanes betwoen lIoor and pedal when !he pedalls pressed. Leakage. damage. or inslallabon cond,llOn 01 brake hose and pipe. Brake Huid level l.oosened wheel nuts and axle nuts, Clutch pedal cearance, ()( the etearance beaween lloor and clulCl when' the pedalls pressed

011 level and leakage

Baltery condition ..

01 Iransimlsslon Operation 01 change lever.

Eng,ne ollevel and leakage Fuelleakage Coolanl level and leakage Loosening or damage 01 V-belt. Operation 01 hghUngsyslom. hom and ",slnJmcnl lIIum,nabon Operallon 01.Wlper and washe, tank Ievef Funclion 01 door Ioci<s Operation 01 seal stide "slde and outside damage 01 body Vehlcle accompanying doclImonls IIka OEM 10015. owne~s manual. and ele. ucence number plate lnslallaton