SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
7A-10 HEATING AND VENTILATION SYSTEM
MODE CONTROLS DO NOT WORK
Refer to “Non A/C Diagrams” for electrical schematic diagram of the circuits described in this procedure.
Mode Controls Do Not Work
Step
1
2
3
4
5
6
7
8
9
10
11Action
Verify the customer’s complaint.
Are the customer’s concerns verified?
Measure the voltage between terminal 8 of heating
and ventilation control (HVC) controller and ground.
Is the voltage within the specified value?
Check fuse F19 in the I/P fuse block.
Is the fuse blown?
1. Turn the ignition ON.
2. Use a short detector to locate the following
possible short:
From the fuse F24 to terminal 8 of C204.
From the terminal 8 of the C212 to terminal 8 of
HVC controller.
3. Repair any short.
4. Replace any blown fuse.
Is the repair complete?
Repair open circuits from fuse F19 to terminal 8 of the
HVC controller.
Is the repair complete?
1. Turn the ignition switch to OFF.
2. Disconnect the mode actuator connector.
3. Using Motor Control Table, measure the resis-
tance between the specified terminals of the
specified motor connector.
4. Change the mode settings and observe the
resistance change.
Are the resistance equal to specified value?
1. Disconnect the HVC controller.
2. Using Motor Control Table, measure the resis-
tance between the specified terminals of the
specified HVC controller.
3. Change the mode settings and observe the
resistance change.
Are the resistance equal to specified value?
Replace the HVC controller.
Is the repair complete?
Repair open or short circuits between HVC controller
and mode moor actuator.
Is the repair complete?
Replace mode control motor.
Is the repair complete?
1. Examine the affected door in the unit for proper
attachment to the actuator.
2. Check the actuator connection to the door.
3. Check that the connector is properly connected.
Is everything connected properly?Yes
Go to Step 2
Go to Step 6
Go to Step 4
System OK
System OK
Go to Step 10
Go to Step 9
System OK
System OK
System OK
Go to Step 13No
System OK
Go to Step 3
Go to Step 5
-
-
Go to Step 7
Go to Step 8
-
-
Go to Step 11
Go to Step 12
Value(s)
-
11 - 14 v
See the
“Motor Control
Table”
See the
“Motor Control
Table”

HEATING AND VENTILATION SYSTEM 7A-11
SSANGYONG MY2002
Defrost (Terminal 5/9)
Defrost/Foot (Terminal 5/9)
Foot (Terminal 5/9)
Bi-Level (Terminal 5/9)
Vent (Terminal 5/9)
Mode Controls Do Not Work (Cont’d)
Step
12
13
14Action
Repair as necessary.
Is the repair complete?
1. Disconnect the actuator at the door.
2. Check the range of the door travel and the effort
required moving it.
Does the door move freely through its entire range of
travel so that it can close at both ends of the range?
Adjust the door travel and repair as necessary.
Is the repair complete?Yes
System OK
Go to Step 5
System OKNo
-
Go to Step 12
-Value(s)
6/7
3.9 - 4.1 Ω
3.9 - 4.1 Ω
≈ 0 Ω
≈ 0 Ω
≈ 0 Ω 14/8
3.9 - 4.1 Ω
≈ 0 Ω
≈ 0 Ω
≈ 0 Ω
≈ 0 ΩConnector Terminal (Controller / Motor)
Mode Setting
Motor Control Table
15/6
3.9 - 4.1 Ω
3.9 - 4.1 Ω
3.9 - 4.1 Ω
≈ 0 Ω
≈ 0 Ω7/5
3.9 - 4.1 Ω
3.9 - 4.1 Ω
3.9 - 4.1 Ω
3.9 - 4.1 Ω
≈ 0 Ω16/4
3.9 - 4.1 Ω
3.9 - 4.1 Ω
3.9 - 4.1 Ω
3.9 - 4.1 Ω
3.9 - 4.1 Ω

SSANGYONG MY2002
7A-12 HEATING AND VENTILATION SYSTEM
AIR SOURCE SELECTION NOT CONTROLLED
Refer to “Non A/C Diagrams” for electrical schematic diagram of the circuits described in this procedure.
Air Source Selection Not Controlled
Step
1
2
3
4
5
6
7
8
9
10
11
12Action
Verify the customer’s complaint.
Are the customer’s concerns verified?
Measure the voltage between terminal 8 of heating
and ventilation control (HVC) controller and ground.
Is the voltage within the specified value?
Check fuse F19 in the I/P fuse block.
Is the fuse blown?
1. Turn the ignition ON.
2. Use a short detector to locate the following
possible short:
From the fuse F19 to terminal 8 of C212.
From the terminal 8 of the C212 to terminal 8 of
HVC controller.
3. Repair any short.
4. Replace any blown fuse.
Is the repair complete?
Repair open circuits from fuse F19 to terminal 8 of the
HVC controller.
Is the repair complete?
1. Turn the ignition switch to OFF.
2. Disconnect the intake air control actuator connec-
tor.
3. Measure the voltage at terminal 3 of the connec-
tor.
Is the voltage within the specified value?
Repair open circuit from terminal 8 of C212 to termi-
nal 3 of the intake air actuator.
Is the repair complete?
Measure the resistance between terminal 2 and 3 of
the actuator.
Is the resistance within the specified value?
Replace the intake air door actuator.
Is the repair complete?
1. Disconnect the HVC controller.
2. Measure the resistance between following point:
Terminal 9 of HVC controller and terminal 1 of
actuator.
Terminal 10 of HVC controller and terminal 2 of
actuator.
Is the resistance within the specified value?
Repair open or short circuit.
Is the repair complete?
Replace the HVC controller.
Is the repair complete?Yes
Go to Step 2
Go to Step 6
Go to Step 4
System OK
System OK
Go to Step 8
System OK
Go to Step 10
System OK
Go to Step 12
System OK
System OKNo
System OK
Go to Step 3
Go to Step 5
-
-
Go to Step 7
-
Go to Step 9
-
Go to Step 11
-
-
Value(s)
-
11 - 14 v
11 - 14 v
≈ 2 k Ω
≈ 0 Ω

HEATING AND VENTILATION SYSTEM 7A-13
SSANGYONG MY2002
TEMPERATURE CONTROLS DO NOT WORK
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15Action
Verify the customer’s complaint.
Are the customer’s concerns verified?
Move the temperature control lever.
Is an excessive effort required to move the control
lever?
Move the blower control switch on 4.
Does the temperature door move too easily?
Remove the temperature control cable from the
controller.
Does the control knob slide freely, without the click
stops?
Check the cable for improper routing, kinks, wiring
interference, or other instrument panel interference.
Is there a problem.
Repair as needed.
Is the repair complete?
1. Remove the cable from temperature door.
2. Circle the door manually.
3. Check for door binding.
Is there any door binding?
Check the door seal for proper installation.
Is the door seal OK?
1. Check a binding door for shaft alignment, a bent
shaft, a bent door, or a warped case.
2. Repair as need.
Is the repair complete?
Repair the door seal, as needed.
Is the repair complete?
Check the control binding.
Does the control bind?
1. Reinstall the cable to the door.
2. Check the clearance for the cable to dash com-
partments.
3. Repair any interface.
Is the repair complete?
1. Remove the cable from the control.
2. Check the control for binding.
Does the control bind?
Replace the control.
Is the repair complete?
Replace the cable.
Is the repair complete?Yes
Go to Step 2
Go to Step 5
Go to Step 4
Go to Step 14
Go to Step 6
System OK
Go to Step 8
Go to Step 9
System OK
System OK
Go to Step 13
System OK
Go to Step 14
System OK
System OKNo
System OK
Go to Step 3
System OK
System OK
Go to Step 7
-
Go to Step 11
Go to Step 10
-
-
Go to Step 12
-
Go to Step 15
-
-Value(s)
-

SSANGYONG MY2002
7A-14 HEATING AND VENTILATION SYSTEM
TOO MUCH HEAT
Step
1
2
3
4
5
6
7
8
9
10
11
12
13Action
Verify the customer’s complaint.
Are the customer’s concerns verified?
Is there too much heat when the mode switch is in the
floor position?
Is there objectionable defroster bleed?
1. Check the door travel, the cable, the actuator, and
the linkage for the heater and the defroster.
2. Adjuster or repair, as required.
Is the repair complete?
1. In vehicles equipped with A/C, set the A/C switch
OFF.
2. Set the blower speed to 4.
3. Set the temperature control lever to full hot.
4. Turn the ignition switch to ON.
5. Start the engine.
6. Check for airflow from the floor outlets.
7. Check the floor outlet attachment.
Is the airflow high?
Check for a change in airflow at different blower
speeds.
Does the airflow change as the setting for the blower
speed switch is changed?
1. Check the temperature door travel, the cable, and
the linkage.
2. Adjust to full hot.
3. Check for full hot.
Is the repair complete?
Adjust or repair the floor/defroster and/or the vent/
floor mode.
Is the repair complete?
In the vent position.
Is the problem objectionable bleed?
1. Check the system case for leaks.
2. Check the floor outlet attachment.
Are there problems?
Repair the system case or the floor outlet attachment
as required.
Is the repair complete?
1. Turn the ignition switch OFF.
2. Turn the temperature control lever to full hot, then
rapidly to full cold.
Did you hear the door slam just before you reached
the end of the control travel?
Adjust the vent door to vent mode.
Is the repair complete?Yes
Go to Step 2
Go to Step 3
Go to Step 4
System OK
Go to Step 6
Go to Step 7
System OK
System OK
Go to Step 10
Go to Step 11
System OK
Go to Step 13
System OKNo
System OK
Go to Step 9
Go to Step 5
-
Go to Step 8
Go to “Blower
Electrical”
-
-
Go to Step 15
Go to Step 12
Go to Step 12
Go to Step 14
-Value(s)
-

HEATING AND VENTILATION SYSTEM 7A-15
SSANGYONG MY2002
Too Much Heat (Cont’d)
Step
14
15
16Action
1. Check the temperature door travel, the cable, and
the linkage.
2. Verify the temperature door goes to full cold.
3. Check the temperature door for full hot.
Is the temperature door travel correct?
Set the intake air control to fresh air (indicator lamp
OFF).
2. Set the temperature control to full cold.
3. Start the vehicle and allow the engine to warm up.
4. Measure the air temperature at the blower inlet, or
cowl, and at the vent air outlet inside the vehicle.
Is the outlet air more than 1 °C (41 °F) warmer than
the inlet air?
1. Check for hot air leaks from the engine compart-
ment to the blower inlet.
2. Repair as needed.
Is the repair complete?Yes
System OK
Go to Step 16
System OKNo
-
System OK
-Value(s)

SSANGYONG MY2002
7A-16 HEATING AND VENTILATION SYSTEM
BLOWER NOISE
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14Action
Verify the customer’s complaint.
Are the customer’s concerns verified?
1. Sit inside the vehicle.
2. Close the doors and windows.
3. Turn the ignition ON.
4. Start the engine.
5. Set the temperature to full cold.
6. Cycle through the blower speeds, the modes, and
the temperature settings in order to find the noise.
Is the blower noise constant at high blower speeds or
in other modes?
Check for vibrations from the blower motor and fan
assembly at each blower speed by feeling the blower
motor housing.
Did you find excessive vibration?
1. Remove the blower motor and fan assembly.
Refer to “Blower Motor” in this section.
2. Check for foreign materials at the opening of the
blower inlet.
Did you find any foreign materials at the blower inlet?
Remove all foreign materials.
Is the repair complete?
1. Examine the blower fan for wear spots, cracked
blades, a cracked hub, a loose fan retaining nuts,
or bad alignment.
2. Examine the blower case for sports.
Did you find any problem?
Repair as required.
Is the repair complete?
Replace the motor and fan assembly.
Is the repair complete?
If the noise is a click/tick or whine, replace the motor.
Is the repair complete?
Reinstall the original motor.
Is the problem still present?
1. Set the blower speed on 4.
2. Check full hot to full cold temperature positions in
the defroster, floor, and vent modes.
Is the noise present in the defrost mode only?
1. Check the ducts for obstructions for foreign
materials.
2. Remove any obstructions or foreign materials.
3. Check floor /defroster door seals.
4. Repair or replace as needed.
Is the repair complete?
Is the noise present in the floor mode only?
Is the noise present in the vent mode only?Yes
Go to Step 2
Go to Step 11
Go to Step 6
Go to Step 5
System OK
Go to Step 7
System OK
System OK
System OK
Go to Step 11
Go to Step 12
System OK
Go to Step 12
Go to Step 15No
System OK
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 9
Go to Step 8
Go to Step 9
Go to Step 10
System OK
Go to Step 14
-
Go to Step 14
Go to Step 16Value(s)
-

HEATING AND VENTILATION SYSTEM 7A-17
SSANGYONG MY2002
Blower Noise (Cont’d)
Step
15
16
17
18Action
1. Check the ducts for obstruction or foreign materi-
als.
2. Remove any obstructions or foreign materials.
3. Check the vent door seals.
4. Repair or replace as needed.
Is the repair complete?
Is the noise present in all modes, but not all tempera-
ture positions?
1. Check the temperature door seals.
2. Repair or replace as needed.
Is the repair complete?
1. Check the system for obstructions for foreign
materials between the fan and the temperature
door.
2. Repair or replace as needed.
Is the repair complete?Yes
System OK
Go to Step 16
System OK
System OKNo
-
Go to Step 18
-
Go to Step 2Value(s)

SSANGYONG MY2002
7A-18 HEATING AND VENTILATION SYSTEM
ON-VEHICLE SERVICE
TEMPREATURE CONTROL CABLE
ADJUSTMENT
Because the cable and the cable housing have fixed
lengths, it is impossible to make a temperature cable
adjustment.
The heater/air distributor case linkage also cannot be
adjusted.
If a malfunction is suspected, verify the proper
operation of the controller and the mechanical doors
for heater/air distributor case assembly.
MAINTENANCE AND REPAIR
KAA7A020
KAA7A030
CONTROLLER ASSEMBLY AND
TEMPERATURE CONTROL CABLE
Removal and installation Procedure
1. Disconnect the negative battery cable.
2. Slide the cable eyelet off the post on the
temperature door lever (under the I/P center).
3. Unsnap the clip that securing temperature control
cable.
Notice: Do not remove the bracket.
4. Remove the I/P center trim plate.
5. Remove four controller retaining screws.
6. Disconnect the electrical connectors.
7. Remove one screw that securing the temperature
control cable.
8. Disconnect the temperature control cable by gently
unsnapping the temperature control cable.
9. Remove and replace temperature control cable as
required.
10. Remove the controller assembly.
11. Installation should follow the removal procedure
in the reverse order.

HEATING AND VENTILATION SYSTEM 7A-19
SSANGYONG MY2002
CONTROL ASSEMBLY KNOB
LIGHTING
Removal and installation Procedure
1. Disconnect the negative battery cable.
2. Remove the heating and ventilation control (HVC)
controller assembly. Refer to “Controller Assembly
and Temperature Control Cable” in this section.
3. Remove the connector cover by sliding away.
4. Remove the connector from the temperature control
cable control mechanism.
5. Separate the temperature control cable control
mechanism.
6. Turn the bulb holder to the left and pull out the
bulb.
7. Installation should follow the removal procedure
in the reverse order.
KAA7A040
KAA7A050
KAA7A060
AIR INTAKE DOOR ACTUATOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the glove box. Refer to Section 9E, Instru-
mentation/Driver Information.
3. Disconnect the connector to intake air control door
actuator.
4. Remove three screws that securing mode control
door actuator to heater/air distributor case.
5. Remove the mode control door actuator by gently
snapping the actuator.
6. Installation should follow the removal procedure
in the reverse order.