engine SSANGYONG KORANDO 1997 Service Repair Manual

MANUAL & SEMIAUTO-HVAC 7C-7
SSANGYONG MY2002
DIAGNOSIS USING THE MANIFOLD GAUGE
On normal operation during the cooling cycle, the
manifold gauge must indicate approximately 1.5 - 2.0
kg/cm
2 at low pressure side and 14.5 - 15 kg/cm2 at
high pressure side, on condition that the temperature
at the cooler inlet, 30 ºC - 35 ºC, 2,000 rpm of the
engine rpm , full cold and maximum blower speed.
Cause Symptom
Action
1. High and low pressure are abnormally low.
2. Air at cooler outlet is not cold.
1. High and low pressure are abnormally high.
1. High and low pressure are abnormally high.
2. Connection at the low pressure is not cold.
There is a gas leak in the
cooling system.
Insufficient cooling and
faulty condenser cooling
by excessive
refrigerant.
Belt is slipped
There is an air in the
cooling system
Check the oil leak,
repair
Add the refrigerant
Keep the specified
amount of the
refrigerant, Clean the
condenser
Repair the belt
Clean and repair the
receiver-drier
Check the oil
contamination etc.
YAD7B070
YAD7B080
YAD7B100 YAD7B090

SSANGYONG MY2002
7C-12 MANUAL & SEMIAUTO-HVAC
AIR CONDITIONER SYSTEM
DIESEL ENGINE
1 Compressor
2 High Pressure Hose
3 Condenser
4 Condenser Fan
5 Liquid Pipe (A)
6 Reveiver Drier
KAA7C030
7 Liquid (B)
8 Evaporator Assembly
9 Blower Unit
10 Heater Unit
11 Low Pressure Hose

MANUAL & SEMIAUTO-HVAC 7C-13
SSANGYONG MY2002
GASOLINE ENGINE
1 Evaporator Assembly
2 Condenser Asembly
3 Screw-Hex SEMS (M8 x 1.5 x 35)
4 Fan & Shroud Assembly-Main
5 Fan & Shroud Assembly-Add
6 Supplement Assembly- c/ fan Mounting
7 Receiver & Bracket Assembly
8 Hose-Discharge
9 Bolt-Hex Sems (M8 x 1.25 x 30)
10 Hose Assembly-Suction11 Pipe Assembly-Suction
12 Pipe-Liquid-A
13 Pipe-Liquid-B
14 Resister-Condenser Fan
15 Clip-Closed-CT (M8)
16 Bolt-Hex FLG (M8 x 1.25 x 25)
17 Nut-Hex (M6 x 1.0)
18 Screw-Hex SEMS (M6 x 1.0 x 25)
19 Screw-Hex SEMS (M6 x 1.0 x 16)
KAA7C040

SSANGYONG MY2002
7C-16 MANUAL & SEMIAUTO-HVAC
Charging Refrigerant
Charging for Gas
1. Connect the tap valve to the refrigerant tank.
2. Open the low pressure and adjust the low-side
reading below 4.2 kg/cm
2.
3. Place the refrigerant tank in the warm water
(40 °C) and keep the gas pressure in the refrigerant
tank higher than the gas pressure in the charging
valve.
4. Run the engine at high speed and operate A/C
system.
Notice: Place the refrigerant tank on the flat floor
to protect the liquid refrigerant from coming
through the suction inlet resulting in the
compressor’s damage.
5. Charge the specified amount to the charging valve
and close the low pressure valve.
Notice:
If the charging speed is low, it’s more efficient
to place the refrigerant tank in the warm water
(40 °C). But the temperature should keep below
(52 °C) at any situation.
Be careful not to contact the heating device or
material.
Charging for Liquid
Notice:
Do not operate when charging the system through
the high-side rpessure.
Do not open the low pressure valve when charging
the system by the liquid refrigerant.
1. Tighten both high pressure and low pressure
completely before evacuating the charging valve.
2. Connect the tap valve of the refrigerant tank.
3. Open the high pressure valve and turn the
refrigerant tank upside down.Single: 850 ± 50 g
Dual: 1200 ± 50 g
Specified amount
YAD7B210
YAD7B220
YAD7B230

MANUAL & SEMIAUTO-HVAC 7C-17
SSANGYONG MY2002


Operation Check
Notice: Operation Check is recommended before
removing the manifold gauge.
1. Install the manifold gauge set.
2. Run the engine at 2,000 rpm and set the blower
switch at ‘HI’ and A/C switch ‘ON’. Set the
temperature control lever at ‘COOL’.
3. Keep opening all of the window and door.
4. Place a dry bulb thermometer to the front duct.
5. Place a psychrometer close to the inlet of the
cooling unit.
6. Check the high pressure gauge reading within
14 - 16 kg/cm
2
If the reading indicates high excessively, spray
the water to the condenser.
If the reading indicates low excessively, cover the
condenser with the towel.
7. Check the temperature of air inlet within 25 - 35 °C.
8. Calculate the relative humidity from the
psychrometic graph comparing the wet/dry
temperature at the air inlet.
9. Measure the wet/dry temperature at the cold air
outlet and calculate the temperature difference of
the dry bulb between the inlet and the outlet.
10. Check the cross point of the relative humidity and
check the temperature difference between the
black line. If the cross point is located between
the black line, the cooling performance is normal.
4. The discharging pressure increases when the
charging valve charges excessively, so charge
the charging valve to the specified amount with
measuring the weight of the refrigerant before
closing the high pressure valve.
5. Charge the specified amount of the refrigerant and
then close the valve of the manifold gauge. Check
the system for any leak.
YAD7B240

SSANGYONG MY2002
7C-18 MANUAL & SEMIAUTO-HVAC
Total Oil Capacity 265 cc
COMPRESSOR OIL
REPLACEMENT
Before Oil Replacement
When any part is replaced or there are a lot of gas
leaks in the A/C system, you should add the specified
amount of the oil to keep the approval oil capacity
because the oil for lubricating the compressor
circulates through the A/C system during operating
the compressor.
Handling Oil
Be careful that moistures, dusts etc. must not flow
into the oil.
Do not mix with any other material.
If the oil leaves outside for long time, it’s possible
to mix it with the moistures and so keep the oil
sealed with a container.
Circulating Oil
For checking or adjusting the oil level, set the control
unit to full cold and max blower speed with keeping
the engine run at idle for 20 - 30 minutes in order to
circulate the oil through the compressor.

MANUAL & SEMIAUTO-HVAC 7C-19
SSANGYONG MY2002
KAA7C200
1 Condenser
2 Bolt................................ 4 - 6 Nm (35 - 53 lb-in)
3 Condenser Fan4 Sub Fan (Gasoline Engine)
5 Resister (Gasoline Engine)
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
CONDENSER
Preceding Work : Removal of the radiator

FATC-HAVC 7D-19
SSANGYONG MY2002
KAA7D230
KAA7D240
KAA7D250
KAA7D260
Water Sensor
Water sensor is a thermistor that detects engine coolant
temperature to operate the blower speed to LO when
water temperature is less than 50.
1. Check that there are water sensor fault code (15,16)
by using self-diagnosis function.
2. Disconnect water sensor 2-pin connector that
installed on the heater unit of inner instrument panel
and remove the water sensor.
3. Check that measured resistance value among
water sensor terminals is as shown in the right
side graph.
Notice: Measure resistance value by soaking the
sensor in the ice water and check changes in
resistance values after soaking it in the very hot
water.
4. If resistance value is out of specification, replace
the water sensor.
5. Install the sensor and turn the ignition switch to
ON position and check that voltage between No.
7a terminal of the water sensor and body (-) is 5V.
6. Check current between the No. 7a and 7b connector
terminals of the water sensor and the No. 3 and 5
connector terminals of the airconditioner control unit
and repair the wire if defective.

SECTION 9A
BODY WIRING SYSTEM
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
General Description.............................................9A-2
Wire Color Chart..................................................9A-2
Engine Room Fuse & Relay Box......................... 9A-3
Usage of Fuse in Engine Room Fuse Box.............9A-5
Passenger Room Fuse Box..................................9A-6
Usage of Fuse in Engine Room Fuse Box.............9A-7
Schematic and Routing Diagrams.......................9A-8
Engine Room Fuse & Relay Circuit.......................9A-8
Wiring Harness & Connector &
Ground Location................................................. 9A-11
W/H Engine Room.............................................9A-11W/H Main..........................................................9A-12
W/H Main (Floor)............................................... 9A-14
W/H Roof..........................................................9A-15
W/H Seat Heater................................................9A-16
W/H Door..........................................................9A-17
W/H Tail Gate....................................................9A-18
W/H Air-Conditioner...........................................9A-19
W/H Engine Control (Gasoline)...........................9A-20
W/H Pre-Heating (Diesel)...................................9A-21
W/H Transmission..............................................9A-22

BODY WIRING SYSTEM 9A-3
SSANGYONG MY2002
ENGINE ROOM FUSE & RELAY BOX
Position Of Relay And Fuse (Front View)
KAA9A010