SSANGYONG KORANDO 1997 Service Repair Manual

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-14 MANUAL & SEMIAUTO-HVAC
REFRIGERANT CHARGING
Installation of Manifold Gauge
1. Close both high/low pressure hand valves of
manifold gauge before installation of gauge to the
charging valve.
2. Both high/low pressure hand valves of manifold
gauge connect the appropriate charging valve.
Tighten the hose nuts by hand.
high pressure hand valve → high pressure
charging valve
low pressure hand valve → low pressure
charging valve
Discharging Refrigerant
1. Connect the manifold gauge to the charging valve.
2. Place the free end of the center hose in a shop
towel.
3. Slowly open the high pressure hand valve and
discharge refrigerant.
Notice: If refrigerant is allowed to escape too fast,
compressor oil will be drawn out of the system.
4. Check whether the shop towel gets wet in oil and
if wet, close the hand valve.
5. After the high pressure gauge reading drops below
3.5 kg/cm
2, slowly open the low pressure valve.
6. When both high and low pressure gauges reading
drops to 0 kg/cm
2, discharging is completed.
Evacuating Refrigeration System
Notice: The unit tank must contain a sufficient amount
of R-134a refrigerant for charging. Check the amount
of refrigerant in the tank. If there is less than 3.6 kg
(8 pounds) of refrigerant, add new refrigerant to the
tank.
1. Verify that the high-side and the low-side hoses
are connected to the A/C system. Open both the
high-side and the low-side valves on the unit’s
control panel.
2. Open both the gas and the liquid valves on the
tank.
YAD7B150
YAD7B160
YAD7B170
MAINTENANCE AND REPAIR

MANUAL & SEMIAUTO-HVAC 7C-15
SSANGYONG MY2002
Important: Refer to the manufacturer’s
instructions for the charging station in use. It is
necessary to evacuate the system before
recharging it with new or recycled refrigerant.
3. Start the vacuum pump and begin the evacuation
process. Non-condensable gases (mostly air) are
vented from the tank automatically during the
recycling process. The pressure being released
may be heard.
4. Check for leaks in the system. Refer to the
manufacturer’s instructions for the charging
station in use.
Important: Change the vacuum pump oil
frequently. Refer to the manufacturer’s
instructions for the charging station in use.
Check for Refrigerant Leaks
1. Connect the center hose of the gauge to the
refrigerant tank.
2. Open the high pressure valve of the gauge to
charge with refrigerant gas.
3. Charge until the low pressure gauge reads 1.0 kg/cm
2
and close the valve.
4. Using a gas leak detector, check the system for
leaks.
5. If any leak is found, replace O-ring or repair the
faulty connection.
How to Use the Tap Valve
1. Rotate the handle counterclockwise fully before
connecting the valve to the refrigerant tank.
2. Rotate the disk counterclockwise fully.
3. Connect the center hose to the valve fitting and
then rotate the disk clockwise fully by hand.
4. Rotate the handle clockwise to drill the sealed
hole.
5. Remove the hose nut securing the center fitting
of the manifold gauge and then tighten the nut
again in a few seconds.
YAD7B180
YAD7B190
YAD7B200

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

SSANGYONG MY2002
7C-20 MANUAL & SEMIAUTO-HVAC
KAA7C210
KAA7C220
KAA7C230
Removal & Installation Procedure
1. Disconnect the inlet and outlet pipes of condenser.
Notice: Before disconnection, evacuate the
refrigerant from the system.
Notice: When installing, check the O-ring and
apply compressor oil.
2. Remove the mounting bolts (2EA) and condenser
assembly.
Installation Notice
3. Remove the main condenser fan from condenser.
Tightening Torque Inlet Side to 10 - 15Nm
(7 - 11 lb-ft)
Outlet Side to 4 - 6 Nm
(35 - 53 lb-in)
4. Installation should follow the removal procedure
in the reverse order.
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)

MANUAL & SEMIAUTO-HVAC 7C-21
SSANGYONG MY2002
KAA7C240
1 Condenser
2 Receiver Drier
3 Bolt................................ 4 - 6 Nm (35 - 53 lb-in)4 Bolt................................ 5 - 8 Nm (44 - 71 lb-in)
5 Bracket
RECEIVER DRIER