section 2c SSANGYONG KORANDO 1997 Service Repair Manual

POWER STEERING GEAR 6C-13
SSANGYONG MY2002
KAA6C150
UNIT REPAIR
RACK AND PINION
Disassembly and Assembly Procedure
1. Remove the rack and pinion assembly from the
vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the valve and pinion assembly from the
rack and pinion steering assembly. Refer to “Valve
and Pinion” in this section.
3. Remove the rack bearing assembly from the rack
and pinion steering assembly. Refer to “Rack
Bearing” in this section.
4. Mark the threads on the inner tie rod to aid in
repositioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie
rod nut and the adjusting nut.
Installation Notice:
When installing the outer tie rod nut, the mark
on the inner tie rod and adjusting nut should
line up.
After installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
KAA6C160
KAA6C170
6. Remove the dust boot retaining clamps and
remove the dust boot.
7. Push back the retainer holding the connection be-
tween the inner tie rod and the power steering gear
rack.

SSANGYONG MY2002
6C-14 POWER STEERING GEAR
8. Counterhold the pinion-side inner tie rod and re-
move the cylinder-side inner tie rod.
Installation Notice:
To prevent the inner tie rods from loosening,
use Loctite 242 (or equivalent) on both inner
tie rod connections to secure them to the rack
shaft.
KAA6C180
KAA6C190
KAA6C210
KAA6C200
Important: The retaining ring can be released by
inserting a small screwdriver through the hole in
the side of the housing.
9. Remove the bulkhead inner cylinder retaining ring.
Installation Notice:
Coat all the seals with power steering fluid to
ensure proper sealing.
10. Place a rag over the rack, counterhold the rack
assembly on the teeth with a wrench, and remove
the pinion-side inner tie rod.
Installation Notice:
The right and left inner tie rods are unequal in
length. Be sure to install the correct inner tie
rod on the proper side of the power steering
gear.
VALVE AND PINION ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to “Rack and Pinion
Assembly” in this section.
2. Remove the dust cover from the lower end of the
housing.
Notice: If the stub shaft is not held, damage to
the pinion teeth will occur.
3. While holding the stub shaft with a wrench, remove
the locknut from the pinion.

POWER STEERING GEAR 6C-15
SSANGYONG MY2002
4. Remove the stub shaft and stub shaft housing.
KAA6C220
KAA6C230
KAA6C240
5. Remove the stub shaft from the stub shaft housing
6. Remove the stub shaft seal in the stub shaft.
Installation Notice:
Coat all the seals with power steering fluid to
ensure proper sealing.
RACK BEARING
Disassembly and Assembly Procedure
Tools Required
DW310-040Power Steering Rack Guide Spring Cap
Wrench
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to “Rack and Pinion
Assembly” in this section.
2. Remove the adjuster plug locknut from the
adjuster plug, and remove the adjuster plug from
the housing with the power steering rack guide
spring cap wrench DW310-040.
Installation Notice
Tightening Torque 59 Nm (43 lb-ft)

SSANGYONG MY2002
6C-16 POWER STEERING GEAR
KAA6C250
KAA6C260
3. Remove the adjuster spring and the rack bearing.
Installation Notice:
Coat the rack bearing, the adjuster spring and
the adjuster plug with lithium-based grease
With the rack centered, turn the adjuster plug
clockwise untila torque of4 Nm (35 lb-in) is ob-
tained, then back it off by 15 degrees. Check
the pinion torque. Maximum pinion preloaded
torque is 25 Nm (18 lb-ft).
RACK BEARING PRELOAD
ADJUSTMENT
Adjustment Procedure
1. Raise and suitably support the vehicle.
2. Center the steering wheel.
3. Remove the power steering gear. Refer to “Rack
and Pinion Assembly” in this section.
4. Loosen the locknut and turn the adjuster plug
clock-wise until a torque of 4 Nm (35 lb-in) is
obtained, then loosen it by 15 degrees. Check the
pinion orque. Maximum pinion preloaded torque
is 25 Nm (18 lb-ft).
5. Tighten the locknut on the adjuster plug while
holding the adjuster plug stationary.
Installation Notice
Tightening Torque 59 Nm (43 lb-ft)
6. Install the power steering gear. Refer to “Rack
and Pinion Assembly” in this section.
7. Be sure to check the returnability of the steering
wheel to center position after adjustment.

SECTION 6E
POWER STEERING AND COLUMN
TABLE OF CONTENTS
Description and Operation...................................6E-2
General Description.............................................6E-2
Ignition Switch Keyhole Lamp..............................6E-2
Ignition Key Reminder .........................................6E-2
Component Locator.............................................6E-3
Diagnostic Information and Procedures..............6E-4
Steering Wheel Freeplay Inspection.....................6E-4
Steering Effort Inspection.....................................6E-4
Steering Column Diagnosis..................................6E-5
Repair Instructions................................................6E-9On-Vehicle Service.................................................6E-9
Headlamp/Turn Signal Switch and Lever...............6E-9
Wiper Switch and Lever.....................................6E-10
Steering Wheel With Sir.....................................6E-10
Ignition Lock Cylinder and Switch......................6E-11
Steering Column................................................6E-12
Specifications.....................................................6E-14
Fastener Tightening Specifications.....................6E-14
Special Tools and Equipment............................6E-15
Special Tools Table............................................6E-15

SSANGYONG MY2002
6E-2 POWER STEERING AND COLUMN
GENERAL DESCRIPTION
Caution: To ensure the energy-absorbing action of
the steering column, it is important to use only the
specified screws, bolts, and nuts, tightened to the
specified torque.
In addition to the steering function, the steering column
provides safety and security.
The energy-absorbing column is designed to compress
in a front-end collision to lessen the chance of driver
injury.
The ignition switch and the lock are mounted on the
column, allowing the ignition and steering operations
to be locked to inhibit theft of the car.
The column levers trigger the turn signals, the headlight
beams, and the windshield washer and wipers.
A tilt steering column uses a spherical joint to allow
the steering wheel to tilt up and down. This enables
the driver to adjust the steering wheel to a comfortable
position.
Notice: Apply a thin coat of lithium grease to all friction
points when reassembling.
The column may be disassembled and reassembled
easily.
DESCRIPTION AND OPERATION
IGNITION SWITCH KEYHOLE LAMP
For description and lamp replacement information, Re-
fer to Section 9B, Lighting Systems.
IGNITION KEY REMINDER
The ignition key reminder alerts the driver that the key
is still in the ignition when the driver attempts to exit
the vehicle.
An internal switch in the ignition lock cylinder supplies
battery voltage to the reminder chime module when all
of the following conditions are true:
•The key is in the ignition switch.
The ignition is OFF.
The driver’s door is open.
For information on removal and installation of the re-
minder chime module, Refer to Section 9E, Instrumen-
tation/Driver Information.

SSANGYONG MY2002
6E-10 POWER STEERING AND COLUMN
KAA6E060
KAA6E080
KAA6E070
WIPER SWITCH AND LEVER
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the upper and the lower steering column
cover screws.
3. Remove the upper and the lower steering column
cover.
4. Remove the wiper switch and lever mounting
mounting screws.
Tightening Torque 65 Nm (48 lb-ft) 5. Disconnect the wiper switch and lever connector.
6. Remove the wiper switch and lever.
STEERING WHEEL WITH SIR
Tools Required
661 589 00 33 00 Steering Wheel Puller
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the SIR module. Refer to Section 8B, Sup-
plemental Inflatable Restraints.
3. Remove the steering wheel nut.
Removal Notice:
In order to install the steering wheel correctly,
match mark the steering column shaft to the
steering wheel.
Installation Notice

SSANGYONG MY2002
6E-12 POWER STEERING AND COLUMN
KAA6E040
KAA6E120
STEERING COLUMN
Important: Remove the steering column only if the
following conditions exist:
The steering column requires replacement.
The steering and the ignition lock housing require
replacement.
Another operation requires the removal of the
steering column
Notice: The steering column is extremely
susceptible to damage after it has been removed
from the vehicle. Dropping the column assembly
on its end or hammering the end of the steering
shaft can collapse the steering shaft or loosen the
plastic injections which maintain column rigidity.
Leaning on the column can cause it to bend or
deform. Any of the above damage can impair the
column’s collapsible design. If it is necessary to
remove the steering wheel, use only the specified
steering wheel puller.
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the upper and the lower steering column
cover screws.
3. Remove the upper and the lower steering column
cover.
KAA6E060
4. Remove the lower instrument trim panel. Refer to
Section 9E, Instrumentation/Driver Information.
5. Remove the immoblilzer module. Refer to Section
9T, Immobilizer Anti-Theft system.
6. Disconnect the airbag electrical connections.
7. Disconnect electrical switch connections.
8. Adjust the steering to the straight-ahead position.
9. Make a mark on the steering column shaft that
lines up with a mark on the intermediate shaft
upper universal joint.
10. Remove the intermediate shaft upper pinch bolt.
Installation Notice
Tightening Torque 27 Nm (20 lb-ft)

SECTION 7A
HEATING AND VENTILATION SYSTEM
CAUTION: The cooling system is pressurized when hot. Injury can result from removing the coolant reservoir
cap before the engine is sufficiently cool.
TABLE OF CONTENTS
Description and Operation ................................7A-2
Heating and Ventilation System .........................7A-2
Components Locator ..........................................7A-3
Heater System ...................................................7A-3
Diagnostic Information and Procedures ..........7A-4
Heater System ...................................................7A-4
Blower Electrical ................................................7A-8
Mode Controls Do Not Work .............................7A-10
Air Source Selection Not Controlled ..................7A-12
Temperature Controls Do Not Work ..................7A-13
Too Much Heat .................................................7A-14
Blower Noise ....................................................7A-16
Repair Instructions ............................................7A-18
On-Vehicle Service..............................................7A-18
Temperature Control Cable Adjustment ............7A-18
Controller Assembly and Temperature
Control Cable .................................................7A-18
Control Assembly Knob Lighting ......................7A-19Air Intake Door Actuator ...................................7A-19
Mode Control Door Actuator .............................7A-20
Heater/Air Distributor Case Assembly ..............7A-20
Blower Motor ....................................................7A-21
Blower Resistor ................................................7A-22
Blower Unit .......................................................7A-22
Heater Inlet Hose ..............................................7A-23
Heater Outlet Hose ...........................................7A-23
Heater Core......................................................7A-24
Rear Heater Duct ..............................................7A-24
Air Filter ............................................................7A-24
Specifications .................................................... 7A-25
Heater Temperature Specification .....................7A-25
Heater Unit .......................................................7A-25
Fastener Tightening Specification .....................7A-25
Schematic and Routing Diagrams ................... 7A-26
Non - A/C Wiring Diagram ................................7A-26
Airflow Through Vents .......................................7A-28

SSANGYONG MY2002
7A-4 HEATING AND VENTILATION SYSTEM
DIAGNOSTIC INFORMATION AND PROCEDURES
HEATER SYSTEM
Insufficient Heating or Defrosting
CAUTION: The cooling system is pressurized when hot. Injury can result from removing the coolant reservoir
cap before the engine is sufficiently cool.
Step
1
2
3
4
5
6
7
8
9
10
11
12
Action
Verify the customer’s complaint.
Are the customer’s concerns verified?
Check the coolant level.
Is the coolant level correct?
Add coolant as needed
Is the repair complete?
Check the serpentine accessory drive belt for tension
or damage.
Is the ’serpentine accessory drive belt OK?
Correct any problem with serpentine accessory drive
belt.
Is the repair complete?
Check the coolant hoses for leaks or kinks.
Are the coolant hoses OK?
Repair any problem with the coolant hoses.
Is the repair complete?
Check the coolant reservoir cap. Refer to Section 1D,
Engine Cooling.
Is the coolant reservoir cap OK?
Repair or replace the coolant reservoir cap as needed.
Is the repair complete?
1. Set the A/C switch OFF on the vehicles equipped
with air conditioning.
2. Set the temperature control lever to full hot.
3. Set the blower motor switch on 4.
4. Turn the ignition ON.
5. Check for the airflow from the vent outlet.
Is there a heavy airflow from the vent outlet?
Check for change in the airflow at various blower
speeds.
Does the blower speed increase as the switch is turned
from 1 to 4?
1. With the engine sufficiently cool, remove the
coolant reservoir cap.
2. Set the blower motor switch on 4.
3. Set the temperature control lever to full hot.
4. Start the engine and idle the engine.
5. Watch for the flow of the coolant.
Is the coolant flow visible?Yes
Go to Step 2
Go to Step 4
System OK
Go to Step 5
System OK
Go to Step 8
System OK
Go to Step 10
System OK
Go to Step 11
Go to Step 12
Go to Step 16No
System OK
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 25
Go to “Blower
Electrical”
Go to Step 13 Value(s)
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