SSANGYONG KORANDO 1997 Service Repair Manual

WATERLEAKS 9I-3
SSANGYONG MY2002
DIAGNOSIS
WATERLEAK DIAGNOSIS
The repair of waterleaks in the body requires proper
testing and diagnosis. Repair waterleaks by adjusting
the misaligned parts and using the proper repair materi-
als. First, determine what conditions cause the leak.
For example, the leak may occur only when the vehicle
is parked on an incline, or water may appear only in
the spare tire compartment. Second, test the area for
the source of the leak using the following testing
methods. If the general leak area is found, determine
the exact entry point of the leak by using a water hose
or an air hose. If the general leak area is not obvious,
use the watertest stands to determine the area of the
leak. It may be necessary to remove some interior trim
panels or some parts in order to locate the leaks.
Important: It is necessary to find the origin of all the
leaks before making any repairs. Random repairs may
stop the leak only temporarily and may make future
repairs more difficult. Continue localized testing in the
general area in order to ensure that all leaks are found.1 1/2-inch by 36-inch Pipe
2 Full-jet Spray Nozzle #1/2 GG-25 or Equivalent .
Nozzle Height at 1,600 mm to the Floor
3 1/2-inch Coupling
4 1/2-inch by 1/2-inch by 1/4-inch Reducing T
(Right Only)
5 1/2-inch Coupling (Left Only)
6 1/2-inch Cross (Right Only)
7 1/2-inch Tee (Left Only)
8 1/2-inch Pipe-to-Hose Nipple (Right Only)
9 5/8-inch Female Hose Coupling
10 5/8-inch Input Hose (2 Feet Long, Right Only)
11 1/2-inch Close Nipple
12 1/2-inch Cross with Weld-on 1/2-inch Cap
13 1/2-inch by 12-inch Nipple
14 1/2-inch Cap
15 5/8-inch Female Hose Coupling
16 5/8-inch Cross Hose (12 Feet Long)
17 5/8-inch Hose Quick Connect
18 1/2-inch Pipe-to-Hose Nipple
19 1/2-inch by 30-inch Pipe (Straight)
20 1/4-inch Water Pressure Gauge (Right Only)
KAA9I010
Generalized Testing
1. Set up the watertest stands.

SSANGYONG MY2002
9I-4 WATERLEAKS
3. Perform the watertest stand leak test. Refer to
“Watertest Stand Specifications” in this section.
4. If the local water pressure does not allow the
required water pressure of 155 kPa (22.5 psi),
move both stands closer to the vehicle so that
the water sprayoverlaps.
Localized Testing (Spot Test)
1. Do localized testing with a water hose or an air
hose.
2. Begin testing by spraying the air or the water at
the base of the suspected leak area. Continue
spraying the air or the water upward until the leak
is found.
KAA9I030
KAA9I020
2. Set up the watertest stand leak test.

WATERLEAKS 9I-5
SSANGYONG MY2002
Water Hose Test
1. Place another person inside the vehicle in order
to detect the location of the leak.
2. Use a water hose without a nozzle.
KAA9I040
KAA9I050
KAA9I060
Air Hose Test
1. Apply soapy water to the outside of the vehicle in
the suspected leak area.
2. Blow air from inside the vehicle. The air pressure
should not exceed 205 kPa (29.7 psi).
3. Determine the location of the leaks from the
bubbles formed in the soapy water.
3. Begin spraying the water at the base of the
suspected leak area. Continue spraying the water
upward until the leak is found.

SSANGYONG MY2002
9I-6 WATERLEAKS
KAA9I080
6. Using a sharp knife, trim off the uneven edges of
the adhesive material around the leak 75 to 100
mm (3 to 4 inches) on both sides of the leak.
KAA9I070
ON-VEHICLE SERVICE
WATERLEAK REPAIR
Some waterleaks around the glass can be repaired
without removing the glass.
Important: This type of repair may be used only for
urethane-installed glass.
1. Remove the reveal molding in the area of the leak.
It may be necessary to remove the garnish molding
or the trim strip lace in order to locate the leak.
2. While spraying water over the leak area, carefully
push the glass outward in order to determine the
size of the leak.
3. Mark the location of the leak.
4. Use water to clean any dirt from the area. Dry the
area with an air hose.
5. Using a sharp knife, trim off the uneven edges of
the adhesive caulking material around the leak for
a distance of 75 to 100 mm (3 to 4 inches) on both
sides of the leak.
MAINTENANCE AND REPAIR

WATERLEAKS 9I-7
SSANGYONG MY2002
KAA9I090
KAA9I100
8. Allow the primer to dry for 5 minutes.
9. Apply the adhesive over the leak and for a
distance of 75 to 100 mm (3 to 4 inches) on both
sides of the leak.
KAA9I080
7. Prime the trimmed area with the primer.
10. Immediately after applying the adhesive, use a
flat stick or a similar tool to work the adhesive into
the leak area and into the joint between the original
material and the vehicle body in order to ensure a
watertight seal.
11. Spray warm or hot water over the repaired area in
order to determine if the leak was repaired. Do
not run a heavy stream of water directly on the
freshly-applied adhesive.
12. Install the trim strip lace if it was removed.
13. Install the garnish molding if it was removed.
14. Install the reveal molding.
Important: After the completion of any waterleak
repair, re-test the area using the watertest stands.
Do not use localized testing procedures on the
newly-repaired areas, as the repair material may
dislodge under abnormal pressure.
15. Installation should follow the removal procedure
in the reverse order.

SECTION 9J
WINDNOISE
TABLE OF CONTENTS
Diagnosis..............................................................9J-2
Windnoise Diagnosis ...........................................9J-2Maintenance and Repair.....................................9J-3
On-Vehicle Service.................................................9J-3
Windnoise Repair................................................9J-3

SSANGYONG MY2002
9J-2 WINDNOISE
DIAGNOSIS
WINDNOISE DIAGNOSIS
Caution: An assistant should drive the vehicle while
the technician checks for the location of the wind-
noise, in order to prevent personal injury or vehicle
damage.
A test drive in the vehicle is necessary to accurately
determine the location of the windnoise. Often there is
a primary leak and secondary leaks. Failure to repair
all leaks will only reduce the windnoise, not eliminate
it.
During the test drive the technician should bring the
following items to aid in determining the location of
the windnoise.
•A mechanics stethoscope or vacuum hose
Masking tape
Strip caulk
A china marking pencil
A screwdriver
Perform the following steps in order to conduct the
road test:
1. Choose a route that includes smooth straight
streets that run in all four directions (north, south,
east, and west).
2. Choose streets with little traffic or noise that would
interfere with the test.
3. Drive the vehicle at the speeds at which the noise
was noticed by the customer or until the noise is
produced. Do not exceed legal speed limits.
4. The windnoise is external if any of the following
conditions occur:
The windnoise is caused by the wind.
The windnoise can be heard with the door glass
lowered and while the vehicle is being driven.
The windnoise is eliminated when tape is placed
over various moldings and gaps.5. Internal windnoise is air leaving the vehicle and
should be repaired in the following manner.
In order to locate the leak, tape off the body
lock pillar pressure relief valves. This will cause
air pressure to build up inside the vehicle and
enhance the windnoise.
Use a stethoscope or a vacuum hose to locate
the leak.
Temporarily repair the leak with masking tape.
Continue testing in order to determine if the noise
has been eliminated or if other leaks exist.
When all leaks have been found, return to the
shop and make permanent repairs with the
proper alignment techniques and sealing
materials.
KAA9J010

WINDNOISE 9J-3
SSANGYONG MY2002
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
WINDNOISE REPAIR
Windnoise leak repairs are very similar to waterleak
repairs. Refer to Section 9I, Waterleaks. The actual
procedure depends on the type of seal being repaired.
Leaks around the door opening weatherstrips do not
al-ways indicate a faulty weatherstrip. A door or window
adjustment may resolve the condition. Refer to Section
9P, Doors or Section 9L, Glass and Mirrors.

SECTION 9K
SQUEAKS AND RATTLES
TABLE OF CONTENTS
Diagnosis..............................................................9K-2
Squeak and Rattle Diagnosis...............................9K-2Maintenance and Repair.....................................9K-4
On-Vehicle Service.................................................9K-4
Squeak and Rattle Repair....................................9K-4

SSANGYONG MY2002
9K-2 SQUEAKS AND RATTLES
•Tap lightly on the brake lines and listen for a rattle.
Install plastic tie straps to secure the brake lines
tightly together.
Raise the vehicle and perform a visual inspection.
Bend the heat shield slightly to gain clearance from
the underbody.
While the vehicle is cold, perform a test drive and
achieve full front suspension travel by driving
through a dip in the road.
Remove the insulators and wrap teflon tape around
the stabilizer shaft. Reinstall the insulators over the
tape.
Open the rear compartment and perform a visual
inspection of the spare tire and the tools.
Tightly secure the spare tire and all tools.
Perform a road test to verify that the noise is elimi
nated.
DIAGNOSIS
SQUEAK AND RATTLE DIAGNOSIS
Rattle Coming From the Side Rail
Check the brake lines.ChecksAction
Rattle Under Vehicle at Higher RPM
Squeak From the Front of the Vehicle in Cold Weather
Check the front stabilizer shaft insulators.ChecksAction
Check for heat shield contact with the underbody.ChecksAction
Thump From Rear of Vehicle on Bumps
Check for a properly secured spare tire in the rear
compartment.ChecksAction
Glass Knock Coming From the Rear of the Vehicle When Driving Over Bumps
Check for an out-of-adjustment hatchback latch.ChecksActionTest drive the vehicle in order to verify this condi-
tion.
Loosen the latch nuts and adjust the latch down-
ward.