air condition SSANGYONG KORANDO 1997 Service Owner's Guide

1A3 -- 10 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
DIAGNOSIS
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair. The following procedures may
help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate loca-
tion of the leak by the drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-- type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil fill
tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid willappear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a gas-
ket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. Thebent flange must be
repaired also. Before attempting to repair a leak, check
for the following conditions and correct them as they
may cause a leak.
Gaskets
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe fasteners are tightened improperly or the threads
are dirty or damaged.
DThe flanges or the sealing surface is warped.
DThere are scratches, burrs or other damage to the
sealing surface.
DThe gasket is damaged or worn.
DThere is cracking or porosity of the component.
DAn improper seal was used (where applicable).
Seals
DThe fluid level/pressure is too high.
DThe crankcase ventilation system is malfunctioning.
DThe seal bore is damaged (scratched, burred or
nicked).
DThe seal is damaged or worn.
DImproper installation is evident.
DThere are cracks in the components.
DThe shaft surface is scratched, nicked or damaged.
DA loose or worn bearing is causing excess seal wear.

OM600 ENGINE MECHANICAL 1B3 -- 15
D AEW OO M Y_2000
12. Remove the hose(air cleaner to turbocharger) with
blow by hose.
13. Disconnect the air cleaner intake hose and remove
the air cleaner cover and element.
14. Disconnect the coolant hose from the water inlet.
15. Remove the air -- conditioner lines from the compres-
sor.
Notice
Evacuate the refrigerant before removal.

1B3 -- 22 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal & Installation Procedure
1. Remove the nut.
2. Push the tensioning lever in direction of arrow with a
rod (F12’ 180mm) and pull out the bolt to the rear.
3. Push back the tensioning lever (arrow direction) to
release the spring tension and remove the belt.
4. Install the poly V-- belt beginning at the tensioning
pulley (7).
7 Tensioning Pulley
8 Crankshaft
9 Generator
10 Water Pump
11 Guide Pulley
12 Power Steering Pump
13 Aircon. Compressor
Length of Belt
Length (L)With Air Conditioner2,100 mm
Length (L)Without Air Conditioner2,040 mm

1B3 -- 26 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
POLY V-- BELT ALIGNMENT & INSPECTION
Without Air Conditioner
With Air Conditioner

1B3 -- 102 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Checking
Notice
The noise which continues short time during short
travel (frequent starting of the engine) or engine
starting after a long time storage is normal operating
conditions. So, it does not need to be repaired. De-
termine the malfunctions in valve clearance com-
pensation device with noise through following tests.
If defective, replace as respectively.
1. Run the engine at more than 3000rpm for approx. 4
minutes.
2. Stop the engine. After 5minutes, check the engine
oil level and adjust if necessary.
3. Remove the cylinder head cover.
4. Check the valve tappets at TDC position of each cyl-
inders.
5. Using a drift, lightly press the valve tappet and mea-
sure clearance between the cam and valve tappet.
Notice
If the clearance exceeds 0.4mm, replace the valve
tappet.
6. If a valve tappet moves down too far in comparison
to the others, replace the valve tappet.
7. Rotate the engine and check the remaining valve
tappets.
Notice
DUnnecessary rotation of the engine will damage
the valve tappets.
DDo not rotate the engine by using the camshaft
sprocket bolt or to the opposite direction of the
engine rotation.

SSANGYONG MY2002
2A-2 SUSPENSION DIAGNOSIS
Inspect the tires for improper pressure and uneven wear.
Inspect the joint from the steering column to the steer-
ing gear for loose connections or wear.
Inspect the front and the rear suspension, the steering
gear, and the linkage for loose or damaged parts.
Inspect for out-of-round tires.
Inspect for out-of-balance tires, bent wheels, and worn
or loose wheel bearings.
Check the power steering pump serpentine belt tension.
Inspect the power steering system for leaks. Also, check
the power steering fluid level.Action
Checks
Checks
Inspect for incorrect toe on the front and the rear wheels.
Inspect for a twisted or a bent suspension arm. Inspect for mismatched or uneven tires.
Inspect for a broken or a sagging spring.
Inspect for a radial tire lateral force.
Check the front-wheel alignment.
Inspect for an off-center steering gear.
Inspect for front-brake dragging.
DIAGNOSIS
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires,
and the wheels involve several systems. Consider all
systems when diagnosing a complaint. Some problems,
such as abnormal or excessive tire wear and scuffed
tires, may be the result of hard driving. Always roadtest the vehicle first. If possible, do this road test with
the customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Preliminary Checks
Replace the tires.
Replace the spring.
Check the wheel alignment. Switch the tire and the
wheel assemblies. Replace the tires, as needed.
Align the front wheels.
Reseat the pinion valve assembly. Replace the pinion
valve assembly, as needed.
Adjust the front brakes.
Car Lead/Pull
Action
Adjust the toe on the front and the rear wheels.
Replace the suspension arm.
Scuffed Tires
Inflate the tires to the proper pressure.
Tighten the intermediate shaft pinch bolts. Replace the
intermediate shaft, as needed.
Tighten the front and the rear suspension. Tighten the
steering gear mounting bracket bolts. Tighten the inter-
mediate shaft pinch bolts. Replace the front and the rear
suspension, as needed. Replace the steering gear, as
needed. Replace the intermediate shaft, as needed.
Perform a free runout test. Match-mount the tires.
Balance the wheels. Replace the wheels. Replace the
wheel bearings.
Tighten the power steering pump serpentine belt.
Repair any leaks. Perform a power steering system test.
Add power steering fluid, as needed.
Action Checks

TIRE AND WHEELS 2E-3
SSANGYONG MY2002
TIRE CHAIN USAGE
Due to limited tire-to-body clearance on certain
vehicles, recommendations for tire chain use are
published in the Owner’s Manual. When tire chains
need to be used, most current Ssangyong vehicles
require SAE Class “S” tire chains. These may also be
designated as 1100 Series, type PL tire chains. These
chains are specifically designed to limit the “fly off”
effect which occurs when the wheel rotates.
Be sure that only fine-link chains are used which do
not add more than 15 mm (0.590 inch), including the
lock, to the tread surface and the inner sides of the
tires. Manufacturers of tire chains have a specific chain
size for each tire size to ensure a proper fit when the chain
is installed. Be sure to purchase the correct chains for the
tires on which they are to be used. Use rubber adjusters to
take up any slack or clearance in loose chains.
Use of chains may adversely affect vehicle handling.
When tire chains are installed, follow these precautions:
Adjust speed to road conditions.
Avoid sharp turns.
Avoid locked-wheel braking.
To prevent chain damage to the vehicle, install the
chains on the front tires as tightly as possible. Tighten
them again after driving 0.4 to 0.8 kilometer (0.3 to 0.5
mile). The use of chains on the rear tires is not recom-
mended because they may contact the vehicle and pos-
sibly damage it. If chains must be used on the rear
tires, be sure there is sufficient clearance between the
chains and the body. Do not exceed 70 km/h (45 mph)
or the chain manufacturer’s speed limit, if lower. Avoid
large bumps, potholes, severe turns and any other
maneuvers which could cause the tires to bounce.
Follow any other instructions of the chain manufacturer
which do not disagree with the above instructions.
REPLACEMENT TIRES
A tire performance criteria (TPC) specification number
is molded in the sidewall near the tire size of all original
equipment tires. This specification number assures that
the tire meets performance standards for traction, en
durance, dimensions, noise, handling and rolling
resistance. Usually a specific TPC number is assigned
to each tire size.
Caution: Do not mix different types of tires on the
same vehicle such as radial, bias and bias-belted
tires except in emergencies, because vehicle han-
dling may be seriously affected and may result in
loss of control.Use only replacement tires with the same size, load
range, and construction as the original. The use of any
other tire size or construction type may seriously affect
ride, handling, speedometer/odometer calibration, ve-
hicle ground clearance, and tire clearance to the body
and the chassis. This does not apply to the spare tire
furnished with the vehicle.
It is recommended that new tires be installed in pairs
on the same axle.
If it is necessary to replace only one tire, pair it with the
tire having the most tread to equalize the braking action.
Although they may appear different in tread design, tires
built by different manufacturers with identical TPC speci-
fications may be used on the same vehicle.
ALL SEASON TIRES
Most vehicles are now equipped with steel-belted all
season radial tires as standard equipment. These tires
qualify as snow tires, with a 37 percent higher average
rating for snow traction than the non-all season radial
tires previously used. Other performance areas, such
as wet traction, rolling resistance, tread life, and air
retention, have also been improved. This was done by
improvements in both tread design and tread
compounds. These tires are identified by an “M + S”
molded in the tire sidewall following the size number.
The suffix “MS” is also molded in the sidewall after
the TPC specification number.
The optional handling tires used on some vehicles are
not all season tires. These will not have the “MS” mark-
ing after the tire size or the TPC specification number.
PASSENGER METRIC SIZED TIRES
All Daewoo vehicles now use passenger (P) metric sized
tires. P-metric tires are available in two load ranges:
standard load (35 psi maximum) and extra load (41 psi
maximum). Most passenger vehicle tires are standard
load.
Most P-metric tire sizes do not have exact correspond-
ing alphanumeric tire sizes. For example, a P175/70R13
is not exactly equal in size and load-carrying capacity
to an FR70-13. For this reason, replacement tires should
be of the same TPC specification number as the origi-
nals. If P-metric tires must be replaced with other sizes,
consult a tire dealer. Tire companies can best recom-
mend the closest match of alphanumeric to P-metric
sizes within their own tire lines.
The metric term for measuring tire inflation pressure is
the kilopascal (kPa). Tire pressure may be printed in
both kPa and psi. One psi equals 6.895 kPa.
See the tire label or refer to “Tire Size and Pressure
Specifications” in this section for tire inflation
pressures.

HYDRAULIC BRAKES 4A-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy,
or covered with loose dirt which can cause tires not to
grip the road unequally. Testing also will be inaccurate
on a crowned roadway because the wheels tend to
bounce.
Test the brakes at different vehicle speeds with both
light-and heavy-pedal pressure; however, avoid locking
the brakes and sliding the tires. Locked brakes and
slid-ing tires do not indicate brake efficiency since
heavily braked but turning wheels will stop the vehicle
in less distance than locked brakes. More tire-to-road
friction is present with a heavily braked, turning tire
than with a sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:
•Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated, and the tread pattern of the right and the
left tires must be approximately equal.
Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.
Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and
the shift lever in NEUTRAL. If the pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking. Perform a visual check to confirm any
suspected leaks.
Check the master cylinder fluid level. While a slight
drop in the reservoir level results from normal lining
wear, an abnormally low level indicates a leak in the
system. The hydraulic system may be leaking either
internally or externally. Refer to the procedure below
to check the master cylinder. The system may appear
to pass this test while still having a slight leak. If the
fluid level is normal, check the vacuum booster pushrod
length. If an incorrect pushrod length is found, adjust
or replace the rod.Check the master cylinder using the following proce
dure:
Check for a cracked master cylinder casting or a
brake fluid leak around the master cylinder. Leaks
are indicated only if there is at least one drop of
fluid. A damp condition is not abnormal.
Check for a binding pedal linkage and for an
incorrect pushrod length. If both of these parts are
in satisfactory condition, disassemble the master
cylinder and check for an elongated or swollen
primary cylinder or piston seals. If swollen seals
are found, substandard or contaminated brake fluid
should be suspected. If contaminated brake fluid
is found, all the components should be
disassembled and cleaned, and all the rubber
components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, the rubber parts have
deteriorated.
If deterioration of the rubber is evident, disassemble
all the hydraulic parts and wash the parts with alcohol.
Dry these parts with compressed air before reassembly
to keep the alcohol out of the system. Replace all the
rubber parts in the system, including the hoses. When
working on the brake mechanisms, check for fluid on
the linings. If excessive fluid is found, replace the
linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush
the master cylinder with brake fluid, refill the master
cylinder, and bleed the system.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of
the outer cover, and for leaks or blisters. Inspect the
hoses for proper routing and mounting. A brake hose
that rubs on a suspension component will wear and
eventually fail. A light and a mirror may be needed for
an adequate inspection. If any of the above conditions
are observed on the brake hose, adjust or replace the
hose as necessary.

SSAMGYONG MY2002
4A-12 HYDRAULIC BRAKES
13. Slowly push and hold the brake pedal. Avoid rapid
pumping of the brake pedal.
14. While the brake pedal is pushed down, loosen the
bleeder valve to purge the air from the caliper.
15. After the air bubbles have escaped into the
container of brake fluid, slightly tighten the rear
bleeder valve.
16. Slowly release the brake pedal. Wait 15 seconds
before proceeding with the next step.
Notice: Keep brake fluid away from painted
surfaces because brake fluid will damage the paint
finish.
17. Repeat Steps 13 - 16 until all of the air is removed.
You will know all of the air is removed when no
bubbles appear in the container when the bleeder
valve is loosened. Keep the master cylinder reser
voir at least one-half full during the bleeding
operation.
18. Tighten the front bleeder valve.
Installation Notice 12. Attach a transparent tube over the rear bleeder
valve at the right rear caliper. Allow the tube to
hang submerged in the brake fluid in a transparent
container. (After the right rear caliper is bled in
the following steps, use this procedure at the left
front, the left rear and the right front bleeder valves.)
19. Bleed the remaining calipers in the following order
: left rear, right front, and left front. Use the
procedure in Steps 12 - 17.
20. After all calipers have been bled, check the brake
pedal for sponginess. If the brake pedal is not firm,
repeat the entire bleeding procedure to correct this
condition.
Tightening Torque 10 Nm (89 lb-ft)
KAA4A060
KAA4A070

ABS AND TCS 4F-75
SSANGYONG MY2002
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DTC 12 - Valve Relay Circuit Fault
Action
Go to Step 3
System OK
Go to Step 4
System OK
Go to Step 7
System OK
Go to Step 9
System OK
Go to Step 11
System OK
Go to Step 13
System OK
Go to Step 15
System OK
System OKGo to Step 2
-
Go to Step 5
-
Go to Step 6
-
Go to Step 8
-
Go to Step 10
-
Go to Step 12
-
Go to Step 14
-
- -
-
-
-
≈ 0 Ω
-
≈ 0 Ω
-
11 - 14v
-
≈ 0 Ω
-
≈ 0 Ω
-
-
1. Use a scan tool to clear all DTCs.
2. Road test the vehicle.
Does DTC 12 set again?
1. Check all system wiring harness connectors and
terminals, especially the electronic brake control
module(EBCM), for any problem that could cause
an intermittent condition.
2. Repair any intermittent problem found.
Is the repair complete?
Check fuse EF 22.
Is fuse EF22 blown?
1. Check for a short circuit and repair it, if necessary.
2. Replace fuse EF 21.
Is the repair complete?
1. Disconnect the valve relay.
2. Check the resistance between the valve relay
connector terminal 86 and terminal 2 of EBCM.
Is the resistance equal to the specified value?
Repair the open circuit between the valve relay
connector terminal 86 and terminal 2 of EBCM.
Is the repair complete?
Check the resistance between the valve relay connec-
tor terminal 85 and terminal 37 of EBCM.
Is the resistance equal to the specified value?
Repair the open circuit between the valve relay
connector terminal 85 and terminal 37 of EBCM.
Is the repair complete?
Check the voltage between the valve relay connector
terminal 30 and ground.
Is the voltage equal to the specified value?
Repair the open circuit between the valve relay
connector terminal 30 and fuse EF21.
Is the repair complete?
Check the resistance between the valve relay connec
tor terminal 87 and terminal 10 of hydraulic modulator.
Is the resistance equal to the specified value?
Replace the valve relay.
Is the repair complete?
1. Disconnect the EBCM.
2. Check the resistance between terminal 28 and 29
of EBCM and ground G303.
Is the resistance equal to the specified value?
Repair the open circuit between the valve relay
connector terminal 87 and terminal 14 of hydraulic
modulator.
Is the repair complete?
Replace the ABS unit.
Is the repair complete?
Value(s) Yes No