section 2c SSANGYONG KORANDO 1997 Service Service Manual

OM600 ENGINE MECHANICAL 1B3 -- 75
D AEW OO M Y_2000
Sectional View
3 Socket Bolt
4 Crankshaft Belt Pulley
5 Vibration Damper
6Bolt
7 Washer
8 Straight Pin9Hub
11 Radial Seal
12 Timing Gear Case Cover
13 Key
14 Crankshaft Sprocket
16 Crankshaft
Notice
The mounting position of vibration damper is fixed by
straight pin (8).
Tools Required
602 589 00 40 00 Engine Lock
103589003000 Puller

D AEW OO M Y_2000
SECTION 1D3
OM600 ENGINE COOLING
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 other -
wise noted.
TABLE OF CONTENTS
Specifications 1D3 -- 1............................
General Specifications 1D3-- 1....................
Fastener Tightening Specifications 1D3 -- 1..........
Diagnosis 1D3 -- 2.................................
Cooling Circulation 1D3 -- 2........................
Thermostat Operation 1D3 -- 3....................
Cooling System Leakage Test 1D3-- 4..............
Maintenance and Repair 1D3 -- 5...................On-- Vehicle Service 1D3-- 5.........................
Drain and Filling of Coolant 1D3 -- 5................
Wat er Pum p 1D3 -- 6.............................
Water Pump Housing 1D3-- 8.....................
Cooling Fan Clutch 1D3 -- 10......................
Radiator 1D3-- 12................................
Cooling Sub-- System 1D3-- 14.....................
Thermostat 1D3 -- 16.............................
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
CoolantALUTEC P-- 78
Mixing Ratio (Water: anticorrosion)50 : 50
Capacity662LA10.5L -- 11Lpy
661LA9.5L -- 10L
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-- FtLb-In
Water Pump Bolt10--89
Belt Pulley Bolt10--89
Water Pump Housing Return Pipe Bolt10--89
Thermostat Bolt10--89
Cooling Fan Clutch Socket Bolt (Center)4533--
Cooling Fan Clutch Socket Bolt (Side)10--89
Radiator Bolt3--7--27 -- 62
Coolant Sub-- tank Bolt3--7--27 -- 62

D AEW OO M Y_2000
SECTION 1E3
OM600 ENGINE ELECTRICAL
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 other -
wise noted.
TABLE OF CONTENTS
Specifications 1E3 -- 1............................
General Specifications 1E3-- 1....................
Maintenance and Repair 1E3 -- 2...................
On-- Vehicle Service 1E3-- 2.........................Glow Plug 1E3-- 2...............................
Generator 1E3-- 6...............................
Starter Motor 1E3-- 8............................
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Generator12V -- 75A
Starter12V -- 2.2kW
Glow Plug11. 5 V

D AEW OO M Y_2000
SECTION 1F3
OM600 ENGINE CONTROLS
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 other -
wise noted.
TABLE OF CONTENTS
Specifications 1F3 -- 1............................
Fastener Tightening Specifications 1F3 -- 1..........
Maintenance and Repair 1F3 -- 2...................
On -- Vehicle Service 1F3 -- 2.........................
Fuel System 1F3 -- 2.............................
Fuel Injection Pump Coding 1F3 -- 3................
Fuel Tank 1F3 -- 4...............................
Vacuum Control System Test 1F3 -- 5..............
Vacuum Pump Test 1F3 -- 10......................
Vacuum Pump 1F3 -- 12..........................
Vacuum Unit Replacement 1F3 -- 14...............
Idle Speed Adjustment 1F3 -- 15...................Fuel Pump Test 1F3 -- 17.........................
Fuel Pump 1F3 -- 20.............................
Injection Nozzle Test 1F3-- 21.....................
Injection Nozzles 1F3-- 24........................
Injection Nozzle Repair 1F3 -- 26...................
Removal and Installation of
Injection Timing Device 1F3 -- 29.................
Injection Timing Device 1F3 -- 34...................
StartofDeliveryTest
(Position Sensor, RIV Method) 1F3 -- 36..........
Fuel Injection Pump 1F3 -- 45.....................
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationN∙mLb-- FtLb-In
Fuel Tank Mounting Nut28 -- 4721 -- 35--
Fuel Pump Pressure Line1310--
Fuel Injection Nozzle35 -- 4026 -- 30--
Fuel Injection Pipe1813--
Nozzle Tensioning Nut8059--
Screw Plug3022--
Left -- Hand Thread Bolt4634--

SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Diagnosis..............................................................2A-2
General Diagnosis................................................2A-2Hub and Bearing.................................................2A-7

SUSPENSION DIAGNOSIS 2A-7
SSANGYONG MY2002
KAA2A010
HUB AND BEARING
Perform the following test to check for looseness in
the hub and bearing assembly:
1. Raise and suitably support the vehicle.
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the caliper and the disc brake rotor. Refer
to Section 4E, Rear Disc Brakes.
4. Mount a dial indicator set with a magnetic base to
a stationary part of the vehicle.
5. Push and pull the wheel hub by hand. If the wheel
hub movement exceeds 0.03 mm (0.001 inch),
replace the hub and bearing assembly. Refer to
Section 2D, Rear Suspension.
6. Install the caliper and the disc brake rotor. Refer
to Section 4E, Rear Disc Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
and Wheels.
8. Lower the vehicle.

SECTION 2B
WHEEL ALIGNMENT
TABLE OF CONTENTS
Description and Operation....................................2B-2
Four Wheel Alignment ..........................................2B-2
Toe-in..................................................................2B-2
Caster.................................................................2B-2
Camber...............................................................2B-2
Diagnostic Information and Procedures...............2B-3
Tire Diagnosis......................................................2B-3
Radial Tire Lead/Pull............................................2B-4Vibration Diagnosis..............................................2B-6
Vehicle Height......................................................2B-7
Front Toe-in Adjustment .......................................2B-7
Front Camber Check............................................2B-8
Front Caster Check..............................................2B-8
Specifications.......................................................2B-9
Wheel Alignment Specifications...........................2B-9
Fastener Tightening Specifications.......................2B-9

WHEEL ALIGNMENT 2B-7
SSANGYONG MY2002
VEHICLE HEIGHT
Adjustment Procedure
1. Check the tire for proper inflation.
2. Measure ‘A’ from the center of the lower arm
rear mounting bolt end to the ground.
KAA2B050
3. Measure ‘B’ from the center of the steering
knuckle shaft to the ground.
KAA2B060
4. If the difference between ‘A’ and ‘B’ is not
within specification, adjust vehicle height using
torsion bar height control bolt.
Adjustment Notice
Specification31 - 36 mm
(1.22 - 1.42 inch)B - A
Notice: Before wheel alignment, adjust vehicle
height adjustment first.
KAA2B070
FRONT TOE-IN ADJUSTMENT
Adjustment Procedure
1. Disconnect the outer tie rods from the knuckle as-
semblies. Refer to Section 6C, Power Steering
Gear.
2. Loosen the front toe adjusting nut.
Notice: In this adjustment, the right and the left tie
rods must be equal in length, or the tires will wear
unevenly.
3. Turn the right and the left outer tie rods to align the
toe to the proper specifications. Refer to “Wheel
Alignment Specifications” in this section.
KAA2B080
4. Hold the outer tie rod and tighten the front toe adjust-
ing nut.
Adjustment Notice
Tightening Torque 73 Nm (54 lb-ft)
5. Reconnect the outer tie rods to the knuckle assem-
blies. Refer to Section 6C, Power Steering Gear.

SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTS
Components Locator............................................2C-2
Diagnostic Information and Procedures..............2C-3
Ball Joint Inspection ............................................2C-3
Repair Instructions................................................2C-4
On-Vehice Service..................................................2C-4
Front Hub Bearing Assembly...............................2C-4
Front Stabilizer.....................................................2C-5
Stabilizer Link......................................................2C-6
Torsion Bar..........................................................2C-7
Lower Control Arm...............................................2C-7
Upper Control Arm...............................................2C-8Front Shock Absorber ..........................................2C-9
Lower Ball Joint.................................................2C-10
Upper Ball Joint.................................................2C-10
Knuckle Assembly.............................................2C-11
Crossmember....................................................2C-12
Unit Repair..........................................................2C-14
Hub and Bearing...............................................2C-14
Specifications.....................................................2C-16
Fastener Tightening Specifications.....................2C-16
Special Tools and Equipment.............................2C-17
Special Tools Table.............................................2C-17

SSANGYONG MY2002
2C-4 FRONT SUSPENSION
REPAIR INSTRUCTIONS
KAA2C020
ON-VEHICE SERVICE
FRONT HUB BEARING ASSEMBLY
Tools Required
DW340-050Sliding Hammer
DW340-060Front Hub Cap Remover/Installer
DW340-070Front Hub Flange Remover
661 589 01 07 00 Front Hub Adjusting Nut Remover/
nstaller
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the caliper assembly. Refer to Section
4D, Front Disc Brakes.
4. Remove the hub cap with front hub cap remover/
Installer DW340-060 and sliding hammer DW340-
050.
KAA2C030
5. Remove the hub flange bolts.
Installation Notice
Tightening Torque 55 Nm (41 lb-ft)
6. Remove the snap ring and hub flange with front
hub flange remover DW340-070 and sliding
hammer DW340-050.
Notice:
When installing, coat the hub flange surface with
Loctitte.