engine SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
9E-2 INSTRUMENTATION, DRIVER INFORMATION
DESCRIPTION AND OPERATION
CIGAR LIGHTER
The cigar lighter is located in the front portion of the
floor console. To use the lighter, push it in completely.
When the lighter is hot, it will release itsef from contact
with the heating element. The lighter and the heating
element can be damaged if the lighter does not fully
release itsef from the heating element.
ASHTRAY
The ashtray is located in the console. To access the
ashtray, pullit out of the ashtray housing. The ashtray
lamp will go on when the parking lamps or headlamps
are turned on.
INSTRUMENT PANEL VENTS
The center and the side vents in the instrument panel
can be adjusted up and down and from side to side.
The side vents can also be aimed toward the side
windows to defog them.
GLOVE BOX
The glove box can be opened by pulling upon the latch
handle.
DIGITAL CLOCK
The digital clock is located in the instrument cluster.
INSTRUMENT CLUSTER
The instrument cluster is located above the steering
column and in the instrument cluster trim panel. The
instrument cluster contains the instruments that
provide the driver with vehicle performance information.
The instrument cluster contains a speedometer, a
tachometer, an odometer, a trip odometer, a
temperature gauge, a fuel gauge, and several indicator
lamps. For replacement of the indicator lamp bulbs
contained in the instrument cluster, refer to “Instrument
Cluster Indicator Lamps Specifications” in the section.
SPEEDOMETER AND
TACHOMETER
The speedometer measures the speed of the vehicle
in km/h (with mph) or mph (with km/h). It consists of
an instrument cluster gauge connected to the vehicle
speed sensor on the transaxle output shaft. The
tachometer measures the engine’s speed in terms of
thousands of revolutions per minute. It consists of an
instrument cluster gauge connected to a sending unit
in the engine con-trol module. Do not operate the
engine in the red zone. Engine damage may occur.
TRIP ODOMETER
The trip odometer measures the distance the vehicle
has traveled since it was last reset. It consists of an
instrument cluster gauge connected to the sending unit
on the tasnsaxle output shaft. The trip oddometer can
be record the distance traveled from any starting point.
FUEL GAUGE
The fuel gauge consists of an instrument cluster gauge
connected to a sending unit in the fuel tank. The fuel
gauge indicates the quantity of fuel in the tank only
when the ignition is turned to ON or ACC. When the
ignition is turned to LOCK or START, the pointer may
come to rest at any position.
TEMPERATURE GAUGE
The temperature gauge consists of an instrument
cluster gauge connected to a temperature sensor that
is in con-tact with the circulating engine coolant. The
temperature gauge indicates the temperature of the
coolant. Prolonged driving or idling in very hot weather
may cause the pointer to move beyond the center of
the gauge. The engine is overheating if the pointer
moves into the red zone at the upper limit of the gauge.
INSTRUMENT CLUSTER
INDICATOR LAMPS
The instrument cluster contains indicator lamps that
indicatethe functioning of certain systems or the
existenceof potential problems with the operation of
the vehicle. The indicator lamps are replaceable. For
replacement of the indicator lamps contained in the
instrument cluster, refer to “instrument cluster indicator
lamps specifications” in this section.
CHIME MODULE
The chime module will sound to bring attention to one
or more of the following conditions:
The lights are on and the ignition not in ACC, ON,
or START.
The ignition key is in the ignition switch when the
driver’s side door is open.
The seat belt is unbuckled when the ignition is in
ACC, ON, or START.
Voltage is supplied at all times through the fuse block
to power the chime module.

SSANGYONG MY2002
9E-6 INSTRUMENTATION, DRIVER INFORMATION
Digital Clock Inoperative (Cont’d)
Step
1
2
3
4
5
6
7
8Action
Repair the open power supply circuit for the fuse.
Is the repair complete?
1. Turn the ignition ON.
2. Use a voltmeter to check the battery voltage
available at the clock connector terminal D1.
Does the voltmeter indicate the value specified?
Repair the open circuit between the clock connector
terminal D1 and the fuse F4.
Is the repair complete?
Turn the ignition ON.
Is battery voltage available at the clock connector
terminal C13?
Repair the open circuit between the clock connector
terminal C13 and the fuse F4.
Is the repair complete?
Check continuity between the clock connector
terminal C13 and ground.
Does the multimeter indicate the value specified?
Replace the clock.
Is the repair complete?
Repair the open ground circuit between the clock
connector terminal C13 and the ground G201.
Is the repair complete?Yes
System OK
Go to Step 7
System Ok
Go to Step 9
System OK
Go to Step 10
System OK
System OKNo
−
Go to Step 6
-
Go to Step 8
-
Go to Step 11
-
- Value(s)
−
11 - 14 v
-
-
-
0 Ω
-
-
SPEEDO METER
Speedometer Is Inoperative
Step
1
2
5
6
7
8Action
Check fuse F28, and F30.
Is fuse F28 and F30 blown?
1. Check for a short circuit and repair if necessary.
2. Replace the fuse F28, and F30.
Is the repair complete?
1. Turn the ignition ON.
2. Check the voltage at fuse F28 and F30.
Is the voltage equal to the specified value?
1. connect a scan tool.
2. Check for engine control diagnostic trouble codes
(DTCs).
Is a vehicle speed sensor DTC set?
1. Remove the instrument cluster.
2. Turn the ignition ON.
3. Check the voltage at instrument cluster connector
terminal A1.
Is the voltage equal to the specified value?
Repair the open circuit between fuse F30 and the
instrument cluster.
Is the repair complete?Yes
Go to Step 7
System OK
Go to Step 5
Go to Section
2F, Engine
Controls
Go to Step 8
System OKNo
Go to Step 3
-
Go to Step 4
Go to Step 6
Go to Step 7
- Value(s)
-
-
11 - 14 v
-
11 - 14 v
-

SSANGYONG MY2002
9E-8 INSTRUMENTATION, DRIVER INFORMATION
TEMPERATURE GAUGE
Temperature Gauge Inoperative, Other Gauges OK
Step
1
2
3
4
5
6
7
8
9Action
Allow the engine to cool to room temperature.
With the ignition ON, does the temperature gauge
always read at the high end of the scale?
Disconnect the coolant temperature sensor electrical
connector.
Does the termperature gauge indicator drop to the
low end of the scale?
Replace the coolant temperature sensor.
Is the repair complete?
Check for a short to ground between the coolant
temperature sensor and the temperature gauge.
Is there a short to ground?
Repair the short to ground.
Is the repair complete?
Replace the temperature gauge.
Is the repair complete?
1. Disconnect the coolant temperature sensor.
2. Turn the ignition ON.
3. Check the voltage at the coolant temperature
sensor connector.
Does the the voltage equal the value specified?
Check for an open circuit between the coolant tem-
perature sensor and the temperature gauge.
Is the repair complete?
Repair the open circuit between the coolant tempera-
ture sensor and the temperature gauge.
Is the repair complete?Yes
Go to Step 7
Go to Step 3
System OK
Go to Step 5
System OK
System OK
Go to Step 10
Go to Step 8
System OKNo
Go to Step 2
Go to Step 4
-
Go to Step 6
-
-
Go to Step 8
Go to Step 6
- Value(s)
-
-
-
-
-
-
11 - 14 v
-
-
Fuel Gauge Inoperative (Cont’d)
Step
1
2
3Action
Check continuity between the fuel tank sending unit
connector C303 terminal 3, and groun.
Does the multimeter indicate the specified value?
Repair the open circuit or poor ground connection.
Is the repair complete?
1. With the fuel tank sending unit electrical connector
C303 disconnected, attach a jumper between
ground and C303 terminal 1.
2. Turn the ignition ON.
Does the fuel gauge move to full?Yes
Go to Step 11
System OK
Go to Step 3No
Go to Step 10
-
Go to Step 6 Value(s)
0 Ω
-
-

SQUEAKS AND RATTLES 9K-3
SSANGYONG MY2002
Check for a lack of lubrication of the door hinge pins.ChecksActionOperate the doors and listen for squeaks.
Lubricate the door hinge pins with light oil and coat
with lithium grease.
Squeak Coming From Console When Shifting Manual Transaxle
(Condition Occurs In Cold Weather with a Cold Engine)
Check the manual transaxle control lever lower boot.ChecksActionMove the control lever between gears and listen for
squeaks.
Remove the floor console and replace the lower shift
boot or apply talcum powder to the lower shift boot.
Squeak When Operating Doors
Check for vibration of the fuse box cover against the
instrument panel side trim.ChecksActionTap on thecoverwith a fingerandlisten fora buzz.
Apply 6.35 mm (0.250 inch) by 25.4 mm (1.00 inch)
felt pads to the side trim where the cover makes
contact.
Squeak Coming From Instrument Cluster Trim Plate
Check for rubbing of the cluster trim plate on the
instrument panel.ChecksActionTest drive the vehicle in order to verify this condi-
tion.
Remove the instrument cluster trim plate and install
felt tape to the edges.
Buzz From the Left Side of Instrument Panel
Check the door lock solenoid.
Check for rattling electrical connectors inside the door
trim panel.ChecksActionRemove the door trim panel and check if the sole-
noid is loose.
Tighten the solenoid bolts.
Tap on the trim panel and listen for a rattle.
Remove the trim panel and wrap foam padding
around the connectors as required.
Rattle Coming From Door

SECTION 9N
FRAME AND UNDERBODY
TABLE OF CONTENTS
Specifications.......................................................9N-2
Fastener Tightening Specifications.......................9N-2
Underbody Dimensions.......................................9N-3
Maintenance and Repair.....................................9N-7
On-Vehicle Service.................................................9N-7
Alignment Checking............................................9N-7Floor Pan Insulators.............................................9N-7
Engine Under Covers ...........................................9N-8
General Description and System Operation........9N-9
General Body Construction..................................9N-9
Engine Under Covers ...........................................9N-9

SSANGYONG MY2002
9N-2 FRAME AND UNDERBODY
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Center Member-to-Crossmember Bolt
Center Member-to-Radiator Bolt
Engine Under Cover Bolts
Forward Engine Mount Through-Bolt
Rear Engine Mount Through-BoltApplication
N•m
Lb-FtLb-In
90
90
10
80
8066
66
-
59
59-
-
89
-
-

FRAME AND UNDERBODY 9N-7
SSANGYONG MY2002
ON-VEHICLE SERVICE
ALIGNMENT CHECKING
An accurate method of determining the alignment of
the underbody uses a measuring tram gauge. The tram
gauge set used to perform the recommended
measuring checks must include a vertical pointer able
to reach 457 mm (18 inches).
Two types of measurements can be made with a tram
gauge: direct point-to-point measurements and
measurements calculated on a horizontal plane (datum
line) parallel to the underbody. Point-to-point
measurements are generally taken on steering and
suspension engine compartment parts and simply
require the vertical pointers to be set equally.
For horizontal plane measurements, the vertical pointers
must be set as specified for each point to be measured.
Dimensions-to-gauge holes are measured to the center
of the holes and flush to the adjacent surface metal
unless otherwise specified. It is recommended that
the diagonal dimensions to the cross-body be checked
on both sides in order to verify the dimensional
accuracy of the vehicle underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the
higher floor pan temperatures that result from the use
of the catalytic converter in the exhaust system.
Therefore, when servicing a vehicle, it is essential that
any insulators that may have been disturbed or removed
be reinstalled in the original sequence and location.
Also, if an insulator needs to be replaced, use only
the insula-tion specified for that location on the floor
pan.
When servicing or replacing interior insulators, observe
the following instructions.
•Install the insulators in the original position and
sequence. Butt the pieces together in order to
avoid gapping or overlapping.
If it is necessary to replace an insulator, use only
the specified insulation.
Use the original part to determine the amount of
re-placement material required and as a template
for cutting and fitting the new piece to the floor
pan.
When installing the insulator, do not enlarge any
cut-outs or holes that are used for the attachment
of interior parts such as the instrument panel or
the floor console.
MAINTENANCE AND REPAIR

SSANGYONG MY2002
9N-8 FRAME AND UNDERBODY
KAA9N040
Route the cross-body harness for interior parts
over the floor pan insulators. Clip it in the original
location.
Do not apply spray-on deadeners or trim
adhesives to the top of the floor pan at the area
directly over the catalytic converter or the muffler.
Any insulator service repair or replacement should be
the same thickness, size, and location as the original
installation in the vehicle.
ENGINE UNDER COVERS
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the bolts and the engine under cover.
3. Install the engine under cover with the bolts.
Installation Notice
Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use
the correct fasteners to prevent premature
corrosion.
4. Lower the vehicle.
5. Installation should follow the removal procedure
in the reverse order.
Tightening Torque 10 Nm (89 lb-in)

FRAME AND UNDERBODY 9N-9
SSANGYONG MY2002
GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL BODY CONSTRUCTION
This vehicle is constructed with a unitized body which
in-corporates integral front and rear frame side rails.
The front suspension lower control arms are bolted to
and retained by supports, one each on the right and
left sides. The front suspension lower control arm
supports are attached to the underbody with three bolts
at two locations. The engine is bolted to the integral
front side rails. The suspension strut towers must be
dimensionally correct in relation to the remainder of
the underbody in order to maintain specified
suspension strut and caster/camber angles.
Since the individual underbody parts contribute directly
to the overall strength of the body, it is essential to
observe proper welding techniques during servicerepair operations. The underbody parts should be
properly sealed and rustproofed whenever body repair
operations destroy or damage the original sealing and
rustproofing. When rustproofing critical underbody
parts, use a good-quality type of air-dry primer, such
as a corrosion-resistant chromate or an equivalent
material. Combination-type primer/surfacers are not
recommended.
ENGINE UNDER COVERS
The engine under covers are molded pieces of plastic
that serve as shields for the underside of the engine.
The covers help protect the engine from small rocks,
gravel and other objects that would otherwise come
into contact with the engine during normal driving
conditions.

SSANGYONG MY2002
9R-2 BODY FRONT END
DESCRIPTION AND OPERATION
BODY FRONT END
This vehicle has a unitized body with a frame assembly
supporting the engine and the transaxle. The fender
panels and the radiator support are also integral parts
of the body.