ad blue SSANGYONG KORANDO 1997 Service Repair Manual

M162 ENGINE MECHANICAL 1B1 -- 43
D AEW OO M Y_2000
Color Dot
MarkingCrankshaft Journal Diameter
(mm)
Blue57.960 -- 57.965
Yellow57.955 -- 57.960
Red57.950 -- 57.955
White57.945 -- 57.950
Violet57.940 -- 57.945
Selection of Crankshaft Main Bearing
1. Crankcase Side
There are seven punching marks on the mating sur-
face to oil pan. This mark is correspondent to the
bearing distinguished by color. Select the relevant
bearing according to the punching mark when re-
paired.
Punching
Mark
Bearing Color Selected
FBlue
FFYellow
FFFRed
2. Crankshaft Bearing Cap Side
Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Marking
Letter
Bearing Color Selected
BBlue
YYellow
RRed
WWhite
VViolet
Service DataUnit: mm
Crankshaft Stan-
dard and Repair
SizeCrankshaft
Bearing Jour-
nal DiameterCrankshaft
Bearing
DiameterCrankshaft
Journal Width
at fit bearingConnecting Rod
Bearing Journal
DiameterConnecting Rod
Bearing Jourmal
Width
Standard size57.940-- 57.9655824.50-- 24.53347.935-- 47.96527.958-- 28.042
1st repair size57.705-- 57.71547.700-- 47.715
2nd repair size57.450-- 57.46547.450-- 47.465
3rd repair size57.205-- 57.215--47.200-- 47.215--
4th repair size56.955-- 56.96546.950-- 46.965

M161 ENGINE MECHANICAL 1B2 -- 47
D AEW OO M Y_2000
Color Dot
MarkingCrankshaft Journal Diameter
(mm)
Blue57.960 -- 57.965
Yellow57.955 -- 57.960
Red57.950 -- 57.955
White57.945 -- 57.950
Violet57.940 -- 57.945
Selection of Crankshaft Main Bearing
1. Crankcase Side
There are seven punching marks on the mating sur-
face to oil pan. This mark is correspondent to the
bearing distinguished by color. Select the relevant
bearing according to the punching mark when re-
paired.
Punching
Mark
Bearing Color Selected
FBlue
FFYellow
FFFRed
2. Crankshaft Bearing Cap Side
Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Marking
Letter
Bearing Color Selected
BBlue
YYellow
RRed
WWhite
VViolet
Service DataUnit: mm
Crankshaft Stan-
dard and Repair
SizeCrankshaft
Bearing Jour-
nal DiameterCrankshaft
Bearing
DiameterCrankshaft
Journal Width
at fit bearingConnecting Rod
Bearing Journal
DiameterConnecting Rod
Bearing Journal
Width
Standard size57.940-- 57.9655824.50-- 24.53347.935-- 47.96527.958-- 28.042
1st repair size57.705-- 57.71547.700-- 47.715
2nd repair size57.450-- 57.46547.450-- 47.465
3rd repair size57.205-- 57.215----47.200-- 47.215--
4th repair size56.955-- 56.96546.950-- 46.965

OM600 ENGINE MECHANICAL 1B3 -- 25
D AEW OO M Y_2000
6. Pull off the tensioning lever (4) from guide rail pin.
7. Remove the spring (17).
Installation Notice
Insert spring (17) with color coding (blue/violet) fac-
ing up.
8. Pry off the closing cover (12) and remove the socket
bolt (11) and then remove the tensioning pulley (10).
Installation Notice
Tightening Torque29 N∙m (21 lb-ft)
9. Pry off the closing cover (16) and remove the fit bolt
(15).
10. Remove the tensioning lever (14) and washer (13).
11. Clean thread in the timing case cover and fit bolt.
Installation Notice
Apply Loctite on thread of fit bolt.
Tightening Torque100 N∙m (74 lb-ft)
12. Installation should follow the removal procedure in
the reverse order.

OM600 ENGINE MECHANICAL 1B3 -- 87
D AEW OO M Y_2000
Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Marking of basic bearing bore in lower
parting surfaceColor code of relevant crankshaft
bearing shell
1 punch mark or blueBlue or white -- blue
2 punch marks or yellowYellow or white -- yellow
3 punch marks or redRed or white -- red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft
Marking of bearing journals on crank websColor code of relevant crankshaft
bearing shell
Blue or white -- blueBlue or white -- blue
Yellow or white-- blueYellow or white -- yellow
Red or white-- blueRed or white -- red

SSAMGYONG MY2002
3A-22 FRONT AXLE
1. Heel contact
2. Toe contact
3. Face contact
4. Flank contactAdjust backlash
(Drecrease backlash)
Select proper shim(s) to
move the drive pinion
toward the ring gear
(toward toe)
Adjust backlash
(Increase backlash)
Select proper shim(s) to
move the drive pinion
against the ring gear
(toward heel)
Adjust backlash
(Increase pinion shim)
Move the drive pinion
toward the ring gear
(toward center of ring
gear)
Adjust backlash
(Decrease pinion shim)
Move the ring gear toward
the drive pinion (toward
ring gear center line) Excessive backlash (little)
Noise can be occurred
Insufficient backlash (little)
Tooth can be damaged
or broken under heavy
load
Excessive backlash (much)
Drive pinion shaft is
apart from the ring gear
Noise can be occurred
Insufficient backlash (much)
Gear contacts on the
low flank
Gear can be damaged
or worn
Noise can be occurred
Inspection of Ring Gear Tooth Contact
Pattern
Normal Contact
Apply gear-marking compound (Prussian blue / red
lead) on the ring gear teeth. Rotate the ring gear and
check the tooth contact pattern.
KAA3A450
Abnormal Contact
Tooth contact pattern Possible cause Remedy
KAA3A460
KAA3A470
KAA3A480KAA3A500
KAA3A510
KAA3A520
KAA3A490KAA3A530

SSANGYONG MY2002
3D-22 REAR AXLE
Adjust backlash
(Drecrease backlash)
Select proper shin to
move the drive pinion
toward the ring gear
(toward toe)
Adjust backlash
(Increase backlash)
Select proper shim to
move the drive pinion
against the ring gear
(toward heel)
Adjust backlash
(Increase pinion shim)
Move the drive pinion
toward the ring gear
(toward center of ring
gear)
Adjust backlash
(Decrease pinion shim)
Move the ring gear
toward the drive pinion
(toward ring gear
center line) Excessive backlash
Noise can be occurred
Insufficient backlash
Tooth can be damaged
or broken under heavy
load
Excessive backlash
Drive pinion shaft is
apart from the ring gear
Noise can be occurred
Insufficient backlash
Gear contacts on the
low flank
Gear can be damaged
or worn
Noise can be occurred
Inspection of Ring Gear Tooth Contact
Pattern
1. Normal Contact
Apply gear-marking compound (prussian blue/red
lead) on the ring rear teeth. Rotate the ring gear
and check the to the contact pattern.
KAA3D500
Tooth contact pattern Possible cause Remedy
KAA3D510
KAA3D530
KAA3D550KAA3D520
KAA3D540
KAA3D560
KAA3D570KAA3D580
2. Abnormal contact
1. Heel contact
2. Toe contact
3. Face contact
4. Flank contact

AUTOMATIC TRANSMISSION 5A-5
SSANGYONG MY2002
Engine Speed
The engine speed signal is derived from the Control-
ler Area Network (CAN) via Engine Control Module
(ECM).
Vehicle Speed
The vehicle speed sensor, which is located in the
transfer case, sends the output shaft speed signal
to the Engine Control Module (ECM). The information
is then transferred to the TCM via the CAN.
Transmission Fluid Temperature
The transmission fluid temperature sensor is a
thermistor located in the solenoid wiring loom within
the valve body of the transmission. This sensor is
a typical Negative Temperature Coefficient (NTC)
resistor with low temperatures producing a high
resistance and high temperatures producing a low
resistance.
If the transmission fluid temperature exceeds 135
°C (275 °F), the TCM will impose converter lock-up
at lower vehicle speeds and in some vehicles
flashes the mode indicator light. This results in
maximum oil flow through the external oil cooler and
eliminates slippage in the torque converter. Both
these actions combine to reduce the oil temperature
in the transmission.
Minimum Temperature
(°C)Resistance (Ohms)
-20
0
20
100
135 (Overheat
Mode Threshold)13,638
5,177
2,278
117
75
Maximum
17,287
6,616
2, 723
196
85
Pin No. Wire ColorConnects to
1 Red Solenoid 1
2 BlueSolenoid 2
3 YellowSolenoid 3
4 OrangeSolenoid 4
5 GreenSolenoid 5
6 VioletSolenoid 6
7 BrownSolenoid 7
8 GreenSolenoid 5
9 White Temperature Sensor
10 Red Temperature Sensor
Pin No. Codes and colors in Solenoid Loom
KAA5A040KAA5A050
Gear Position Sensor
The gear position sensor is incorporated in the inhibitor
switch mounted on the side of the transmission case.
Inhibit starting of the vehicle when the shift lever is
in a position other than Park or Neutral
Illuminate the reverse lamps when Reverse is se-
lected
Indicate to the TCM which lever position has been
selected by way of a varying resistance. The gear position sensor is a multi-function switch pro-
viding three functions;
KAA5A060

SSANGYONG MY2002
9A-2 BODY WIRING SYSTEM
GENERAL DESCRIPTION
WIRE COLOR CHART
Green
Light Green
Blue
Brown
Orange
Yellow
Grey
Sky Blue
Red
Black
Pink
White
PurpleWire Color Abbreviation On SchematicDK GRN
LT GRN
DK BLU
BRN
ORN
YEL
GRY
LT BLU
RED
BLK
PNK
WHT
PPL

SSANGYONG MY2002
9R-4 BODY FRONT END
ON-VEHICLE SERVICE
UNIT REPAIR
LUBRICATION
The hood hinges and the locking mechanisms require
periodic lubrication for proper operation. Refer to
Section 0B, General Information for the specific types
and intervals of lubrication.
FASTENERS
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fasteners to prevent premature corrosion.
Many aluminum components are used on current
models. Aluminum in contact with steel may corrode
rapidly if it is not protected by special finishes or
isolators.
The fasteners used have a special finish which provides
adequate protection from corrosion. These special
fasteners differ in color to easily identify them from
the standard metric fasteners, which are medium blue
in color.
When replacing fasteners, avoid substituting otherwise
similar fasteners in the same location.
ANTICORROSION MATERIALS
To provide rust resistance, anticorrosion materials have
been applied to the interior surfaces of most of most
of the metal panels. When servicing these panels,
properly recoat them with a service-type anticorrosion
material if any of the original material has been
disturbed.
REPAIR INSTRUCTIONS

HOW TO USE ELECTRICAL WIRING DIAGRAM HOW TO USE ELECTRICAL WIRING DIAGRAM HOW TO USE ELECTRICAL WIRING DIAGRAM HOW TO USE ELECTRICAL WIRING DIAGRAM
HOW TO USE ELECTRICAL WIRING DIAGRAM
1-3 1-31-3 1-3
1-3
Connector
Diode
Fuse in engine room fuse & relay box
Fuse in passenger room fuse box
GroundJoint - Inline wire connected pointSplice pack(Junction connector) C CC C
C
D DD D
D
Ef EfEf Ef
Ef
F FF F
F
G GG G
G
J JJ J
J
S SS S
S
2. 2.2. 2.
2.
CIRCUIT IDENTIFICA CIRCUIT IDENTIFICACIRCUIT IDENTIFICA CIRCUIT IDENTIFICA
CIRCUIT IDENTIFICA
TION SYMBOL TION SYMBOLTION SYMBOL TION SYMBOL
TION SYMBOL
3. 3.3. 3.
3.
FUNCTION OF PO FUNCTION OF POFUNCTION OF PO FUNCTION OF PO
FUNCTION OF PO
WER SUPPL WER SUPPLWER SUPPL WER SUPPL
WER SUPPL
Y LINE (NUMBER) Y LINE (NUMBER)Y LINE (NUMBER) Y LINE (NUMBER)
Y LINE (NUMBER)
IDENTIFICATION IDENTIFICATIONIDENTIFICATION IDENTIFICATION
IDENTIFICATION
SYMBOL SYMBOLSYMBOL SYMBOL
SYMBOLMEANING MEANINGMEANING MEANING
MEANINGPower supply No Power supply NoPower supply No Power supply No
Power supply No
Power supply condition Power supply conditionPower supply condition Power supply condition
Power supply condition
Battery Voltage(B+) supply in Ignition Switch "ON" and "ST" (IGN 1)Battery Voltage(B+) supply in Ignition Switch "ON" (IGN 2)
Battery Voltage(B+) supply in Ignition Switch "ON" and "ACC"
Battery Voltage(B+) supply directly regardless of Ignition Switch
Ground connected to battery(–)Battery Voltage(B+) supply in Head Lamp Switch 1st and 2nd step(Illumination circuit) 15 1515 15
15
15A 15A15A 15A
15A
15C 15C15C 15C
15C
30 3030 30
30
31 3131 31
31
58 5858 58
58
Abbreviation AbbreviationAbbreviation Abbreviation
Abbreviation
Color ColorColor Color
Color
Brown
Green
Violet
Pink
White
Orange
Light Green Br BrBr Br
Br
G GG G
G
V VV V
V
P PP P
P
W WW W
W
Or OrOr Or
Or
Lg LgLg Lg
Lg
Abbreviation AbbreviationAbbreviation Abbreviation
Abbreviation
Color ColorColor Color
Color
Sky Blue
Red
Blue
Yellow
Gray
Black Sb SbSb Sb
Sb
R RR R
R
L LL L
L
Y YY Y
Y
Gr GrGr Gr
Gr
B BB B
B
4. 4.4. 4.
4.
WIRING HARNESS COLOR IDENTIFICA WIRING HARNESS COLOR IDENTIFICAWIRING HARNESS COLOR IDENTIFICA WIRING HARNESS COLOR IDENTIFICA
WIRING HARNESS COLOR IDENTIFICA
TION TIONTION TION
TION5. 5.5. 5.
5.
HO HOHO HO
HO
W W W W
W
T TT T
T
O CHECK O CHECK O CHECK O CHECK
O CHECK
TERMINAL NUMBER OF CONNECT TERMINAL NUMBER OF CONNECTTERMINAL NUMBER OF CONNECT TERMINAL NUMBER OF CONNECT
TERMINAL NUMBER OF CONNECT
OR OROR OR
OR
- Terminal number is given based on Female Terminal Connector
ex) Terminal Number 4 of C901 connection
LockingTerminal Number 4
of total 6 pins
Male Connector
(W/H Fuel Tank)
4
C901
Female Connector
(W/H Floor) C901
W/H Floor132
465