cap SSANGYONG KORANDO 1997 Service Repair Manual

GENERAL INFORMATION 0B -- 3
D AEW OO M Y_2000
Clutch - Manual Type
Application661LA662NA662LA2.0L
DOHC2.3L
DOCH3.2L
DOCH
Ty p eSingle Dry Diaphram
Outside Diameter (mm)225225240225225240
Inside Diameter (mm)150150150150150155
Thickness9.29.29.29.29.29.3
FluidCommon use :Brake Fluid
Manual Transmission
Application661LA662NA662LA2.0L
DOHC2.3L
DOCH3.2L
DOCH
MakerTREMECTREMECTREMECTREMECTREMECTREMEC
Type or ModelT5T5T5T5T5T5
Gear Ratio : 1st3.9693.9693.9693.9693.9693.969
2nd2.3412.3412.3412.3412.3412.341
3rd1.4571.4571.4571.4571.4571.457
4th1.0001.0001.0001.0001.0001.000
5th0.8510.8510.8510.8510.8510.851
Reverse3.7053.7053.7053.7053.7053.705
Final Drive Ratio4.554.554.554.894.553.73
Oil Capacity (L)3.43.43.43.43.43.4
Auto Transmission
Application661LA662LA2.3L DOCH3.2L DOCH
MakerBTRABTRABTRABTRA
Type or ModelM74 4WDM74 4WDM74 4WDM74 4WD
Gear Ratio : 1st2.7412.7412.7412.741
2nd1.5081.5081.5081.508
3rd1.0001.0001.0001.000
4th0.7080.7080.7080.708
Reverse2.4292.4292.4292.429
Final Drive Ratio5.3804.8905.8604.890
Oil Capacity (L)9999
Brake
ApplicationSpecifications
Booster Sizenon-- ABS8inch + 9inch
ABS 5.07inch + 8inch
ABS 5.38inch + 9inch
Master Cylinder Diameter(mm)φ25.4
Booster Ratio5.6 : 1
Front Brake : Disc Type
Rear Brake : Disc TypeVentilated
Solid

0B -- 4 GENERAL INFORMATION
D AEW OO M Y_2000
Tire and Wheel
ApplicationSpecifications
Standard Tire SizeP235/75 R15, 255/70 R15
Standard Wheel Size7JJx15
Inflation Pressure At Full Lode
P235 / 75 : Front
Rear
P255 / 75 : Front
Rear
30 Psi
30 Psi
30 Psi
30 Psi
Steering System
ApplicationSpecifications
Gear TypeRACK & PINION
Wheel Alignment:
Front: Toe -- in
Front: Caster
Front: Camber
0--4mm
2°30′±30′
0°±30′
Oil Capacity1L
Suspension
ApplicationSpecifications
Front TypeDouble Wishbone
Rear Type5--Link
Fuel System
ApplicationSpecifications
Fuel Pump TypeElectric Motor Pump
Fuel Capacity70 L
Lubricating System
Application661LA662NA662LA2.0L
DOHC2.3L
DOCH3.2L
DOCH
Oil Pump TypeExternal Gear pump
Oil Filter TypeCombination (Full & Part)Full Flow
Oil Capacity (L)
(Including Oil Filter)8.09.09.57.27.58.2
Cooling System
Application661LA662NA662LA2.0L
DOHC2.3L
DOCH3.2L
DOCH
Coolant Capacity (L)9.5 -- 1010.510.5 -- 1110.510.511. 3
Radiator TypeForced Circulation
Water Pump TypeCentrifugal

0B -- 6 GENERAL INFORMATION
D AEW OO M Y_2000
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
ApplicationSpecifications
Overall Length(mm)4330
Overall Width (mm)1841
Overall Height (mm)1840
Wheel Base(mm)2840
Tread : Front (mm)
Rear (mm)1510
1520
Vehicle Weights
Application661LA662NA662LA2.0L
DOHC2.3L
DOCH3.2L
DOCH
Manual : Curb Weight (kg)
Gross Vehicle
Weight (kg)1790
25151810
25151830
25151790
25151790
25151840
2515
Automatic : Curb Weight (kg)
Gross Vehicle
Weight (kg)1810
25151815
25151850
2515--
--1810
25151860
2515
Passenger Capacity555555

0B -- 14 GENERAL INFORMATION
D AEW OO M Y_2000
EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Inspect other brake parts, the parking
brake, etc., at the same time. Inspect the brakes more
often if habit or conditions result in frequent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle
boot and seals for damage, tears or leakage. Replace
the seals if necessary.
Exhaust System Inspection
Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the ex-
haust system. Look for broken, damaged, missing, or
out -- of -- position parts as well as open seams, holes,
loose connections, or other conditions which could
cause heat buildup in the floor pan or could let exhaust
fumes seep into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints
and throttle cable joints, the intermediate throttle shaft
bearing, the return spring at throttle valve assembly, and
the accelerator pedal sliding face with suitable grease.
Check the throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the sec-
ondary latch. It should keep the hood from opening all
the way when the primary latch is released. The hood
must close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
and the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare
tire, all the jacking equipment, and the tools must be se-
curely stowed at all times. Oil the jack ratchet or the
screw mechanism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the
latches, the glove box and the console doors, and any
folding seat hardware.
Underbody Flushing
Flushing the underbody will remove any corrosive mate-
rials used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then
flush the underbody with plain water.
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the
fluid is dirty or rusty, drain, flush and refill the engine
cooling system with new coolant. Keep the coolant at
the proper mixture in order to ensure proper freeze
protection, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
swollen, or deteriorated hoses. Tighten the clamps.
Clean the outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure
test the cooling system and the cap in order to help en-
sure proper operation.

GENERAL INFORMATION 0B -- 15
D AEW OO M Y_2000
RECOMMENDED FLUIDS AND LUBRICANTS
UsageCapacityFluid/Lubricant
Engine Oil
(Change with filter)3.2L DOHC8.2 LQuality class -- API ; SH grade or above
ACEA ; A2 or A3
(Changewithfilter)
2.3L DOHC7.5 L
ACEA;A2orA3
MB sheet ; 229.1
Viscosity -- MB sheet ; 224.1
662LA9.5 LQuality class -- API ; CG grade or above
ACEA ; B2 or B3
MBsheet;22812283661LA8.0 LMBsheet ; 228.1, 228.3,
228.5, 229.1
Viscosity -- MB sheet ; 224.1
Engine Coolant3.2L DOHC11. 3 LALUTEC P-- 78g
2.3L DOHC10.5 L
662LA10.5 -- 11.0 L
661LA9.5 -- 10.0 L
Brake / Clutch FluidApprox. 0.5L level must
be maintained between
MAX&MINlevelDOT -- 3 & SAE J 1703
Power Steering System1.0 LATF DEXRON--II
Parking Brake CableAs requiredGrease
Hood Latch AssemblyAs requiredGrease
Hood and Door Hinges
Fuel Door Hinge
Rear Compartment Lid HingesAs requiredSpray type grease
WeatherstripsAs requiredSilicone grease

1A1 -- 2 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
SPECIFICATIONS
ENGINE SPECIFICATIONS
ApplicationE32 Engine
Engine ModelM162.990
Displacement (CC)3199
Cylinder (Bore x Stroke)(mm)89.9 x 84.0
Fuel Injection / Ignition SystemMSE 3.62S
Compression Ratio10 : 1
Number of Cylinders6
Camshaft Valve ArrangementDOHC
Camshaft Drive TypeChain-- Driven
Max. Output (ps/rpm)222 / 5500
Max. Torque (kgSm/rpm)31.6 / 3750
Firing Order1--5--3--6--2--4
Ignition TypeDistributorless Double Ignition
Ignition TimingBTDC 8°±2°
Valve TimingIntakeOpen/CloseAT DC 11°/ ABDC 34°g
ExhaustOpen/CloseBBDC 31°/BTDC14°
Valve Clearance AdjustmentAutomatic Control
Idle Speed (rpm)700±50
Fuel Injection Pressure (kg/cm@)3--4
Oil Capacity (liter)8.2
Lubrication TypeForced by Gear Pump
Oil Filter TypeFull Flow with Paper Filter
FuelUnleaded Gasoline
MSE 3.62S/3.53S (Motorsteuer Elektronik : German)
MSE : Engine Control Electronic
3.62S : 6 Cylinder Version
3.53S : 4 Cylinder Version

1A1 -- 10 GENERAL ENGINE INFORMATION
D AEW OO M Y_2000
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap
4 Vibration Damper6 Cylinder Pressure Leakage Tester with
Connecting Hose
Permissible Pressure Leakage
At Whole EngineMax. 25 %
At Valve and Cylinder Head GasketMax. 10 %
At Piston and Piston RingMax. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC MarkOT (TDC)a(120°)b (240°)
Cylinder Number1, 62, 53, 4
Universal Tool
Cylinder Pressure Leakage TesterBosch, EFAW 210A
Sun, CLT 228

GENERAL ENGINE INFORMATION 1A1 -- 11
D AEW OO M Y_2000
Leakage Test
1. Warm the engine up to normal operating tempera-
ture.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant
surge tank cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the
scale of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotat-
ing the crankshaft.
9. Connect the connecting hose to tester and measure
the leakage volume after blowing up compressed
air.
Notice:Measure the leakage volume in the completely
opening condition of throttle valve by pulling the accel-
eration cable.
10. Perform the pressure test according to the firing or-
der.
Notice:
FiringOrder:1--5--3--6--2--4
11. Compare the leakage pressure with the specifica-
tions.

1B1 -- 2 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-FtLb-In
Fuel Feed and Return Line21 -- 2515 -- 18--
Exhaust Manifold and Pipe3022--
Propeller Shaft to Transmission81 -- 8960 -- 66--
Engine Mounting Nuts7052--
Generator Carrier Bolts2518--
Tensioning Pulley Bolt40.5 -- 49.529.9 -- 36.5--
Steering Pump Bolts22.5 -- 27.516.6 -- 20.3--
A/C Bracket Bolts22.5 -- 27.516.6 -- 20.3--
Intake Air Duct Mounting Nuts9--11--80 -- 97
Spark Plug Cover Bolts9--11--80 -- 97
Cylinder Head Cover Bolts9--11--80 -- 97
Magnetic Assembly Bolt9--11--80 -- 97
Cylinder Head Front Cover Bolt22.5 -- 27.516.6 -- 20.3--
Cylinder Head Bolts55
+90°
+90°41
+90°
+90°
--
Timing Gear Case Cover BoltsM822.5 -- 27.516.6 -- 20.3--g
M69--11--80 -- 97
Crankshaft Sealing Rear Cover Mounting Bolts9--11--80 -- 97
Vibration Damper Center Bolt200 + 20
+90°+10°148 + 15
+90°+10°--
Connecting Rod Bearing Cap Bolts40
+90°30
+90°--
Flywheel Mounting Bolt45 + 5
+90°+10°33 + 3.7
+90°+10°--
Amarture Bolt3526--
Camshaft Adjuster Flange Bolts18 -- 22
60°±5°13 -- 16
60°±5°--
Intake Flange Shaft Bolts18 -- 22
60°±5°13 -- 16
60°±5°--
Exhaust Camshaft Sprocket Bolts18 -- 22
60°±5°13 -- 16
60°±5°--
Camshaft Bearing Cap Bolts22.5 -- 27.516.6 -- 20.3--
Chain Tensioner Screw Plug4030--
Chain Tensioner Assembly72 -- 8853 -- 65--
Oil Pump Sprocket Bolt29 -- 3521 -- 26--
Tensioning Device Bolts26 -- 3219 -- 24--
Water Pump Pulley Bolts22.5 -- 27.516.6 -- 20.3--
Upper Intake Manifold Bolt22.5 -- 27.516.6 -- 20.3--
Lower Intake Mainfold Bolt22.5 -- 27.516.6 -- 20.3--
Flange Bolt to Exhaust Mainfold3022--

M162 ENGINE MECHANICAL 1B1 -- 3
D AEW OO M Y_2000
FASTENER TIGHTENING SPECIFICATIONS (Cont’d)
ApplicationNSmLb-FtLb-In
Exhaust Mainfold Nut to Stud Bolt26 -- 3419 -- 25--
Oil Drain Plug2518--
Oil Filter Cover2518--
Oil Filter Bolt2518--
Oil Pump Drive Sprocket Bolt29 -- 3521 -- 26--
Oil Pump Mounting Bolt22.5 -- 27.516.6 -- 20.3--
Oil Strainer Bracket Bolt9--11--89 -- 97
Oil Pressure Relief Valve Screw Plug5037--
Oil Dipstick Guide Tube Bolt9--11--89 -- 97
Oil Gallery Screw Plug1511--
Torque Converter Mounting Bolts4231--
Crankshaft Bearing Cap Bolts55/+90°41/+90°--
Oil Pan Mounting BoltsM82518--g
M610--89