seats SSANGYONG KORANDO 1997 Service Repair Manual

GENERAL INFORMATION 0B -- 13
D AEW OO M Y_2000
OWNER INSPECTIONS AND SERVICES
WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal
travel or repeated puling to one side when braking. Also,
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes inthe sound of the system or
the smell of the fumes. These are signs that the system
may be leaking or overheating. Have the system in-
spected and repaired immediately.
Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the
seats at normal highway speeds. This may mean a
wheel needs to be balanced. Also, a pull right or left on a
straight, level road may show the need for a tire pres-
sure adjustment or a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or has
too much free play, or is unusual sounds are noticed
when turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system
may indicate a problem. Have the system inspected and
repaired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best
time to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil level
on it.
5. Add oil, if needed, to keep the oil level above the low-
er mark. Avoid overfilling theengine, since this may
cause engine damage.
6. Push the indicator all the way back down into the en-
gine after taking the reading.If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the pan
fast enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and
add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST TWICE A MONTH
Tire And Wheel Inspection and Pressure
Check
Check the tire for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold ( check the spare also, unless it is a stow-
away). Maintain the recommended pressures. Refer to
“Tire and Wheel” is in section 0B.
AT LEAST MONTHLY
Light Operation
Check the operation of the license plate light, the head-
lights (including the high beams), the parking lights, the
fog lights, the taillight, the brake lights, the turn signals,
the backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air condition-
ing system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to Section 6A,
Power Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid
level can indicate worn disc brake pads which may need
to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open pas-
sage.
Weather- Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

0B -- 16 GENERAL INFORMATION
D AEW OO M Y_2000
GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
DIf a floor jack is used, the following precautions are
recommended.
DPark the vehicle on level ground, “block” the front or
rear wheels, set the jack against the frame, raise the
vehicle and support it with chassis stands and then
perform the service operation.
DBefore performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damaged and burning due to short --
cir cuiting.
DUse a cover on the body, the seats and the floor to
protect them against damage and contamination.
DHandle brake fluid and antifreeze solution with care
as they can cause paint damage.
DThe use of proper tools, and the recommended es-
sential and available tools where specified, are impor-
tant for efficient and reliable performance of the
service repairs.
DUse genuine DAEWOO parts.DDiscard used cotter pins, gaskets, O -- rings, oil seals,
lock washers and self -- locking nuts. Prepare new
ones for installation. Normal function of these parts
cannot be maintained if these parts are reused.
DKeep the disassembled parts neatly in groups to facil-
itate proper and smooth reassembly.
DKeep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi-
tion of the installation.
DClean the parts before inspection or reassembly.
DAlso clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
DLubricate rotating and sliding faces of parts with oil or
grease before installation.
DWhen necessary, use a sealer on gaskets to prevent
leakage.
DCarefully observe all specifications for bolt and nut
torques.
DWhen service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

1B3 -- 30 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
603 589 00 09 00 Serration Wrench
667589036300 SlidingHammer
Removal & Installation Procedure
1. Using the serration wrench (4), remove the threaded
ring (1).
Serration Wrench 603 589 00 09 00
2. Install the sliding hammer into the prechamber.
Sliding Hammer 667 589 03 63 00
3. Remove the perchamber (2).
Notice
After removing the prechamber, cover over the
bores with clean rag.
4. Inspect the prechamber.
Notice
If the prechamber seats in the cylinder head are
leaking or if the prechambers are replaced, the seal-
ing surfaces in the cylinder head must be rema-
chined.

1B3 -- 126 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
15. Hang the cylinder head (1) to the lifting device and
heat in a water tank to approx. 80_C.
16. Cool down new valve seat ring (2) into the cooling
box with liquidnitrogen.
Notice
Do not touch the cooled valve seat rings with hand.
Super Cooling Box 345 589 00 63 00
17. Drive in new valve seat ring (2) with a proper wood-
en drift.
18. Install the valve guide (3) with a proper drift and as-
sembling tool.
Notice
Thevalveguidemustbedriveninfromthecylinder
head cover.
Drift (Intake) 8mm
Drift (Exhaust) 9mm
19. Machine the valve seats.

1B3 -- 130 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
5. Clean the vales, valve seats and valve guides.
6. Coat the valve stem with oil and insert it into valve
guide.
7. Insert the valves (1) into the valve guides according
to marking.
8. Measure amount by which the valve arrears ’a’.
Arrears ’a’0.1 -- 0.7 mm
Notice
If out of standard, replace the valve seat ring.
9. Measure camshaft cam basic diameter (w).
Diameter ’w’38±0.2 mm
or 37.6±0.2 mm
10. Measure distance ’z’ (cylinder head cover parting
surface -- valve stem).

TRANSFER CASE 5D1-75
SSANGYONG MY2002
KAA5D510
KAA5D520
KAA5D460
3. Install the front output shaft oil seal using oil seal
installer, if removed.
4. Install the front output shaft/flange and install the
snap ring.
8. Assemble the planetary carrier to the sun gear and
input shaft and install the internal snap ring to the
planetary carrier.
9. While expanding the tanged snap ring with SST
snap ring pliers install planetary carrier assembly.
10. Install the high-low shift fork and collar as an
assembly.
Notice: Make sure that the nylon wear pads are
installed on the shift fork and snapped securely
into place. 6. Slide the sun gear, thrust plate and thrust washer
into position on the input shaft.
Notice: The recessed face of the sun gear and
the snap ring groove on the bearing outer race
should be toward the rear of the transfer case.
The stepped face of the thrust washer should face
toward the bearing.
7. Install the bearing over the input shaft using input
shaft bearing installer SST. Install the external snap
ring. 5. Install a new input shaft needle bearing and a new
bushing, if removed. Keep the following steps to
install the bearing and the bushing:
Position the input shaft on input shaft support.
Press a new needle bearing into the end of the
input shaft until it seats in the input shaft using
bearing remover/installer.
Press in a new bushing.

SSANGYONG MY2002
7A-24 HEATING AND VENTILATION SYSTEM
HEATER CORE
Removal and Installation Procedures
1. Disconnect the negative battery cable.
2. Remove the heater/air distribution case from the
vehicle. Refer to “Heater/Air Distribution Case
Assembly” in this section.
3. Remove the plastic holder and two screws that
secure the heater core to heater/air distributor case
assembly.
4. Slowly separate the heater/air distributor case as-
sembly and remove the heater core.
5. Installation should follow the removal procedure
in the reverse order.
REAR HEATER DUCT
This vehicle is equipped with rear seat heater ducts.
Should there be no airflow to the rear, look for any ob-
structions, such as items on the floor under the front
seats. Also check for air leaks between the heater/air
distributor assembly and the rear ducts.
KAA7A190
KAA7D130
KAA7D140
AIR FILTER
Removal and Installation Procedures
Notice: Replace earlier if air pollution is heavy.
1. Open the glove box and pull it inward to release
the upper left and right locking portion.
Notice: Remove the glove box by unscrewing
lower 2 screws, if necessary.
2. Press the 2 filter cover holds and remove the air
filter cover.
3. Remove the 2 air filters.
Notice: For installation, remember the installed
direction of the air filter before removal.
Replacement Interval Every 10,000 km

SSANGYONG MY2002
9G-6 INTERIOR TRIM


y y
y
KAA9G100
KAA9G090
2. Remove the armrest. Refer to Section 9H “SEATS”.
3. Remove the ashtray and compartment lamp from
lower quarter trim panel.
4. Remove the roof rear trim and back panel cover.
LOWER QUARTER TRIM PANEL
Removal and Installation Procedure
1. Lift up the rear seat from the floor.
KAA9G120
KAA9G110
COWL SIDE TRIM PANEL
Removal and Installation Procedure
1. Remove the cowl side trim panel. Refer to front
rocker trim panel in this section.
2. Remove the cowl side trim panel with the screws.
3. Installation should follow the removal procedure
in the reverse order. 5. Remove the lower quarter trim panel with the
screws.
6. Installation should follow the removal procedure
in the reverse order.

INTERIOR TRIM 9G-7
SSANGYONG MY2002
KAA9G140
KAA9G130
FLOOR CONSOLE
Removal and Installation Procedure
1. Remove the screws.
2. Remove the floor console.
3. Disconnect the electrical connector.
4. Installation should follow the removal procedure
in the reverse order.
FRONT ROCKER TRIM PANEL
Removal and Installation Procedure
1. Remove the screws.
2. Remove the rocker trim panel.
3. Installation should follow the removal procedure
in the reverse order.
KAA9G160
KAA9G150
6. Remove the luggage hook with the mounting
screws.
7. Remove the front seat. Refer to Section 9H, Seats.
FLOOR CARPET
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the rear seat. Refer to Section 9H, Seats.
3. Remove the bolts and the left and the right lower
seat belt anchors.
4. Remove the child seat anchor. Refer to Section
9H, Seats.
5. Remove the floor carpet screws.

SECTION 9H
SEATS
TABLE OF CONTENTS
Components Locator............................................9H-2
Seats ...................................................................9H-2
Repair Instructions................................................9H-3
On-Vehicle Service Unit Repair................................9H-3
Front Seat............................................................9H-3
Front Seat Cushion..............................................9H-3
Front Seatback....................................................9H-4
Front Seat Guide Rail ...........................................9H-4
Front Seat Recliner Lever.....................................9H-5
Front Seat Trim....................................................9H-5
Head Restraint.....................................................9H-5Walk In Device....................................................9H-6
Front Seat Armrest...............................................9H-6
Rear Seat Armrest ...............................................9H-6
Rear Seat............................................................9H-7
50/50 Split Rear Seat Cushion Hinge....................9H-7
50/50 Split Rear Seat Cushion Lock Striker...........9H-8
Child Seat Anchorage ..........................................9H-8
Specifications.......................................................9H-9
Fastener Tightening Specifications.......................9H-9
Schematic and Routing Diagram......................9H-10
Seat Heater.......................................................9H-10