1997 SSANGYONG KORANDO maintenance

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--

1F3 -- 2 OM600 ENGINE CONTROLS
D AEW OO M Y_2000
MAINTENANCE AND REPAIR
ON -- VEHICLE SERVICE
FUEL SYSTEM
1 Fuel Injection Pump
2 Fuel Feed Pump
3 Overflow Valve
4 Injection Nozzle
5 Pre -- filter6 Fuel Retrun Hose
7 Injection Line
8 Fuel Tank
9 Fuel Filter
10 Choke Orifice

SECTION 2E
TIRES AND WHEELS
TABLE OF CONTENTS
Description and Operation....................................2E-2
Tire and Wheel Balancing....................................2E-2
Tire Chain Usage.................................................2E-3
Replacement Tires...............................................2E-3
All Season Tires...................................................2E-3
Passenger Metric Sized Tires...............................2E-3
Tire Label............................................................2E-4
Spare Tire............................................................2E-4
Wheels................................................................2E-4
Inflation of Tires...................................................2E-4
Diagnostic Information and Procedures..............2E-5
Wheel Runout......................................................2E-5
Maintenance and Repair.....................................2E-6
On-Vehicle Service.................................................2E-6Wheel..................................................................2E-6
On-Vehicle Balancing ...........................................2E-7
Unit Repair............................................................2E-8
Alloy Wheel Porosity............................................2E-8
Alloy Wheel Refinishing .......................................2E-8
Off-Vehicle Balancing ..........................................2E-9
Correcting Non-Uniform Tires...............................2E-9
Tire and Wheel Match-Mounting...........................2E-9
Tire Mounting and Dismounting............................2E-9
Specifications.....................................................2E-10
Tire Size and Pressure Specifications.................2E-10
Inflation Pressure Conversion Specifications.......2E-10
Fastener Tightening Specifications.....................2E-10

SSANGYONG MY2002
2E-6 TIRE AND WHEELS
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
WHEEL
Removal Procedure
1. Remove the hub cap.
2. Loosen the wheel nuts.
3. Raise and suitably support the vehicle.
4. Remove the wheel nuts.
Notice: Never use heat to loosen a tight wheel. It
can shorten the life of the wheel, the wheel nuts,
and the wheel bearings. Excessive force, such as
hammering the wheel or tire, can also cause
damage and is not recommended. Slight tapping
of the wheel sidewall with one’s hand or with a
rubber mallet is acceptable.
5. Remove the wheel and tire assembly.
Difficulty in removing the wheels from the vehicle can
be due to foreign material or to a tight fit between the
wheel centerhole and the hub or the rotor. These wheels
can be removed by
1. Retightening the wheel nuts on the affected wheel
and then loosening the wheel nuts by two turns.
2. Lowering the vehicle and rocking it from side to
side as hard as possible, using one or more
person’s body weight to loosen the wheel.
3. Raising the vehicle and removing the wheel.
Caution: Do not allow the penetrating oil to get on
the vertical surfaces between the wheel and the drum
(or rotor) because penetrating oil in this area could
cause the wheel to work loose as the vehicle is
driven, resulting in loss of control and an injury
accident.
Penetrating oil is not effective in removing tight wheels.
If it is used, however, apply it sparingly and only to the
wheel’s centerhole area.
Installation Procedure
Notice: Before installing the wheels, remove any build-
up of corrosion on the wheel mounting surface and the
rotor mounting surface by scraping and brushing them
with a wire brush. Installing the wheels without good
metal-to-metal contact at the mounting surfaces can
cause the wheel nuts to loosen, which can later allow a
wheel to come off while the vehicle is moving. Wheel
bolts must be tightened in sequence and to the proper
torque to avoid bending the wheel or the rotor.
KAA2E050

FRONT AXLE 3A-5
SSANGYONG MY2002
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
VACUUM LINE
1 Hub A-Auto Vac Locking
2 Valve-Check
3 Valve A-Solenoid
4 Connector
5 House-Vcuum
6 Hose-Vacuum
7 Hose-Vacuum
8 Hose-Vacuum
9 Hose
10 Tube-corruagated
11 Clip
12 Band
KAA3A030
13 Clip
14 Bolt
15 Tube A-Vacuum
16 Clip-L/Hub Hose MTG
17 Cap-Hub Flange FRT
18 Flange-Hub FRT
19 Cap
20 Bolt
21 Washer
22 Ring-Retainer
23 Bolt

SECTION 3D
REAR AXLE
TABLE OF CONTENTS
General Description and Operation.................3D-2
Specifications...................................................3D-2
Fastener Tightening Specifications..................3D-2
Diagnostic Information and Procedures........3D-3
Component Locator .........................................3D-4
Rear Axle Assembly .........................................3D-4
Cross Sectional View........................................3D-5
Rear Axle Shaft Assembly...............................3D-6
Maintenance and Repair..................................3D-8
On-Vehicle Service ..............................................3D-8Axle Shaft Assembly (With Disc Brake)..........3D-8
Axle Shaft Assembly (With Drum Brake)...... 3D-11
Rear Axle Housing .......................................... 3D-13
Unit Repair....................................................... 3D-18
Axle Assembly............................................... 3D-18
Differential Gear Assembly............................ 3D-20
Drive Shaft...................................................... 3D-25
Special Tools and Equipment....................... 3D-26
Special Tools Table........................................ 3D-26

SSANGYONG MY2002
3D-8 REAR AXLE
ON-VEHICLE SERVICE
AXLE SHAFT ASSEMBLY
(WITH DISC BRAKE)
Removal
1. Remove the tire.
KAA3D050
KAA3D070
KAA3D060
2. Release the parking brake.
3. Remove the fixing pin of parking brake.
4. After detaching the parking brake lever, detach
the cable.
5. Remove the two fixing bolt of brake caliper.
Notice: Be careful not to damage the brake oil
hose.
6. Remove the brake caliper assembly.
Notice: If replacing the brake pad only, remove the
upper fixing bolt of caliper pad and lower it.
MAINTENANCE AND REPAIR

FRONT BRAKES 4D-5
SSANGYONG MY2002





yyyy yyyy
yyyy
yyyy
yyyy
yyyy






yyyyy yyyyy
yyyyy
yyyyy
yyyyy
yyyyy
yyyyy
DIAGNOSTIC INFORMATION AND PROCEDURES
KAA4D020
PAD INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the front wheel. Refer to Section 2E, Tires
and Wheels.
3. Visually check the linings for minimum thickness
and wear.
4. Measure the thickness.
Important: The minimum discard thickness of the
lining is 2 mm (0.08 inch).
5. Install the pads in axle sets only.
6. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
FRONT DISC BRAKE ROTOR
INSPECTION
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the
rotor.
A rotor that varied by more than 0.013 mm (0.0005
inch) can cause pedal pulsations and/or front end
vibration during brake applications. A rotor that does
not meet these specifications should be refinished to
specifications or replaced.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness, thick-
ness variation, and lateral runout are held very close.
The maintenance of close tolerances on the shape of
the braking surfaces is necessary to prevent brake
roughness.In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic
performance and to extend lining life.
Light scoring of the rotor surfaces not exceeding 0.4
mm (0.016 inch) in depth, which may result from normal
use, is not detrimental to brake operation.
Using a commercially available dial indicator, check
lateral runout as follows:
Notice: Permissible lateral runout is a maximum 0.07
mm (0.003 inch). If lateral runout exceeds the specifica-
tion, ensure that there is no dirt between the rotor and
the hub and that contact surfaces are smooth and free
from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten the brake rotor to the wheel hub with two
wheel nuts. Refer to Section 2E, Tires and Wheels.
KAA4D030
4. Fasten a dial indicator to the brake caliper.
5. Set the gauge probe tip to approximately 10 mm
(0.394 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.
6. Remove the dial indicator and the wheel nuts that
connect the rotor to the hub.
Important: Since accurate control of the tolerances
is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only
with precision equipment.
7. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
8. Install the rotor. Refer to “Rotor” in this section.