1997 SSANGYONG KORANDO manual transmission

SSANGYONG MY2002
5D2-2 TRANSFER CASE (PART TIME - 4408)
2WD Drive (Rear
Wheel Drive)
4WD Drive (High
Speed)
4WD Drive (Low
Speed)
2WD Drive
↔ 4WD
Drive (High Speed)
2WD Drive, 4WD
Drive (High Speed)
↔ 4WD Drive (Low
Speed)
GENERAL INFORMATION AND OPERATION
4WD OPERATION OVERVIEW
Driving Type
Transferring2H
4H
4L
2H
↔ 4H
2H, 4H
↔ 4L Application
•Normal Driving on the normal road or highway, or
high speed driving
Slipped road such as snow, rainy, sand, mud etc.
Max driving force requiring condition such as
towing, rough road.
When a vehicle is driven in turning at low speed on
the paved road, a vibration and a noise may be
occurred by tight corner braking.
2WD ↔ 4WD transfer is possible below 70 km
without operating the clutch.
Manual Transmission
Transfer starts after the vehicle stops and the clutch
is applied
Automatic Transmission
Transfer starts after the vehicle stops and the shift
lever is shifted [N] position.
Notice: After the vehicle stops and the mode switch
is selected with applying the brake pedal, shifting
[N-R-N] makes the mode transfer easier.
Operation ConditionMode Position

SSANGYONG MY2002
5D2-8 TRANSFER CASE (PART TIME - 4408)
KAA5D050
KAA5D060
KAA5D070
1. Shifting from 2H to 4H
Position the transfer case switch from ‘2H’ to
‘4H’.
Shifting is possible during driving.
‘4WD Hl’ indicator light will turn on.
2. Shifting from 4H to 2H
Position the transfer case switch from ‘4H’ to
‘2H’.
Shifting is possible during driving.
4WD Hl’ indicator light will turn off.
SYSTEM DESCRIPTION
Transfer Case Control Unit (TCCU)
TCCU is located under the front left handed seat and
permits the vehicle to shift from two-wheel drive to
four-wheel drive (and back shift) according to drivers
switch operation during driving (For the shifting
between 4WD HIGH and 4WD LOW, stop the vehicle).
3. Shifting between 4H and 4L
Shifting is possible when the vehicle is almost
stopped (below approx. 2 km/h), so it would be
better stop the vehicle.
In case of manual transmission equipped
vehicle, apply clutch pedal.
In case of auto transmission equipped vehicle,
put the lever position into ‘N’.
Position the transfer case switch ‘4H’ to ‘4L’
or ‘4L’ to ‘4H’.
According to the shifted position, indicator light
will turn on.
Notice: If there are malfunctions during shifting,
‘4H’ or ‘4L’ indicator light will blink.

BODY WIRING SYSTEM 9A-23
SSANGYONG MY2002
Manual Transmission
1 C302
2 Back up switch
3 Micro switch4 Engine oil pressure switch
5 Engine speed sensor
YAD9B350

2-4 2-4 2-4 2-4
2-4
ELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMSELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMS
ELECTRICAL WIRING DIAGRAMS
Engine Room Fuse Box - W/H Main
Engine Room Fuse Box - W/H Main
Engine Room Fuse Box - W/H Main
Engine Room FuseBox - W/H Main
Engine Room Fuse Box - W/H Engine Room
Engine Room Fuse Box - W/H Engine Room
Engine Room Fuse Box - W/H Engine Room
Engine Room Fuse Box - W/H Engine Room
W/H Engine Room - W/H Pre - Heating
W/H Engine Room - W/H Alternator
W/H Engine Room - W/H Alternator
W/H Engine Room - W/H Wheel G. sensor
W/H Engine Room - W/H Main
W/H Engine Room - W/H Main
W/H Engine Control - W/H ECM Main
W/H Engine Control - W/H ECM Main
W/H Main - W/H Fuel Cut Solenoid
W/H Main - W/H Roof
W/H Main - W/H Air Bag
W/H Main - W/H Air Bag
W/H Main - W/H SDM
W/H Main - W/H Air Conditioner
W/H Main - W/H ECM Main
W/H Main - W/H Transmission
W/H Main - W/H Transmission
W/H Main - W/H Transmission
W/H Main - W/H Fuel Pump
W/H Main - W/H Fuel Pump
W/H Main - W/H Fuel Pump
W/H Main - W/H Seat Heater
W/H Main - W/H Main
W/H Main - W/H FRT LH Door
W/H FRT LH Door - W/H Speaker
W/H Main - W/H FRT RH Door
W/H FRT RH Door - W/H Speaker
G201W/H Main Upper Front Left Leg Room
G202W/H Main Upper Front Left Leg Room
G203W/H Main Left Upper Center Facia
G204W/H Main Left Lower Center Facia
G205W/H Main Center "A" Pillar Front Right
G301W/H Main Below Front Left seat
G302W/H Main Below Center Console
G303W/H Main Below Front Right seat
G401W/H Main Inside Lower Trim Rear Left Quater
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Engine Room Fuse Box
Bhind Battery
Below Air Cleaner
Below Air Cleaner
Upper Front Right Control Arm
Next to Hydraulic Unit
Next to Hydraulic Unit
Behind Hydraulic Unit
Behind Hydraulic Unit
Next to Engine Room Fuse Box
Inside Left Cluster
Above FRT LH Seat Under Cover
Above FRT LH Seat Under Cover
Lower Rear Center Facia
Upper Evaporator
Lower "A" Piller(Upper ECM)
Upper Transfer Case
Upper Transfer Case
Upper Transfer Case
Upper Transfer Case
Upper Transfer Case
Upper Transfer Case
Below FRT LH Seat
Below Center Console
Upper Fuse Box
(Passenger Room)
Inside FRT LH Door Trim
Behind Front Right Panel
Inside FRT RH Door Trim
2. 2.2. 2.
2.
CONNECT CONNECTCONNECT CONNECT
CONNECT
OR, OR,OR, OR,
OR,
GR GR GR GR
GR
OUND AND SPLICE PA OUND AND SPLICE PAOUND AND SPLICE PA OUND AND SPLICE PA
OUND AND SPLICE PA
CK INFORMA CK INFORMACK INFORMA CK INFORMA
CK INFORMA
TION TIONTION TION
TION1) 1)1) 1)
1)
CONNECTOR CONNECTORCONNECTOR CONNECTOR
CONNECTORConnector Number Connector NumberConnector Number Connector Number
Connector Number
(Pin Number, Color) (Pin Number, Color)(Pin Number, Color) (Pin Number, Color)
(Pin Number, Color)Connecting Connecting Connecting Connecting
Connecting
Wiring Harness Wiring HarnessWiring Harness Wiring Harness
Wiring Harness
Connector Position Connector PositionConnector Position Connector Position
Connector Position
C101 (19Pin, White)
C102 (4Pin, Colorless)
C103 (22Pin, White)
C104 (8Pin, Colorless)
C105 (10Pin, White)
C106 (3Pin, Black)
C107 (20Pin, White)
C108 (6Pin, Colorless)
C109 (1Pin, Black)
C110 (2Pin, Black)
C110 (4Pin, Black)
C111 (3Pin, Black)
C112 (6Pin, Black)
C113 (12Pin, Black)
C114 (6Pin, Gray)
C115 (40Pin, Black)
C116 (3Pin, Black)
C201 (8Pin, White)
C202 (4Pin, White)
C203 (2Pin, Black)
C204 (4Pin, Colorless)
C205 (17Pin, White)
C206 (6Pin, Black)
C301 (2Pin, Black)
C301 (16Pin, Black)
C302 (10Pin, Black)
C303 (3Pin, Black)
C303 (4Pin, Black)
C303 (6Pin, Black)
C304 (10Pin, White)
C305 (14Pin, White)
C351 (22Pin, White)
C352 (2Pin, Black)
C361 (22Pin, Blue)
C362 (2Pin, Black)
2) 2)2) 2)
2)
SPLICE PACK SPLICE PACKSPLICE PACK SPLICE PACK
SPLICE PACK
S201
S202
S203
S204
S205Splice Pack Position Splice Pack PositionSplice Pack Position Splice Pack Position
Splice Pack Position Wiring WiringWiring Wiring
Wiring
Harness HarnessHarness Harness
Harness Color ColorColor Color
Color Splice Pack Splice PackSplice Pack Splice Pack
Splice Pack
Number NumberNumber Number
Number
Colorless
Black
Colorless
Colorless
ColorlessW/H Main
W/H Main
W/H Main
W/H Main
W/H MainUpper Fuse Box(Passenger Room)
Behind Cluster
Behind 4WD Switch
Behind Audio
Behind Front Right Kick Panel
Remark RemarkRemark Remark
Remark
Diesel only
Gasoline
Diesel
Gasoline
Gasoline
Diesel
Gasoline
Manual T/M
Automatic T/M
Diesel
Diesel
Gasoline
GSL : EURO IIIBehind Left Tail Lamp
Behind Left Tail Lamp
Inside Rear Bumper
Inside Tail Gate
Connector Number Connector NumberConnector Number Connector Number
Connector Number
(Pin Number, Color) (Pin Number, Color)(Pin Number, Color) (Pin Number, Color)
(Pin Number, Color)Connecting Connecting Connecting Connecting
Connecting
Wiring Harness Wiring HarnessWiring Harness Wiring Harness
Wiring Harness
Connector Position Connector PositionConnector Position Connector Position
Connector Position
C401 (2Pin, Black)
C402 (12Pin, Black)
C403 (3Pin, Black)
C404 (2Pin, Black)W/H Tail Gate - W/H Main
W/H Tail Gate - W/H Main
W/H Rear Bumper - W/H Main
W/H Tail Gate - W/H HMSL
Remark RemarkRemark Remark
Remark
3) 3)3) 3)
3)
GROUND GROUNDGROUND GROUND
GROUND
G101
G102
G103Ground Position Ground PositionGround Position Ground Position
Ground Position
Wiring Harness Wiring HarnessWiring Harness Wiring Harness
Wiring Harness Number NumberNumber Number
Number
Ground GroundGround Ground
Ground
W/H Engine Room
Battery
W/H Engine RoomLeft Fender Next to Battery
Center Engine Block
Right Fender Engine Room
Pin PinPin Pin
Pin
Number NumberNumber Number
Number
8
20
14
14
8

2-14 2-14 2-14 2-14
2-14
ELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMSELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMS
ELECTRICAL WIRING DIAGRAMS10) 10)10) 10)
10)
W/H TRANSMISSION W/H TRANSMISSIONW/H TRANSMISSION W/H TRANSMISSION
W/H TRANSMISSION
1. C301
2. C302 (Diesel E/G)
3. Transmission
4. T/M Lever
5. Inhibitor switch
6. Micro switch (Diesel E/G)
7. Throttle position sersor (Diesel E/G)
8. Engine oil pressure switch
9. Engine speed sensor (Diesel E/G)1. C302
2. Back up switch
3. Micro switch
4. Engine oil pressure switch
5. Engine speed sensor • AUTOMATIC TRANSMISSION MANUAL TRANSMISSION

CONTENTS CONTENTSCONTENTS CONTENTS
CONTENTS
1. 1.1. 1.
1.
ST STST ST
ST
AR ARAR AR
AR
TING & CHARGING SYSTEM TING & CHARGING SYSTEMTING & CHARGING SYSTEM TING & CHARGING SYSTEM
TING & CHARGING SYSTEM
........................................................................................... ...................................................................................................................................................................................... ...........................................................................................
...........................................................................................
5-6 5-6 5-6 5-6
5-6
1) DIESEL..................................................................................................................................................................... 5-6
2) GASOLINE.................................................................................................................................................................. 5-8
2. 2.2. 2.
2.
DIAGNOSIS CONNECTOR DIAGNOSIS CONNECTORDIAGNOSIS CONNECTOR DIAGNOSIS CONNECTOR
DIAGNOSIS CONNECTOR
........................................................................................................ ................................................................................................................................................................................................................ ........................................................................................................
........................................................................................................
5-10 5-10 5-10 5-10
5-10
1) DIESEL................................................................................................................................................................... 5-10
2) GASOLINE.............................................................................................................................................................. 5-12
(1) W/O EURO III .................................................................................................................................................................................... 5-12
(2) W/ EURO III ....................................................................................................................................................................................... 5-14
3. 3.3. 3.
3.
PRE-HEA PRE-HEAPRE-HEA PRE-HEA
PRE-HEA
TING SYSTEM TING SYSTEMTING SYSTEM TING SYSTEM
TING SYSTEM
............................................................................................................ ........................................................................................................................................................................................................................ ............................................................................................................
............................................................................................................
5-16 5-16 5-16 5-16
5-16
4. 4.4. 4.
4.
EGR (EXHA EGR (EXHAEGR (EXHA EGR (EXHA
EGR (EXHA
UST GAS RECIRCULA UST GAS RECIRCULAUST GAS RECIRCULA UST GAS RECIRCULA
UST GAS RECIRCULA
TION) SYSTEM TION) SYSTEMTION) SYSTEM TION) SYSTEM
TION) SYSTEM
............................................................... .............................................................................................................................. ...............................................................
...............................................................
5-18 5-18 5-18 5-18
5-18
1) MANUAL TRANSMISSION .................................................................................................................................... 5-18
2) AUTOMATIC TRANSMISSION.............................................................................................................................. 5-20
5. 5.5. 5.
5.
ECM (ELECTRONIC CONTROL MODULE) : E23 MSE ECM (ELECTRONIC CONTROL MODULE) : E23 MSEECM (ELECTRONIC CONTROL MODULE) : E23 MSE ECM (ELECTRONIC CONTROL MODULE) : E23 MSE
ECM (ELECTRONIC CONTROL MODULE) : E23 MSE
......................................................... .................................................................................................................. .........................................................
.........................................................
5-22 5-22 5-22 5-22
5-22
1) SENSOR (CRANK SHAFT POSITION, ACCELERATION PEDAL), THROTTLE MOTOR & SENSOR, IGNTION
COIL & SPARK PLUG ........................................................................................................................................... 5-22
SECTION 5 SECTION 5SECTION 5 SECTION 5
SECTION 5
ELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMSELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMS
ELECTRICAL WIRING DIAGRAMS

5-18 5-18 5-18 5-18
5-18
ELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMSELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMS
ELECTRICAL WIRING DIAGRAMS
a. a.a. a.
a.
CONNECTOR INFORMATION CONNECTOR INFORMATIONCONNECTOR INFORMATION CONNECTOR INFORMATION
CONNECTOR INFORMATION
b. b.b. b.
b.
CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITIONCONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
EGR UNIT
EGR SOLENOID ENGINE SPEED
SENSOR
C302 (BLACK)
4. 4.4. 4.
4.
EGR (EXHA EGR (EXHAEGR (EXHA EGR (EXHA
EGR (EXHA
UST GAS RECIRCULA UST GAS RECIRCULAUST GAS RECIRCULA UST GAS RECIRCULA
UST GAS RECIRCULA
TION) SYSTEM TION) SYSTEMTION) SYSTEM TION) SYSTEM
TION) SYSTEM1) 1)1) 1)
1)
MANUAL TRANSMISSION MANUAL TRANSMISSIONMANUAL TRANSMISSION MANUAL TRANSMISSION
MANUAL TRANSMISSION
MICRO SW
C302 (10Pin, Black)
G205
G301CONNECTOR(NUMBER) CONNECTOR(NUMBER)CONNECTOR(NUMBER) CONNECTOR(NUMBER)
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESS CONNECTING. WIRING HARNESSCONNECTING. WIRING HARNESS CONNECTING. WIRING HARNESS
CONNECTING. WIRING HARNESSCONNECTOR POSITION CONNECTOR POSITIONCONNECTOR POSITION CONNECTOR POSITION
CONNECTOR POSITION
W/H Main - W/H Transmission
W/H Main
W/H MainUpper Transfer Case
Center "A" Pillar Front Right
Below Front Left Seat

ELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMSELECTRICAL WIRING DIAGRAMS ELECTRICAL WIRING DIAGRAMS
ELECTRICAL WIRING DIAGRAMS
5-19 5-19 5-19 5-19
5-19
c. c.c. c.
c.
POSITION OF CONNECTORS AND GROUNDS POSITION OF CONNECTORS AND GROUNDSPOSITION OF CONNECTORS AND GROUNDS POSITION OF CONNECTORS AND GROUNDS
POSITION OF CONNECTORS AND GROUNDS
W/H MAIN
W/H TRANSMISSION (MANUAL TRANSMISSION)