1997 SSANGYONG KORANDO service

SSANGYONG MY2002
9M-4 EXTERIOR TRIM
KAA9M030
KAA9M040
B-PILLAR COVER
Removal and Installation Procedure
1. Remove the B-pillar cover.
2. Installation should follow the removal procedure
in the reverse order.
AIR EXTRACTOR GRILLE
Removal and Installation Procedure
1. Remove the air extractor grille.
2. Installation should follow the removal procedure
in the reverse order.
KAA9M020
ON-VEHICLE SERVICE
UNIT REPAIR
B-PILLAR MOLDING
Removal and Installation Procedure
1. Remove the door guide rail from the door. Refer
to Section 9P, Doors.
2. Remove the screws from the door.
3. Remove the B-pillar molding.
4. Installation should follow the removal procedure
in the reverse order.
REPAIR INSTRUCTIONS

SECTION 9N
FRAME AND UNDERBODY
TABLE OF CONTENTS
Specifications.......................................................9N-2
Fastener Tightening Specifications.......................9N-2
Underbody Dimensions.......................................9N-3
Maintenance and Repair.....................................9N-7
On-Vehicle Service.................................................9N-7
Alignment Checking............................................9N-7Floor Pan Insulators.............................................9N-7
Engine Under Covers ...........................................9N-8
General Description and System Operation........9N-9
General Body Construction..................................9N-9
Engine Under Covers ...........................................9N-9

FRAME AND UNDERBODY 9N-7
SSANGYONG MY2002
ON-VEHICLE SERVICE
ALIGNMENT CHECKING
An accurate method of determining the alignment of
the underbody uses a measuring tram gauge. The tram
gauge set used to perform the recommended
measuring checks must include a vertical pointer able
to reach 457 mm (18 inches).
Two types of measurements can be made with a tram
gauge: direct point-to-point measurements and
measurements calculated on a horizontal plane (datum
line) parallel to the underbody. Point-to-point
measurements are generally taken on steering and
suspension engine compartment parts and simply
require the vertical pointers to be set equally.
For horizontal plane measurements, the vertical pointers
must be set as specified for each point to be measured.
Dimensions-to-gauge holes are measured to the center
of the holes and flush to the adjacent surface metal
unless otherwise specified. It is recommended that
the diagonal dimensions to the cross-body be checked
on both sides in order to verify the dimensional
accuracy of the vehicle underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the
higher floor pan temperatures that result from the use
of the catalytic converter in the exhaust system.
Therefore, when servicing a vehicle, it is essential that
any insulators that may have been disturbed or removed
be reinstalled in the original sequence and location.
Also, if an insulator needs to be replaced, use only
the insula-tion specified for that location on the floor
pan.
When servicing or replacing interior insulators, observe
the following instructions.
•Install the insulators in the original position and
sequence. Butt the pieces together in order to
avoid gapping or overlapping.
If it is necessary to replace an insulator, use only
the specified insulation.
Use the original part to determine the amount of
re-placement material required and as a template
for cutting and fitting the new piece to the floor
pan.
When installing the insulator, do not enlarge any
cut-outs or holes that are used for the attachment
of interior parts such as the instrument panel or
the floor console.
MAINTENANCE AND REPAIR

SSANGYONG MY2002
9N-8 FRAME AND UNDERBODY
KAA9N040
Route the cross-body harness for interior parts
over the floor pan insulators. Clip it in the original
location.
Do not apply spray-on deadeners or trim
adhesives to the top of the floor pan at the area
directly over the catalytic converter or the muffler.
Any insulator service repair or replacement should be
the same thickness, size, and location as the original
installation in the vehicle.
ENGINE UNDER COVERS
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the bolts and the engine under cover.
3. Install the engine under cover with the bolts.
Installation Notice
Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use
the correct fasteners to prevent premature
corrosion.
4. Lower the vehicle.
5. Installation should follow the removal procedure
in the reverse order.
Tightening Torque 10 Nm (89 lb-in)

FRAME AND UNDERBODY 9N-9
SSANGYONG MY2002
GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL BODY CONSTRUCTION
This vehicle is constructed with a unitized body which
in-corporates integral front and rear frame side rails.
The front suspension lower control arms are bolted to
and retained by supports, one each on the right and
left sides. The front suspension lower control arm
supports are attached to the underbody with three bolts
at two locations. The engine is bolted to the integral
front side rails. The suspension strut towers must be
dimensionally correct in relation to the remainder of
the underbody in order to maintain specified
suspension strut and caster/camber angles.
Since the individual underbody parts contribute directly
to the overall strength of the body, it is essential to
observe proper welding techniques during servicerepair operations. The underbody parts should be
properly sealed and rustproofed whenever body repair
operations destroy or damage the original sealing and
rustproofing. When rustproofing critical underbody
parts, use a good-quality type of air-dry primer, such
as a corrosion-resistant chromate or an equivalent
material. Combination-type primer/surfacers are not
recommended.
ENGINE UNDER COVERS
The engine under covers are molded pieces of plastic
that serve as shields for the underside of the engine.
The covers help protect the engine from small rocks,
gravel and other objects that would otherwise come
into contact with the engine during normal driving
conditions.

Description and Operation..................................9O-2
Bumpers............................................................9O-2
Components Locator ...........................................9O-3
Bumpers and Fascias .........................................9O-3
Repair Instructions...............................................9O-4
On-Vehicle Service Unit Repair...............................9O-4
Front Bumper Fascia ...........................................9O-4
SECTION 9O
BUMPERS AND FASCIAS
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
otherwise noted.
TABLE OF CONTENTS
Rear Bumper Fascia...........................................9O-5
Front Bumper Impact Bar....................................9O-5
Rear Bumper Impact Bar....................................9O-6
Roof Molding......................................................9O-6
Specifications......................................................9O-7
Fastener Tightening Specifications......................9O-7

SSANGYONG MY2002
9O-4 BUMPERS AND FASCIAS
KAA9O030
KAA9O040
2. Remove the front bumper with the bolts.
Installation Notice
•Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use
the correct fasteners to prevent premature
corrosion.
3. Remove the front bumper fascia.
4. Installation should follow the removal procedure
in the reverse order.
KAA9O020
ON-VEHICLE SERVICE
UNIT REPAIR
FRONT BUMPER FASCIA
Removal and Installation Procedure
1. Remove the side support bracket nuts.
Installation Notice
Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use
the correct fasteners to prevent premature
corrosion.
REPAIR INSTRUCTIONS
Tightening Torque 11 Nm (97 lb-in)
Tightening Torque117 Nm (154 lb-ft)

SECTION 9P
DOORS
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
otherwise noted.
TABLE OF CONTENTS
Description and Operation...................................9P-2
Power Door Locks................................................9P-2
Power Windows...................................................9P-2
Door Lock Striker.................................................9P-2
Components Locator............................................9P-3
Doors ..................................................................9P-3
Repair Instructions................................................9P-4
On-Vehicle Service Unit Repair................................9P-4
Door Glass Run...................................................9P-4
Door Side Opening Weatherstrip..........................9P-4
Door Lock Striker.................................................9P-4
Door Lock Striker Adjustment...............................9P-5
Front Door Lock...................................................9P-6
Inside Door Handle..............................................9P-7
Outside Door Handle ...........................................9P-7Door Lock Cylinder..............................................9P-7
Power Window Regulator.....................................9P-8
Front Door Assembly ...........................................9P-8
Tail Gate Assembly.............................................9P-8
Door Hinge..........................................................9P-9
Door Hold Open Link ...........................................9P-9
Outside Channel Molding.....................................9P-9
Door Weatherstrip................................................9P-9
Door Seal Trim...................................................9P-10
Specifications.....................................................9P-11
Fastener Tightening Specifications.....................9P-11
Schematic and Routing Diagrams.....................9P-12
Central Door Locks System................................9P-12
Power Windows.................................................9P-13