CHASSIS GENERAL INFORMATION

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CHASSIS GENERAL INFORMATION

MAJOR COMPONENTS SPECIAL TOOLS AND EQUIPMENT

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1. MOUNTING LOCATIONS (CHASSIS)..... 2 1. NEW SPECIAL TOOLS.......................... 22
2. CHASSIS COMPONENT LAYOUT......... 4 2. NORMAL EQUIPMENTS........................ 23
3. SUB FRAME AND STEERING
GEAR BOX LAYOUT.............................. 6
4. FRONT SUSPENSION COMPONENT
LAYOUT................................................. 8
5. REAR SUSPENSION COMPONENT
LAYOUT................................................. 10
6. BRAKE SYSTEM AND ESP SYSTEM
LAYOUT................................................. 12
7. STEERING SYSTEM LAYOUT.............. 14

DURING SERVICE WORK

1. GUIDELINES FOR SERVICE WORK

SAFETY................................................. 16
2. JACK-UP POINTS.................................. 20
3. STANDARD BOLTS SPECIFICATIONS.. 21
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1. MOUNTING LOCATIONS (CHASSIS)

HECU (Hydraulic & Electronic Control Unit)
HECU for ABS HECU for EPS
Motor Motor

HU ECU HU
(Hydraulic (Electronic (Hydraulic ECU (Electronic
Unit) Control Unit) Unit) Control Unit)
The HECU (Hydraulic & Electronic Control Unit) determines the slip conditions of vehicle
wheels by calculating each wheel's speed and the increment/decrement of speed based on the
information detected by the sensors, and controls the pumping and boosting/reducing/keeping

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pressure by operating the valve and motor of HECU.

EPS unit
Motor angle Connector to vehicle (8P)
(8P) Battery (2P)

Torque angle
sensor (8P)
Motor power (3P)
The ECU controls the electric power
steering system depending on the driving
conditions, based on the signals from the
torque and angle sensor.

Fuse for vehicle with EPS

Steering wheel angle sensor (SWAS)
The steering wheel angle
sensor is mounted between
the steering column and the
steering column shaft. It is
commonly used by the ESP
(Electronic Stability Program)
system. And it receives
signals of the steering wheel
The vehicle with EPS has EPS fuse (80A) angle sensor from the ESP
mounted to the positive (+) terminal of the HECU (Hydraulic & Electronic
battery not in the fuse box. Control Unit).

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Sensor cluster TGS Lever assembly

The TGS communicates with
TCU (Transmission Control
Unit), ECU, ESP HECU and
instrument cluster to let the
driver select the desired
transmission gear and to
maintain the desired driving
condition. Also, the tip switch is
The sensor cluster is linked installed on the lever knob and
to the sensors on the unit the steering wheel so that the
board and CAN interface. driver select the gear manually
And they are housed in one when the shift lever is in "M".
case and mounted to the
body.
G-sensor

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For the vehicle with the ABS, a speed difference
between the wheels is not noticeable as all the
wheels are slipping during abrupt braking.
Therefore, the vehicle needs the speed information
from other sensors other than the wheel speed
sensor. The longitudinal acceleration sensor (G-
sensor) is used for this case. It controls the ABS by
using the signals from the sensor during abrupt
braking and acceleration.

TCU unit

E-coupling unit

The transmission control unit (TCU) is

installed under the driver seat, and controls
The E-coupling unit is a control unit which the transmission.
determines the magnetic force by considering The TCU is operated by the ignition power
CAN signals (wheel speed, engine torque, supply and receives and processes the
pedal opening, ABS/ESP CAN signals, etc.) following information from the inner sensors
from other ECUs. through CAN buses.

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2. CHASSIS COMPONENT LAYOUT

1) 4WD Vehicle With Automatic Transmission
M11 6-speed A/T assembly

Inhibitor
switch

Oil pan
Torque converter

M11 6-speed automatic transmission is available

as 4WD- and 2WD-type, and provides 6 speeds
for forward travel and 1 reverse travel. It is also
equipped with the torque converter with inner Propeller

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lock-up clutch and electronically controlled shaft
solenoid which controls all hydraulic functions.

PTU (Power Transfer Unit)

The PTU is a device that transfers the power

generated from the engine to the rear axle
through propeller shaft and E-coupling by
changing the power flow direction by 90° in Rear axle assembly
the front wheel drive type 4WD vehicle.

E-coupling control unit (E-Coupling ECU)

E-coupling side Rear axle side

The rear axle installed in this car is a
removable axle, called IRDA (Independent
Rear Differential Axle). The rear differential
The E-coupling unit is a control unit which carrier is installed directly on the sub frame,
determines the magnetic force by considering and there is an independent suspension that
CAN signals (wheel speed, engine torque, pedal allows each wheel on the same axle to move
opening, ABS/ESP CAN signals, etc.) from other vertically independently of each other with the
ECUs. universal joint and the slip joint.

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2) 2WD Vehicle With Manual Transmission

The 2WD vehicle with manual transmission is a front wheel drive type vehicle that doesn't have
PTU, propeller shaft, E-coupling and rear axle which are applied to 4WD vehicle. Its under
structure is very simple.

M6LF1 manual transmission

Transmission side Control shaft assembly

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Transaxle side Concentric slave assembly
M6LF1 manual transmission is a model modified from
the one that used in other vehicle so that it can be
applied to FF (Front engine-Front wheel driving) type
vehicle, and has an axle in one piece. The engine
torque and gear ratio of this transmission have been
optimized to maximize driving performance. It provides
6 speeds for forward travel and 1 reverse travel.

Clutch assembly

Clutch disc Pressure plate

Manual gear selector lever

M6LF1 manual transmission is a model modified from

the one that used in other vehicle so that it can be
applied to FF (Front engine-Front wheel driving) type
vehicle, and has an axle in one piece. The engine
torque and gear ratio of this transmission have been
optimized to maximize driving performance. It provides
6 speeds for forward travel and 1 reverse travel.

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3. SUB FRAME AND STEERING GEAR BOX LAYOUT

Front sub frame with HPS type steering gear box assembly

Rear side HPS type steering

gear box assembly

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Front sub frame
Front side assembly

The front sub frame consists of 4 body bush mountings and 2

transmission bush mountings which reduce the vibration from the
powertrain and road, and also control the torque. And the frame is
equipped with hydraulic pressure pipe of the HPS type steering gear
box.

Front sub frame with EPS type steering gear box assembly

Rear side EPS type steering

gear box assembly

Front sub frame

Front side assembly

This kind of front sub frame system has the same mounting structure
with the frame with HPS. But the EPS type steering gear box has no
hydraulic pressure pipe since it is driven by the electric motor.

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Rear sub frame assembly for 4WD

Rear side
Body mounting Body mounting

Axle mounting

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Body mounting Body mounting
Front side

The rear sub frame for 4WD vehicle consists of 4 body (bush)
mountings and 2 axle (direct) mountings which reduce the
vibration from the powertrain and road, and also control the
torque.

Rear sub frame assembly for 2WD

Body mounting Rear side Body mounting

Body mounting Body mounting

Front side

The rear sub frame for 2WD vehicle functions in the same way as
the one for 4WD vehicle, but the structure is different from the one
for 4WD. It consists of 4 body (bush) mountings.

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4. FRONT SUSPENSION COMPONENT LAYOUT

Front suspension supports the vehicle weight and absorber the vibration from tires. And, in this
type of suspension, the steering linkage tie rod is mounted on the knuckle. The Macpherson
Strut suspension is an independent suspension which has a spring on the strut with a built-in
shock absorber. The lower arm is installed on sub frame and large strut damper is installed on
the knuckle to support the tire.

Stabilizer bar assembly

Stabilizer bar

Bushing
Clamp

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Link

The stabilizer bar assembly is not activated if the

left/right wheels move up/down simultaneously, but if
both wheels move up/down differently it is activated
with frame to minimize the tilting of the body.

Lower arm assembly

The lower arm assembly connects the frame and

knuckle. It supports the load transferred to the tire
knuckle, relieves the impact from the vehicle and
ground conditions, and ensures driving stability.

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Front coil spring assembly

Coil spring

Shock absorber
assembly

The coil spring is made by winding solid steel rod to

form the coil shape. Its energy absorption rate per
weight is higher than that of the leaf spring and it
allows to absorb small vibration properly resulted in
keeping the ride comforts. Therefore, it's difficult to
make an effect on vibration damping because there
is not any friction between coils.

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5. REAR SUSPENSION COMPONENT LAYOUT

Multi-link type suspension is the independent suspension. It provides good ride comfort and
drivability by reducing the coil spring weight. Also, it increases the space for passenger
compartment by lowering the floor.
This type of suspension consists of multiple links such as trailing arm, upper arm, lower arm
and track rod.

Shock absorber assembly

This vehicle uses the gas
shock absorber. This
relieves the vertical
vibrations of vehicle to
provide ride comforts,
prevents the spring

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break, enhances
drivability, and extends
the life span of steering
components.

Upper arm assembly

Upper arm is installed between knuckle and

sub frame and controls the lateral load and
vehicle height.

Trailing arm assembly

Track rod assembly

Trailing arm is installed between knuckle Track rod is installed between knuckle and
and vehicle body and controls the front and rear sub frame and controls and
rear load. compensates the lateral load.

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Stabilizer bar assembly

Stabilizer bar

Bushing
Clamp

Link

The stabilizer bar assembly is not activated if the

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left/right wheels move up/down simultaneously,
but if both wheels move up/down differently it is
activated with frame to minimize the tilting of the
body.

Coil spring

Coil spring is installed between

the coil spring link and body
frame. It relieves the vibrations
and impacts from wheels to
vehicle body.

Lower arm assembly

The lower arm is installed between knuckle and

rear sub frame and relieves the load to coil
spring from wheel. In other word, it controls the
longitudinal load.

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6. BRAKE SYSTEM AND ESP SYSTEM LAYOUT

A. Indicators on instrument cluster

Parking brake ESP indicator

warning light
ABS warning lamp

B. Master cylinder assembly

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Description for master cylinder in this chapter
is based on ABS/ESP equipped vehicle. For
CBS, there is an extra pressure valve
mounted to the master cylinder.

C. HECU assembly D. Front brake assembly

Caliper Disc

The HECU assemblies for ABS and ESP The disc brake for 4WD vehicle is the same
have similar appearance but they have with the one for 2WD vehicle.
different inner structure and connector
connections from each other.

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G. Brake pedal

H. Parking brake
4WD and 2WD 2WD Rear side
Front side

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The wheel speed sensor for 4WD has the same
structure and mounting location with the one for
2WD vehicle. But the rear side wheel speed
sensor for 2WD vehicle has different sensor
appearance and mounting status because the
knuckle shape is different from the 4WD vehicle.

E. Rear brake assembly H. Parking brake

Caliper

Disc
The parking brake is the mechanical device
to hold the vehicle. When pulling up the lever,
The disc brake for 4WD vehicle has the same the parking brake cable between the lever
structure with the one for 2WD vehicle, but and the rear drum brake trailing shoe pulls
the appearance and knuckle shape is the parking brake lining to contact to drum.
different from each other.

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7. STEERING SYSTEM LAYOUT

1) HPS (Hydraulic Power Steering)
The hydraulic pump is a The oil reservoir sends the There is a shock absorber
vane type pump and oil to the power steering which is folded in the axial
consists of the flow control pump and receives the oil direction when the vehicle is
valve and pressure relief from the power steering crashed and a ignition switch
valve. gear. assembly on the column
shaft.

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Steering wheel Column shaft
assembly

Lower shaft

Hydraulic pipe & hose

The lower shaft minimizes the
torque change using a CV
joint which has constant
angular speed.

The steering gear box assembly consists of power cylinder and control valve. The power
cylinder has a cylinder, piston and piston rod. The control valve directs the oil to one end face
of the piston to enhance the steering force. There is a safety check valve which lets the driver
steer manually when there is a malfunction in the hydraulic circuit.

Hydraulic pipe Gear box

Steering cylinder
Tie rod end
Tie rod end

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2) EPS (Electric Power Steering)

The ECU controls the The vehicle with EPS has The column shaft assembly
electric power steering EPS fuse (80A) mounted consists of BLAC motor, ECU,
system depending on the to the positive (+) terminal torque and angle sensors. The
driving conditions, based of the battery, and this fuse electric power steering (EPS)
on the signals from the supplies power to the EPS system uses the electric motor to
torque and angle sensor. unit directly. assist the steering force. It
functions independently
regardless of whether the engine
is running or not, unlike the
existing hydraulic power steering.
The lower shafts functions in the
same way as the hydraulic type.

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Column
Steering wheel assembly shaft

BLACK motor ECU

Lower
shaft

When the driver turns the steering wheel, a torque is generated and the torque sensor and the
steering angle sensor in the EPS system detect the rotation of the steering column to run the
electric motor. At this time, the worm gear connected to the motor drives the helical gear
mounted to the steering column to generate the assist torque for the steering column. This
allows the driver to operate the steering wheel easier.

Gear box
Tie rod end Steering cylinder Tie rod end

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1. GUIDELINES FOR SERVICE WORK SAFETY

1) For Safety
To maintain and operate the vehicle under optimum state by performing safe service works, the
service works should be done by following correct methods and procedures.
Accordingly, the purpose of this manual is to prevent differences that can be caused by
personal working method, skill, ways and service procedures and to allow prompt/correct
service works.
While using this manual, there are a lot of Note or Notice having below meaning.

Note means detailed description of supplementary information on work procedure or skill.

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Notice means precautions on tool/device or part damages or personal injuries that can
occur during service works.

However, above references and cautions cannot be inclusive measures, so should have habits
of taking concerns and cautions based on common senses.

2) Equipment
- Korando C is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system
are integrated into the engine compartment. Thus 2-post lift and general equipment are
needed when working on the engine and transmission.
- Major dedicated equipment: Engine and transmission jack (use the one for Chairman W),
Engine stand, Engine crane, transmission jack, Engine hanger

Engine crane

Engine stand Transmission jack

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Lower the engine and transmission (transaxle) at the same time.

- Manual transmission: Can be removed and installed after lowering with the engine and sub
frame at the same time.
- Automatic transmission: Only transmission can be removed and installed after removing the
sub frame.

3) During Service Work

(1) Before lifting up the vehicle with lift, correctly support the lifting points and lift up.
(2) When using a jack, park the vehicle on the level ground and place wheel chocks
underneath the tires. Position the jack under the frame and lift up the vehicle and then
support with chassis stand before service work.
(3) Before service work, be sure to disconnect battery negative (-) terminal to prevent
damages by bad wire and short.
(4) If service from interior of the vehicle, use protection cover to prevent damage and

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contamination of seat and floor.
(5) Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them
during service work.
(6) Use recommended and specified tools to increase efficiency of service work.
(7) Use only genuine spare parts.
(8) Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut.
Replace them with new.
(9) If reused, normal functions cannot be maintained.
(10) Align the disassembled parts in clean according to disassembling order and group for easy
assembling.
(11) According to installing positions, the bolts and nuts have different hardness and design.
So be careful not to mix removed bolts and nuts each other and align them according
installing positions.
(12) To inspect and assemble, clean the parts. Securely clean the parts that related with oil not
to be affected by viscosity of oil.
(13) Coat oil or grease on the driving and sliding surfaces before installing parts. Use sealer or
gasket to prevent leakage if necessary.
(14) Tighten every bolt and nut with specified torque.
(15) When service work is completed, check finally whether the work is performed properly or
the problem is solved.

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4) Basic Inspection
(1) Horn operation
- Listen for horn sound by operating the horn.

(2) Brake operation

- Check if there is any abnormal noise, braking distance is increased or the braking force is
applied to the only one wheel. If the brake warning lamp is not turned off or flashing, recheck
the brake system because there is a fault in the brake system.
- Check the brake pipes and hoses for connection, oil leak, crack or interference after
changing tire location. When replacing tires check the brake disc for surface condition and
wear, too.
- Check the parking brake cable and brake operation. Inspect the brakes more often if habit
or conditions result in frequent braking.

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(3) Exhaust system
- Be alert to any changes in the sound of the system or the smell of the fumes. These are
signs that the system may be leaking or overheating. Have the system inspected and
repaired immediately.
- Inspect the complete system (including the catalytic converter if equipped). Inspect the body
near the exhaust 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.

(4) Tires
- 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 pressure adjustment or a wheel alignment.

(5) Steering and suspension system

- 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.

(6) Engine oil

- Check the oil level and add oil if necessary. The best time to check the engine oil level is
when the oil is warm.

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(7) Coolant
- Check the coolant level in the coolant reservoir and coolant condition (contamination, foreign
material), coolant hose damage or leakage. Replace or add Ssangyong genuine coolant, if
needed.

(8) Engine drive belt

- Check all drive belts of the engine for wear, crack, looseness, tension. Retighten or replace
the belt, if needed.

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2. JACK-UP POINTS
▶ Stand jack-up points and installation status (front side)

Stand jack-up points and installation

status (front side)

Mounting status

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Jack-up points Jack-up points
for 2-post lift for 2-post lift

Stand jack-up points and installation

status (rear side)

Mounting status

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3. STANDARD BOLTS SPECIFICATIONS

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1) Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be
classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.
2) Observe standard tightening torque during bolt tightening works and can adjust torque to be
proper within 15 % if necessary. Try not to over max. allowable tightening torque if not
required to do so.
3) Determine extra proper tightening torque if tightens with washer or packing.
4) If tightens bolts on the below materials, be sure to determine the proper torque.
- Aluminum alloy: Tighten to 80 % of above torque table.
- Plastics: Tighten to 20 % of above torque table.

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1. NEW SPECIAL TOOL

To repair Korando C, new special tools which are developed for new engine and systems,
normal equipments and conventional tools are used.

Name and Part Number Special tool Use

Part number: T99300010A
Name: Centering pin for
installing clutch

Use:
Used when installing clutch
disc and pressure plate to
engine.

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Part number: T99410010A
Name: Rear knuckle bushing
adapter

Use:
Used when removing and
installing rear knuckle
bushing

Part number: T99420010A A dedicated tool for

Name: Differential gear oil
transmission
seal installer

Use:
Used when installing
differential side gear side
(inner) oil seal with a
dedicated tool for
transmission.

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2. NORMAL EQUIPMENTS
1) Engine Assembly Removal & Installation Equipments
Name and Part Number Tool Use
Name: Engine and
transmission jack

Use:
High load jack dedicated for
Chairman W,
but can be used for Korando
C to support module when
lowering engine and
transmission mounted to sub
frame at the same time

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(replacing manual
transmission).
Name: Engine stand
(1 tone or more)

Use:
Used to fix the removed
engine or engine and
transmission (transaxle) and
can support at least 1 tone.

Name: Engine crane

(1 tone or more)

Use:
Used to move engine module
(including transaxle) to
working space or engine
stand, and can support at
least 1 tonne.

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2) Tool Only For Manual Transmission

Name and Part Number Tool Use
Tool only for manual
transmission

Used when assembling

manual transmission after
disassembling. It consists of
14 components.

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Name:
1. Differential carrier taper
roller bearing installer

Use:
Used when installing taper
roller bearing of differential
carrier.

Name:
2. Differential carrier taper
roller bearing installer

Use:
Used when installing taper
roller bearing of differential
carrier.

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Name and Part Number Tool Use

Name:
3. Clutch housing oil seal
installer

Use:
Used as a connecting rod
(13) when installing clutch
Connecting rod
housing oil seal.

Name:
4. Transmission housing oil
seal installer

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Use:
Used as a connecting rod
(13) when installing clutch
housing oil seal.
Connecting rod

Name:
5. Differential carrier front
bearing outer race installer

Use:
Used as a connecting rod
(13) when installing
differential carrier front
bearing outer race of clutch
housing (outer diameter: 89
mm). Connecting rod

Name:
6. Primary output shaft
bearing race installer

Use:
Used as a connecting rod
(13) when installing bearing
outer race of primary output
shaft (outer diameter: 79 Connecting rod
mm).

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Name and Part Number Tool Use

Name:
7. Bearing support installer

Use:
Used to support bottom of
shaft when installing gears
and hubs to output shafts.

Name:
8. Output shaft bearing
installer

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Use:
Used as a bearing support
installer (7) when installing
Bearing
taper roller bearing to output
shafts. support
installer

Name:
9. Bearing outer race
installer

Use:
Used as a connecting rod
(13) when installing
differential carrier bearing
outer race of transmission
housing (outer diameter: Connecting rod
75.5 mm).
Name:
10. Control shaft oil seal
installer

Use:
Used when installing control
shaft oil seal.

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Name and Part Number Tool Use

Name:
11. Bearing outer race Secondary
installer output shaft

Use:
Used as a connecting rod
(13) when installing
transmission housing input
shaft and secondary output Input shaft
shaft bearing.
(Outer diameter: 70.5 mm)
Name:
12. Bearing outer race

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installer

Use:
Used as a connecting rod
(13) when installing clutch
housing input shaft bearing
outer race.
(Outer diameter: 64.5 mm) Connecting rod

Name:
14. Synchro hub installer

Use:
Used as a bearing support
installer (7) when installing
gear and hub to output
shafts.

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