SSANGYONG KORANDO SERVICE MANUAL Body Exterior Korando 2012

BODY EXTERIOR5110-01/5120-00/5125-00/5210-00/5510-00/5610-00/5620-00/5710-00/5720-00/5730-00/6110-00/6210-00/6310-00/6410-00/7090-00/7110-01/7120-00/7121-00/7210-01/7220-00/7221-00/7310-00/7810-01/7830-00/7840-00/7850-00/7870-00/7880-00/

7910-00/7930-00/7940-00/7940-20/7970-00

BODY EXTERIOR

COMPONENT

7221-00 REAR WEATHERSTRIP...............7310-00 TAILGATE OPENING SYSTEM...7830-00 BACK WINDOW WIPER................7840-00 GLASS.........................................7850-00 OUTSIDE REAR VIEW MIRROR...7870-00 FRONT BUMPER.........................7880-00 REAR BUMPER............................7910-00 RADIATOR GRILLE......................7930-00 SIDE BODY MOLDING.................7940-00 ROOF AND REAR BODY MOLDING.....................................7970-00 WHEEL HOUSE COVER...............

202122232425262728

2930

5110-00 WHITE BODY...............................5120-00 BODY MOUNTING.......................5125-00 BODY FRAME..............................5210-00 SIDE AND REAR BODY................5510-00 ROOF PANEL...............................5610-00 FRONT FLOOR PANEL.....,,.........5620-00 REAR FLOOR PANEL..................5710-00 FRONT END PANEL.....................5720-00 FENDER AND APRON PANEL......5730-00 DASH PANEL AND COWL............6110-00 HOOD PANEL..............................6210-00 FRONT DOOR PANEL..................6310-00 REAR DOOR PANEL....................6410-00 TAILGATE PANEL.......................7090-00 FUEL FILLER DOOR LOCK..........7121-00 FRONT WEATHERSTRIP.............

346789

10111213141516171819

BODY EXTERIOR

REMOVAL AND INSTALLATION

7870-01 FRONT BUMPER.........................7880-01 REAR BUMPER............................6110-01 HOOD PANEL..............................6410-01 TAILGATE PANEL ASSEMBLY...7930-10 SIDE SEAL GARNISH ASSEMBLY..................................6210-01 FRONT DOOR PANEL..................7120-01 FRONT WINDOW LIFTER.............7110-01 FRONT DOOR LATCH AND CABLE ASSEMBLY.....................6310-01 REAR DOOR PANEL ASSEMBLY..................................7220-01 REAR WINDOW LIFTER...............7210-01 REAR DOOR LATCH AND CABLE ASSEMBLY.....................5720-04 FENDER PANEL...........................7910-01 RADIATOR GRILLE......................5730-01 COWL GRILLE ASSEMBLY.........7940-20 REAR SPOILER...........................7850-01 OUTSIDE REAR VIEW MIRROR...

31343840

424447

50

5254

586064666971

06-3

BODY EXTERIORkorando 2010.10

5110-01

WHITE BODYWhite body (with sunroof)

1.2.

06-4

korando 2010.10

5120-00

BODY EXTERIOR

06-5


5120-00

Bush - FRT subframe MTGStopper - Subframe MTG FRT UPRStopper - FRT subframe FRT LWRBolt - Body MTGStopper - Subframe MTG RR UPRStay - FRT subframeBush - RR subframe MTG FRTStopper - RR subframe MTG LWRBush - RR subframe MTG RRBolt

1.2.3.5.6.7.8.9.

10.12.

06-6

korando 2010.10

5125-00

BODY EXTERIOR

Member assy - FRT H frameMember assy - RR H frame

1.2.

06-7


5210-00

Reinf assy - Side OTRBrkt - RR bumper MTG LWRBrkt assy - Fender MTG LWRPillar compl - D OTRHousing assy - Fuel fillerPNL compl - Q/INR & W/HSE

2.3.4.6.7.8.

PNL - side OTR FRTPNL - Side OTR RRReinf assy - RR DR strikerPNL assy - Cowl side INRPNL - Wheel house RR OTRPillar assy - B INR

9.10.11.12.15.16.

06-8

korando 2010.10

5510-00

BODY EXTERIOR

PNL - RoofPnl - RoofRail assy - Roof FRTReinf assy - SunroofRail - Roof No1 CTRRail - Roof No2 CTRRail - Roof No3 CTRRail assy - Roof RR

1.2.3.4.5.6.7.9.

06-9


5610-00

PNL compl - FRT floorPNL - Side sill INR

1.13.

06-10

korando 2010.10

5620-00

BODY EXTERIOR

PNL compl - RR floorMember assy - RR endReinf - RR floor cornerPNL assy - Back OTR

1.11.13.14.

06-11


5710-00

PNL compl - Engine roomBeam assy - FRT end LWRMember assy - Head lampMember - FRT end UPRBoltMember assy - FRT end CTR

1.2.3.4.5.6.

06-12

korando 2010.10

5720-00

BODY EXTERIOR

PNL assy - Fender apronPNL assy - Fender apronBrkt - Fender MTG FRTPNL - FenderPad - Fender MTG sealingBoltSeal - FenderReinf - Fender

1.2.3.4.5.6.7.8.

06-13


5730-00

PNL compl - Dash & cowlMember compl - Cowl side UPRCross member assy

1.2.3.

06-14

korando 2010.10

6110-00

BODY EXTERIOR

Pnl assy - HoodHinge assy - HoodBoltInsulator - HoodFastener - Hood insulation padLatch assy - HoodBoltExtension - Cowl grilleBumper - Hood over slamSeal assy - Hood FRT subSeal assy - Hood RRBumper - Trunk lid over slam

1.2.3.4.5.6.7.8.

10.12.13.16.

Cable assy - Hood latch releaseClip - F/filr DR REL CBLHandle - Hood latch releaseScrewGrille assy - CowlScrew - RivetRod assy - Hood stayBRKT - Hood stay rod MTGRetainer - Hood stay rodNutClip - Hood stay rodHolder - Hood stay rod

17.18.19.20.21.23.24.25.26.27.28.29.

06-15


6210-00

PNL assy - FRT DRHinge assy - FRT DR UPRHinge assy - FRT DR LWRBoltBolt

1.2.3.4.5.

06-16

korando 2010.10

6310-00

BODY EXTERIOR

PNL assy - RR DRHinge assy - RR DR UPRHinge assy - FRT DR LWRBoltBolt

1.2.3.4.5.

06-17


6410-00

PNL assy - TailgateHinge assy - TailgateBoltNut

1.2.3.5.

06-18

korando 2010.10

7090-00

BODY EXTERIOR

Cable assy - F/filr DR RELHandle assy - F/filr DR RELDR assy - Fuel fillerBoltScrew

1.4.6.7.8.

06-19


7121-00

W/strip - FRT DR body sideW/strip assy - FRT DR openingCap - W/stripClip - W/stripW/strip assy - F/DR belt O/SScrewTape - DR tooling hole sealingTape - FRT DR frame ATape - FRT DR frame BVinyl seal - FRT DR trim

1.2.3.4.5.6.7.9.

10.11.

06-20

korando 2010.10

7221-00

BODY EXTERIOR

W/strip - RR DR body sideW/strip assy - RR DR DR sideCap - W/stripClip - W/stripW/strip assy - RR DR belt O/SScrew

1.2.3.4.5.6.

Tape - DR tooling hole sealingTape - RR DR frame BTape - RR DR frame AVinyl seal - RR DR trimCover assy - RR DR trim UPRCover - RR DR DR side stripMolding assy - RR DR deltaScrew

7.9.

10.12.13.17.18.19.

06-21


7310-00

Latch assy - T/gateBoltStriker assy - T/gateScrew - DR striker MTGLifter assy - T/gateBall studBumper - Trunk lid over slamBumper assy - T/gate O/slam CTRW/strip - T/gate opening

1.2.3.4.

20.21.28.29.30.

06-22

korando 2010.10

7830-00

BODY EXTERIOR

Blade assy - RR wiperArm assy - T/gate wiperMotor assy - RR wiperSpacer assy - T/gate wiperSplash ring - T/gate wiperNutCap - Wiper arm

1.2.3.5.6.7.9.

06-23


7840-00

Glass assy - WindshieldPlate - I/S RR view mirror baseMolding assy - WindshieldDam - WindshieldSpacer assy - Windshield glass

1.2.3.4.5.

Glass - FRT DR dropGrommet - DR glass MTGBolt - DR glass MTGGlass assy - T/gate

10.12.13.20.

06-24

korando 2010.10

7850-00

BODY EXTERIOR

Mirror assy - O/SMirror assy - O/SGlass holder assy - O/S mirrScrewLamp assy - Turn signal Cover - O/S mirror FRTRivet - Plastic

1.2.3.4.5.

10.11.

06-25


7870-00

Fascia - FRT bumper UPRFascia - FRT bumper LWRGrille - IntakeMolding - IntakeScrewAbsorber - Energy FRT bumperReinf - FRT bumper CTRCover - Fog lamp FRTBlanking cover - Fog lamp FRTGarnish - License plate

1.2.3.4.5.6.7.8.9.

10.

Spring - NutClip - LockScrewScrewScrewScrivetGrommet - ScrewScrew rivet - RR fascia MTGBrkt assy - Side FRT bumperBolt

11.12.13.14.15.16.19.21.22.24.

06-26

korando 2010.10

7880-00

BODY EXTERIOR

Fascia - RR bumper UPRFascia - RR bumper RR LWRAbsorber - Energy RR bumperLamp assy - Reflex reflectorScrewNutClipScrewSpring - NutScrew

1.2.3.4.5.6.7.8.9.

12.

BoltGrommet - ScrewBeam assy - Impact RR bumperScrivetScrewBoltGrommet - ScrewBRKT assy - Side RR bumperNut

13.14.15.16.17.18.19.20.21.

06-27


7910-00

Grille - RadiatorScrewMolding - Radiator grilleScrew

1.2.3.4.

06-28

korando 2010.10

7930-00

BODY EXTERIOR

Cover assy - QuadrantClip - Side sill molding MTGGarnish assy - FRT wheel archGarnish assy - RR wheel archClip - DR molding MTGGarnish assy - Side sillClip - Side sill molding MTG

1.2.3.4.5.

10.11.

Clip - Side sill molding MTG LWRScrewGrommetScrewClip - DR garnish MTGScrew

12.13.14.15.16.17.

06-29


7940-00

Molding assy - RoofMolding assy - Roof No1Molding assy - Roof No2Rail assy - FashionNutSpoiler assyCover - LWRScrewGarnish assy - Tailgate

1.2.3.

10.11.20.21.22.30.

06-30

korando 2010.10

7970-00

BODY EXTERIOR

Cover assy - FRT wheel houseScrewScrewCover - Crankshaft pulleyCap nutCover - RR wheel houseUnder cover - RRNutMud guard - RRBRKT - RR mud guard MTGNut

1.2.4.5.6.

10.15.16.20.21.22.

06-31


7870-00

2 Mounting bolts (10 mm)

6 Scrivets

Front bumper

Open the engine hood and remove the 6 scrivets and the 2 mounting bolts (10 mm) securing the front bumper upper fascia.

1.

06-32

korando 2010.10

7870-00

BODY EXTERIOR

Remove the lower scrivets (two on each side) from the wheel house.

2.

Remove the upper scrivets (3 on each side) from the wheel house.

3.

Remove the wheel house cover and unscrew the mounting screws (one on each side) securing the bumper.

4.

Remove the two scrivets securing the front bumper lower fascia.

5.

06-33


7870-00

Pull out the front bumper slightly without detaching it to disconnect the front fog lamp connectors on each side.

6.

Remove the front bumper after disconnecting the front fog lamp connector.

7.

Install in the reverse order of removal.8.

06-34

korando 2010.10

7880-00

BODY EXTERIOR

Disconnect the negative battery cable.

Open the tailgate and unscrew the two mounting screws for the rear combination lamp.

1.

Remove the rear combination lamp housing.2.

Make sure that the painted surface and the wirings are not damaged when removing.

Rear bumper

06-35


7880-00

Disconnect the rear combination lamp connector.

3.

Remove the mounting screws (A, one on each side) and the scrivets (two on each side) securing the rear bumper.

4.

Unscrew the two mounting bolts (A, 12 mm) and 3 nuts (B, 10 mm) securing the rear undercover.

5.

Remove the rear undercover.6.

06-36

korando 2010.10

7880-00

BODY EXTERIOR

Unscrew the rear wheel house cover mounting screws (3 on each side).

7.

Unscrew the rear bumper lower fascia mounting screws (one on each side).

8.

Unscrew the rear bumper lower fascia mounting bolts (10 mm, 3 on each side).

9.

Remove the rear bumper.10.

06-37


7880-00

Disconnect the parking aid sensor (PAS) connector.

11.

Remove the rear bumper.12.


06-38

korando 2010.10

6110-00

BODY EXTERIOR

Separate the washer fluid nozzle hose mounted on the engine hood.

1.

Hood assembly

06-39


6110-00

Unscrew the mounting bolts (10 mm, two on each side) on the hood to remove the hood assembly.

2.


Mounting points for securing hood insulator

Put matchmarks on the hood and hinge.

06-40

korando 2010.10

6410-00

BODY EXTERIOR

Remove the head lining and disconnect the washer fluid nozzle hose and connector.

1.

Disengage the mounting clips on each side to remove the tailgate shock absorber.

2.

Tailgate panel assembly

06-41


6410-00

Unscrew the tailgate hinge mounting bolts (12 mm, two on each side) to remove the tailgate assembly.

3.


06-42

korando 2010.10

7930-00

BODY EXTERIOR

Side seal garnish assembly

Unscrew the two mounting bolts on the front side of the side seal garnish assembly.

1.

06-43


7930-00


Unscrew the mounting bolt on the rear side of the side seal garnish assembly.

2.

Lift the vehicle with a lift and unscrew the 6 mounting bolts on the bottom of the side seal garnish assembly to remove the side seal garnish assembly.

3.

06-44

korando 2010.10

6210-00

BODY EXTERIOR

Front door panel

Remove the door scuff front trim assembly.1.

Front door panel

06-45


6210-00

Unscrew the mounting bolt (A) for the cowl side trim assembly to remove the cowl side trim assembly.

2.

Remove the body main wiring connector assembly and cover.

3.

Disconnect the door main connector inside the vehicle.

4.

Unscrew the door check link mounting bolt (10 mm) on the body.

5.

06-46

korando 2010.10

6210-00

BODY EXTERIOR

Unscrew the two mounting bolts (10 mm) for the front door upper hinge assembly.

6.

Unscrew the two mounting bolts (10 mm) for the front door lower hinge assembly.

7.

Remove the front door panel.8.


06-47


7120-00

Front door power window front regulator

Unscrew the two mounting bolts (10 mm) for the front door pull handle mounting bracket assembly.

1.

Remove the front door trim. Refer to "Front Door Trim" section of "Body Interior".1.

06-48

korando 2010.10

7120-00

BODY EXTERIOR

Disconnect the front door panel speaker connector.

2.

Remove the vinyl seal of the front door panel.

3.

Unscrew the two mounting bolts (10 mm) for the clamp grip.

4.

Remove the window glass.5.

06-49


7120-00

Unscrew the 7 mounting nuts (10 mm) after disconnecting the front door power window front regulator connector.

6.

Remove the front door power window front regulator.

7.


06-50

korando 2010.10

7110-01

BODY EXTERIOR

Front door latch & cable assembly

Unscrew the 3 mounting bolts (T30) for the front door latch and cable.

1.

Unscrew the latch and cable mounting nut (A, 10 mm) and remove the fixing part (B).

2.

Remove the front door trim. Refer to "Front Door Trim" section of "Body Interior".1.

06-51


7110-01

Remove the front door outside handle rods A and B.

3.

Disconnect the front door latch and cable assembly connectors A and B.

4.

Remove the front door latch and cable assembly.

5.


06-52

korando 2010.10

6310-00

BODY EXTERIOR

Rear door panel

Remove the B-pillar door trim.1.

Remove the rubber cover on the B-pillar and disconnect the door main connector inside the vehicle.

1.

Rear door panel

06-53


6310-00

Unscrew the door check link mounting bolt (10 mm) on the body.

2.

Unscrew the two mounting bolts (10 mm) for the front door upper hinge assembly.

3.

Unscrew the two mounting bolts (10 mm) for the front door lower hinge assembly.

4.

Remove the front door panel.5.


06-54

korando 2010.10

7220-00

BODY EXTERIOR

Unscrew the two mounting bolts (10 mm) for the rear door pull handle mounting bracket assembly.

1.

Rear window lifter

Remove the rear door trim. Refer to "Rear Door Trim" section of "Body Interior".1.

06-55


7220-00

Disconnect the rear door panel speaker connector.

2.

Remove the vinyl seal of the rear door panel.

3.

Unscrew the two mounting bolts (10 mm) for the clamp grip.

4.

Unscrew the 4 mounting screws on the rear door trim upper cover.

5.

06-56

korando 2010.10

7220-00

BODY EXTERIOR

Remove the rear door delta molding assembly.

6.

Remove the rear door window glass.7.

Disconnect the rear door power window rear regulator connector.

8.

Unscrew the 7 mounting nuts (10 mm) for the rear door power window rear regulator connector.

9.

06-57


7220-00

Remove the rear door power window rear regulator.

10.


06-58

korando 2010.10

7210-01

BODY EXTERIOR

Rear door latch

Unscrew the 3 mounting bolts (T30) for the rear door latch and cable.

1.

Unscrew the latch and cable mounting nut (A, 10 mm) and remove the fixing part (B).

2.

06-59


7210-01

Remove the front door outside handle rod.3.

Disconnect the rear door latch and cable assembly connectors A and B.

4.


06-60

korando 2010.10

5720-00

BODY EXTERIOR

Fender panel

Open the hood and remove the 3 lower scrivets for the cowl on each side.

2.

Remove the front tires, 5 wheel house cover scrivets (A) and 3 mounting screws (B) to remove the wheel house cover.

1.

Remove the front bumper. Refer to "Front Bumper" section of "Body Exterior".1.

06-61


5720-00

Remove the cowl grille expansion with a flat-bladed screwdriver.

3.

Remove the quadrant cover assembly.4.

Remove the rear wheel arch garnish assembly.

6.

Unscrew the two mounting bolts (10 mm) for the side front bumper bracket assembly.

5.

Take care not to damage the fastener mounting parts of the rear wheel arch garnish assembly when removing it from the inside of the vehicle.

06-62

korando 2010.10

5720-00

BODY EXTERIOR

Mounting point

Unscrew the 7 mounting bolts (10 mm) on the fender panel.7.

Mounting point Mounting point

Mounting point Mounting point

Mounting point

06-63


5720-00

Remove the fender panel.8.


06-64

korando 2010.10

7910-00

BODY EXTERIOR

Radiator grille

Unscrew the 6 mounting bolts (10 mm) and two mounting screws to remove the front bumper center reinforcement.

1.

Unscrew the 6 mounting bolts (10 mm) on the upper part of the radiator grille.

2.

Remove the front bumper. Refer to "Front Bumper" section of "Body Exterior".1.

06-65


7910-00

Remove the front bumper from the radiator grille.

3.

Remove the radiator grille molding from the radiator grille by unscrewing the 12 mounting screws.

4.

Unscrew the two mounting screws (A) for emblem from the radiator grille and unfold the 4 fixing parts to remove the emblem.

5.


06-66

korando 2010.10

7810-01

BODY EXTERIOR

Open the engine hood.1.

06-67


7810-01

Cowl grille expansionFender cover

Remove the 6 mounting screw rivets for the cowl grille.3.

Remove the 3 lower mounting screw rivets for the cowl grille on each side.

4. Remove the cowl grille expansions with a flat-bladed screwdriver.

5.

Cowl mounting clip (6 EA)

06-68

korando 2010.10

7810-01

BODY EXTERIOR

Remove the cowl grille.6.

06-69


0000-00

Remove the upper trim of the tailgate.1.

Disconnect the high mounted stop lamp connector and nozzle hose.

2.

Rear washer nozzle hose

High mounted stop lamp connector


Rear Spoiler

06-70

korando 2010.10

0000-00

BODY EXTERIOR

Remove two rubber covers.3.

Remove the rear spoiler.5.

Remove the high mounted cover from the rear spoiler.

6.

Unscrew the two mounting nuts (10 mm).4.

06-71


7850-00


Outside rear view mirror

Remove the tweeter speaker.1.

Remove the two outside rear view screw rivets.

2.

06-72

korando 2010.10

7850-00

BODY EXTERIOR

Disconnect the outside rear view mirror connector.

3.

Unscrew the outside rear view mirror mounting screw.

5.

Remove the outside rear view mirror.6.

Unscrew the two mounting bolts (10 mm) on the outside rear view mirror.

4.


Documents

SSANGYONG KORANDO SERVICE MANUAL Body Exterior Korando 2012