SSANGYONG KORANDO 1997 Service Repair Manual

1F1 -- 48 M162 ENGINE CONTROLS
D AEW OO M Y_2000
Failure
CodeDescriptionTrouble AreaMaintenance Hint
77No. 3 injector short
circuit to ground or open
When malfunction of injector
circuit
Injector #3 short circuit to
ground or openDInspection the ECM pin 66 about short
circuit or open with bad contact
DInspection the injector
DInspection the ECM
78No. 4 injector short
circuit to battery
When malfunction of injector
circuit
Injector #4 short circuit to
powerDInspection the power to injector #4 or
bad contact
DInspection the injector
DInspection the ECM
79No. 4 injector short
circuit to ground or open
When malfunction of injector
circuit
Injector #4 short circuit to
ground or openDInspection the ECM pin 62 about short
circuit or open with bad contact
DInspection the injector
DInspection the ECM
192No. 5 injector short
circuit to battery
When malfunction of injector
circuit
Injector #5 short circuit to
powerDInspection the power to injector #5 or
bad contact
DInspection the injector
DInspection the ECM
193No. 5 injector short
circuit to ground or open
When malfunction of injector
circuit
Injector #5 short circuit to
ground or openDInspection the ECM pin 65 about short
circuit or open with bad contact
DInspection the injector
DInspection the ECM
194No. 6 injector short
circuit to battery
When malfunction of injector
circuit
Injector #6 short circuit to
powerDInspection the power to injector #6 or
bad contact
DInspection the injector
DInspection the ECM
195No. 6 injector short
circuit to ground or open
When malfunction of injector
circuit
Injector #6 short circuit to
ground or openDInspection the ECM pin 64 about short
circuit or open with bad contact
DInspection the injector
DInspection the ECM
YAA1F420YAA1F430
Injector Spray Pattern Check
1. Turn the ignition switch OFF.
2. Remove the fuel injector connectors.
3. Remove the fuel distributor and injector with a unit. At this time, do not remove the supply and return line.

M162 ENGINE CONTROLS 1F1 -- 49
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Notice:Prepare the beaker for taking the fuel.
4. Connect the shop made cable to the injector with a firing order.
5. Connect the other end of shop made cable to the positive battery cable and negative battery cable.
6. Turn the ignition switch ON.
7. Check the injector for normal spray pattern as shown in the figure. Check injector for leaks or later drop
Injector Resistance Inspection
1. Turn the ignition switch OFF.
2. Remove the fuel injector connectors.
3. Measure the fuel injector coil resistance using a multimeter.
Specified Value
14 ~ 17Ω
Notice:Replace the fuel injector if the measured value is out of the specified values. Check the connector and wire
connection between the ECM and the injector if the measured values are normal.
Injector Pulse Width Inspection
1. Turn the ignition switch OFF.
2. Install the scan tool.
3. Turn the ignition switch ON.
4. Monitor the “INJECTION TIME” with a scan tool.
Cranking
8.0 ms
Engine Idle3~5ms
Wide Open Throttle (WOT)14 ms

1F1 -- 50 M162 ENGINE CONTROLS
D AEW OO M Y_2000
PURGE CONTROL VALVE
YAA1F440
The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere.
The fuel vaporized gas that is accumulated in the canister abstracts through the purge control valve purification during
the engine combustion (except the decreasing mode) and coolant temperature of over 80°C. For this reason, the En-
gine Control Module (ECM) transacts the engine speed, air inflow quantity, coolant temperature, and intake tempera-
ture.
The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the continuous valve opening interval.
The purge control valve is activated by the ECM for the following conditions:
DCoolant temperature of over 80°C
DEngine speed of over 1,000 rpm
D2 minutes after starting
DWhen the fuel cut -- off mode is not activated

M162 ENGINE CONTROLS 1F1 -- 51
D AEW OO M Y_2000
KAB1F230
Failure
CodeDescriptionTrouble AreaMaintenance Hint
40Purge control valve
short circuit to batteryWhen short circuit to power
sourceDInspection the ECM pin 34 about short
circuitoropenwithbadcontact
41
Purge control valve
short circuit to ground or
openWhen short circuit to ground or
open
circuitor open withbadcontact
DInspection the source power of valve
DInspection the purge control solenoid
vale
54Purge control circuit
malfunctionWhen malfunction of purge
control : not workvale
DInspection the ECM
Test
YAA1F460
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECM terminal No. 11 and No. 34 and
check for normal operation through the output waves
using oscilloscope.Notice:Test during purge control valve operation after
the minimum of 1 minute after the engine turned on.
3. Connect the ECM terminal No. 34 and No.10 and
check for current consumption during the ignition
switch ON.
Specified Value
0.3 ~ 0.5 A
4. Remove the line to canister and measure the pres-
sure with the vacuum pressure gauge.
Specified Value
> 500 mbar
(after approx. 1 min.)
purge control valve operates
at this time
Notice:Test while at normal temperature and at idling
state by operating the engine.

1F1 -- 52 M162 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL RAIL
YAA1F470

M162 ENGINE CONTROLS 1F1 -- 53
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Fuel Pressure Test
Tools Required
103 589 00 21 00 Fuel Pressure Gauge
1. Turn the ignition switch to “OFF” position.
2. Remove the fuel pressure test connector.
KAA1F430
3. Connect the fuel pressure gauge to the fuel pressure test connector.
4. Test the fuel pressure at idling by operating the engine using the fuel pressure gauge 103 589 00 21 00.
Vacuum Hose Connected (bar)
3.2~3.6
Vacuum Hose Disconnected (bar)3.7~4.2
5. Replace the pressure regulator diaphragm if out of the specification.
Internal Leakage Test
1. Connect the fuel pressure gauge 103 589 00 21 00 to
the fuel pressure test connector.
KAA1F420
2. Stop the engine for approximately 30 minutes and then check the fuel pressure changes.
Pressure change
Fuel pressure drops slowlyDFuel leakage at the injector
DFaulty fuel pressure regulator ’s diaphragm and O-ring
Fuel pressure drops rapidlyDFaulty check valve in the fuel pump
3. If there is no change in fuel pressure and maintain the following pressure over 30minutes, it is normal.
Fuel pressure (bar)
≥2.5

1F1 -- 54 M162 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL PRESSURE REGULATOR
YAA1F480
Function of the Fuel Pressure Regulator
The fuel pressure regulator maintains the fuel pressure
in the fuel line with the pressure of 3.2 bars to 3.8 bars
according to the intake manifold pressure. This operat-
ing pressure cannot be changed, and the fuel injection
volume will be only determined by the injection time.
Over supplied fuel returns to the fuel tank through the
return line.

There is no negative pressure applied to the spring
chamber (9) during the full load, and it is separated from
the fuel chamber (8) by the diaphragm (5).
When the fuel pressure goes up, the diaphragm forces
the compression spring (6) in the direction of compres-
sion . At this moment, the valve (3) sticks to the dia-
phragm by the fuel pressure, and the fuel return line (2)
opens. The fuel over supplied returns to the fuel tank
through the return line.
YAA1F490
2. Fuel return line
3. Valve
5. Diaphragm
6. Compression Spring
8. Fuel Chamber
9. Spring Chamber
A. Valves Closed
B. Valves Opened

M162 ENGINE CONTROLS 1F1 -- 55
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The pressure difference between the fuel pressure and
the intake manifold is about 3.8 bars during the full load.
YAA1F500
1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return (to fuel tank)
4. Fuel Supply (from fuel pump)
5. Fuel Pressure (approx. 3.8 bars)
6. Intake Manifold Negative Pressure (0 bar)

The spring chamber (9) is connected to the intake man-
ifold with the vacuum hose at the intake pipe connection
(7). The negative pressure generated in the intake man-
ifold activates the diaphragm, and thus the fuel pressure
gets reduced to the rate of the operating extent of the
diaphragm by the intake manifold’s negative pressure.
YAA1F510
Consequently, the fuel pressure in the fuel distributor
changes by the intake manifold’s negative pressure, and
the injector ’s fuel pressure gets reduced independentlyto the throttle valve’s position. Thus, the fuel injection
volume can only be determined according to the injec-
tor’s injecting duration.
The pressure difference between the fuel pressure and
the intake manifold is approx. 3.2 bars during idling.
YAA1F520
1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return (to fuel tank)
4. Fuel Supply (from fuel pump)
7. Fuel Pressure (approx. 3.2 bars)
8. Intake Manifold Negative Pressure (0.6 bars)

YAA1F530
A. Fuel pressure
B. Intake Manifold Negative Pressure
LL. Idling
TL. Partial load
VL. Full load

1F1 -- 56 M162 ENGINE CONTROLS
D AEW OO M Y_2000
INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR
YAA1F540
The throttle actuator is actuated by the Engine Control Module (ECM) according to the position of the accelerator pedal
position.
It has two potentiometers which signal the position of the throttle valve to the ECM to enable it to recognize the various
engine load states.
Ignition “Off”
In the de-- energized states the throttle valve position is determined to be spring capsule.
Ignition “On”
When the ignition S/W on the servo motor in the throttle actuator is operated by the ECM. The throttle valve adopts a
position in line with the coolant temperature.
Closed position
In the closed throttle position, the servo motor controls engine speed by operating the throttle valve further (greater
mixture) or closing it further (reduced mixture), depending on coolant temperature and engine load. When this is done,
the throttle valve can be closed further by the servo motor overcoming the force of the spring capsule (mechanical end
stop). If the actuator is de-- energized, the throttle valve is resting against the spring capsule.
Consequently, the throttle valve opening is a constant 10-- 12°approximately.
At no load, this produces an engine speed of about 1,800 rpm
Driving
When driving (part/full throttle), the servo motor controls the throttle valve in line with the various load states and ac-
cording to the input signals from the pedal value sensor according to the input signals from the pedal value sensor
according to the position of the accelerator pedal.
The function of the EA (electronic accelerator) in the ECM determines the opening angle of the throttle valve through
the throttle actuator. Further functions are;
DIdle speed control
DCruise control
DReducing engine torque for ASR/ABS operation
DElectronic accelerator emergency running
DStoring faults
DData transfer through CAN

M162 ENGINE CONTROLS 1F1 -- 57
D AEW OO M Y_2000
KAB1F240
Failure
CodeDescriptionTrouble AreaMaintenance Hint
104Throttle position sensor
1 low voltageTPS 1 short circuit to ground
or open
105Throttle position sensor
1 high voltageTPS 1 short circuit to power
108Throttle position sensor
2 low voltageTPS 2 short circuit to ground
or open
109Throttle position sensor
2 high voltageTPS 2 short circuit to powerDMonitoring the actual values through
scantool
116Throttle actuator
learning control failureWhen actuator adaption
fluctuation or not meet the
conditionscantool
DInspection the ECM pin 84, 85, 87,
112, 67, 68 about short circuit or open
with bad contact
119Throttle valve return
spring failureWhen return spring defective
of actuator
withbadcontact
DInspection the throttle valve actuator
DInspection the ECM
121Throttle actuator failureWhen supply voltage of the
actuator short circuit to power
InspectiontheECM
123
Different mass air flow
sensor signal with
throttle position sensorWhen shut down of output
driver
125Both throttle position
sensor failureWhen defective of both
potentiometers