check engine SSANGYONG KORANDO 1997 Service Repair Manual

MANUAL & SEMIAUTO-HVAC 7C-7
SSANGYONG MY2002
DIAGNOSIS USING THE MANIFOLD GAUGE
On normal operation during the cooling cycle, the
manifold gauge must indicate approximately 1.5 - 2.0
kg/cm
2 at low pressure side and 14.5 - 15 kg/cm2 at
high pressure side, on condition that the temperature
at the cooler inlet, 30 ºC - 35 ºC, 2,000 rpm of the
engine rpm , full cold and maximum blower speed.
Cause Symptom
Action
1. High and low pressure are abnormally low.
2. Air at cooler outlet is not cold.
1. High and low pressure are abnormally high.
1. High and low pressure are abnormally high.
2. Connection at the low pressure is not cold.
There is a gas leak in the
cooling system.
Insufficient cooling and
faulty condenser cooling
by excessive
refrigerant.
Belt is slipped
There is an air in the
cooling system
Check the oil leak,
repair
Add the refrigerant
Keep the specified
amount of the
refrigerant, Clean the
condenser
Repair the belt
Clean and repair the
receiver-drier
Check the oil
contamination etc.
YAD7B070
YAD7B080
YAD7B100 YAD7B090

MANUAL & SEMIAUTO-HVAC 7C-17
SSANGYONG MY2002


Operation Check
Notice: Operation Check is recommended before
removing the manifold gauge.
1. Install the manifold gauge set.
2. Run the engine at 2,000 rpm and set the blower
switch at ‘HI’ and A/C switch ‘ON’. Set the
temperature control lever at ‘COOL’.
3. Keep opening all of the window and door.
4. Place a dry bulb thermometer to the front duct.
5. Place a psychrometer close to the inlet of the
cooling unit.
6. Check the high pressure gauge reading within
14 - 16 kg/cm
2
If the reading indicates high excessively, spray
the water to the condenser.
If the reading indicates low excessively, cover the
condenser with the towel.
7. Check the temperature of air inlet within 25 - 35 °C.
8. Calculate the relative humidity from the
psychrometic graph comparing the wet/dry
temperature at the air inlet.
9. Measure the wet/dry temperature at the cold air
outlet and calculate the temperature difference of
the dry bulb between the inlet and the outlet.
10. Check the cross point of the relative humidity and
check the temperature difference between the
black line. If the cross point is located between
the black line, the cooling performance is normal.
4. The discharging pressure increases when the
charging valve charges excessively, so charge
the charging valve to the specified amount with
measuring the weight of the refrigerant before
closing the high pressure valve.
5. Charge the specified amount of the refrigerant and
then close the valve of the manifold gauge. Check
the system for any leak.
YAD7B240

SSANGYONG MY2002
7C-18 MANUAL & SEMIAUTO-HVAC
Total Oil Capacity 265 cc
COMPRESSOR OIL
REPLACEMENT
Before Oil Replacement
When any part is replaced or there are a lot of gas
leaks in the A/C system, you should add the specified
amount of the oil to keep the approval oil capacity
because the oil for lubricating the compressor
circulates through the A/C system during operating
the compressor.
Handling Oil
Be careful that moistures, dusts etc. must not flow
into the oil.
Do not mix with any other material.
If the oil leaves outside for long time, it’s possible
to mix it with the moistures and so keep the oil
sealed with a container.
Circulating Oil
For checking or adjusting the oil level, set the control
unit to full cold and max blower speed with keeping
the engine run at idle for 20 - 30 minutes in order to
circulate the oil through the compressor.

FATC-HAVC 7D-19
SSANGYONG MY2002
KAA7D230
KAA7D240
KAA7D250
KAA7D260
Water Sensor
Water sensor is a thermistor that detects engine coolant
temperature to operate the blower speed to LO when
water temperature is less than 50.
1. Check that there are water sensor fault code (15,16)
by using self-diagnosis function.
2. Disconnect water sensor 2-pin connector that
installed on the heater unit of inner instrument panel
and remove the water sensor.
3. Check that measured resistance value among
water sensor terminals is as shown in the right
side graph.
Notice: Measure resistance value by soaking the
sensor in the ice water and check changes in
resistance values after soaking it in the very hot
water.
4. If resistance value is out of specification, replace
the water sensor.
5. Install the sensor and turn the ignition switch to
ON position and check that voltage between No.
7a terminal of the water sensor and body (-) is 5V.
6. Check current between the No. 7a and 7b connector
terminals of the water sensor and the No. 3 and 5
connector terminals of the airconditioner control unit
and repair the wire if defective.

SSANGYONG MY2002
9E-6 INSTRUMENTATION, DRIVER INFORMATION
Digital Clock Inoperative (Cont’d)
Step
1
2
3
4
5
6
7
8Action
Repair the open power supply circuit for the fuse.
Is the repair complete?
1. Turn the ignition ON.
2. Use a voltmeter to check the battery voltage
available at the clock connector terminal D1.
Does the voltmeter indicate the value specified?
Repair the open circuit between the clock connector
terminal D1 and the fuse F4.
Is the repair complete?
Turn the ignition ON.
Is battery voltage available at the clock connector
terminal C13?
Repair the open circuit between the clock connector
terminal C13 and the fuse F4.
Is the repair complete?
Check continuity between the clock connector
terminal C13 and ground.
Does the multimeter indicate the value specified?
Replace the clock.
Is the repair complete?
Repair the open ground circuit between the clock
connector terminal C13 and the ground G201.
Is the repair complete?Yes
System OK
Go to Step 7
System Ok
Go to Step 9
System OK
Go to Step 10
System OK
System OKNo
−
Go to Step 6
-
Go to Step 8
-
Go to Step 11
-
- Value(s)
−
11 - 14 v
-
-
-
0 Ω
-
-
SPEEDO METER
Speedometer Is Inoperative
Step
1
2
5
6
7
8Action
Check fuse F28, and F30.
Is fuse F28 and F30 blown?
1. Check for a short circuit and repair if necessary.
2. Replace the fuse F28, and F30.
Is the repair complete?
1. Turn the ignition ON.
2. Check the voltage at fuse F28 and F30.
Is the voltage equal to the specified value?
1. connect a scan tool.
2. Check for engine control diagnostic trouble codes
(DTCs).
Is a vehicle speed sensor DTC set?
1. Remove the instrument cluster.
2. Turn the ignition ON.
3. Check the voltage at instrument cluster connector
terminal A1.
Is the voltage equal to the specified value?
Repair the open circuit between fuse F30 and the
instrument cluster.
Is the repair complete?Yes
Go to Step 7
System OK
Go to Step 5
Go to Section
2F, Engine
Controls
Go to Step 8
System OKNo
Go to Step 3
-
Go to Step 4
Go to Step 6
Go to Step 7
- Value(s)
-
-
11 - 14 v
-
11 - 14 v
-

SSANGYONG MY2002
9E-8 INSTRUMENTATION, DRIVER INFORMATION
TEMPERATURE GAUGE
Temperature Gauge Inoperative, Other Gauges OK
Step
1
2
3
4
5
6
7
8
9Action
Allow the engine to cool to room temperature.
With the ignition ON, does the temperature gauge
always read at the high end of the scale?
Disconnect the coolant temperature sensor electrical
connector.
Does the termperature gauge indicator drop to the
low end of the scale?
Replace the coolant temperature sensor.
Is the repair complete?
Check for a short to ground between the coolant
temperature sensor and the temperature gauge.
Is there a short to ground?
Repair the short to ground.
Is the repair complete?
Replace the temperature gauge.
Is the repair complete?
1. Disconnect the coolant temperature sensor.
2. Turn the ignition ON.
3. Check the voltage at the coolant temperature
sensor connector.
Does the the voltage equal the value specified?
Check for an open circuit between the coolant tem-
perature sensor and the temperature gauge.
Is the repair complete?
Repair the open circuit between the coolant tempera-
ture sensor and the temperature gauge.
Is the repair complete?Yes
Go to Step 7
Go to Step 3
System OK
Go to Step 5
System OK
System OK
Go to Step 10
Go to Step 8
System OKNo
Go to Step 2
Go to Step 4
-
Go to Step 6
-
-
Go to Step 8
Go to Step 6
- Value(s)
-
-
-
-
-
-
11 - 14 v
-
-
Fuel Gauge Inoperative (Cont’d)
Step
1
2
3Action
Check continuity between the fuel tank sending unit
connector C303 terminal 3, and groun.
Does the multimeter indicate the specified value?
Repair the open circuit or poor ground connection.
Is the repair complete?
1. With the fuel tank sending unit electrical connector
C303 disconnected, attach a jumper between
ground and C303 terminal 1.
2. Turn the ignition ON.
Does the fuel gauge move to full?Yes
Go to Step 11
System OK
Go to Step 3No
Go to Step 10
-
Go to Step 6 Value(s)
0 Ω
-
-

SQUEAKS AND RATTLES 9K-3
SSANGYONG MY2002
Check for a lack of lubrication of the door hinge pins.ChecksActionOperate the doors and listen for squeaks.
Lubricate the door hinge pins with light oil and coat
with lithium grease.
Squeak Coming From Console When Shifting Manual Transaxle
(Condition Occurs In Cold Weather with a Cold Engine)
Check the manual transaxle control lever lower boot.ChecksActionMove the control lever between gears and listen for
squeaks.
Remove the floor console and replace the lower shift
boot or apply talcum powder to the lower shift boot.
Squeak When Operating Doors
Check for vibration of the fuse box cover against the
instrument panel side trim.ChecksActionTap on thecoverwith a fingerandlisten fora buzz.
Apply 6.35 mm (0.250 inch) by 25.4 mm (1.00 inch)
felt pads to the side trim where the cover makes
contact.
Squeak Coming From Instrument Cluster Trim Plate
Check for rubbing of the cluster trim plate on the
instrument panel.ChecksActionTest drive the vehicle in order to verify this condi-
tion.
Remove the instrument cluster trim plate and install
felt tape to the edges.
Buzz From the Left Side of Instrument Panel
Check the door lock solenoid.
Check for rattling electrical connectors inside the door
trim panel.ChecksActionRemove the door trim panel and check if the sole-
noid is loose.
Tighten the solenoid bolts.
Tap on the trim panel and listen for a rattle.
Remove the trim panel and wrap foam padding
around the connectors as required.
Rattle Coming From Door

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
9T2-2 IMMOBILIZER SYSTEM
DESCRIPTION AND OPERATION
Immobilizer is a device disabling vehicle ignition unless
a speific key is used and designed to help prevent
vehicle theft.
Immobilizer is comprised of two devices, a key with
encoded transponder and engine control unit (ECU)
with the same encoding of the transponder. When a
key is inserted into the key hole to start vehicle and
turned to ‘ON’, the ECU reads and decodes the
transponder code and, if the same, starts the engine,
it is called immobilizer. It means immobilizer system
disables starting by stopping fuel supply if the code
in the transponder does not match the code stored in
ECU each other.
Notice:
If vehicle is equipped with immobilizer system and
the engine cranks normally but not start, check
immobilizer system first rather than ignition and
other electrical systems because it can be
disabled fuel supply of injectors by ECU due to
defective immobilizer system.
Programming of the immobilizer system will be
performed by authorized personnel only. If
following defective codes for immobilizer system
appear during diagnosis of vehicle with SCANNER,
ask immobilizer programming to authorized
personnel and actual programming should be
performed by authorized per-sonnel only.
Display of defectives relevant to immobilizer
system : SCANNER
1. No communication with transponder
2. No immobilizer programming
The transponder in the key can be damaged by
shocks of dropping or hitting other objectives, so
handle it with care.
Each supplied key has programming of code on
its own. Accordingly if ECU needs to be replaced,
replace the transponder in the key.
The vehicle equipped with immobilizer system will
never be started with remote ignition device, so
do not attempt to install it.
The immobilizer system will never be removed from
the vehicle. So never attempt to remove it to install
a remote ignition device or others.
If engine does not start during service, use every
key to start the engine and then check immobilizer
sys-tem finally.
Cases that requires immobilizer
programming
1. Replacement ECU
In this case, replace the every transponder of the
key at once.
2. Replacement of the transponder
3. Additional key for lost 1 or 2 keys
1) Clear all codes for current keys from the ECU
2) When using current key : clear code of the trans-
ponder and re-program it
3) Additional (purchased) key : perform programming
4. When lost all keys
1) Clear all memorized key codes from the ECU
2) Replace the key and key set
3) Immobilizer programming