engine coolant SSANGYONG KORANDO 1997 Service Manual PDF

1D2 -- 16 M161 ENGINE COOLING
D AEW OO M Y_2000
Removal & Installation Procedure
1. Drain coolant from the radiator.
2. Remove the coolant thermo connector from the ra-
diator.
3. Remove the each coolant hoses.
4. Remove the automatic transmission fluid cooler
pipes from radiator.
Installation Notice
Tightening Torque
20 NSm (15 lb-ft)
5. Remove all the bolts (7) from the radiator bracket (9)
and remove the bracket (9) and insulator (8).
Installation Notice
Tightening Torque
3--7NSm (27 -- 62 lb-in)
6. Remove the radiator (10).
7. Check the radiator pin for crack, damage, leakage
and bending and replace it if necessary.
8. Installation is reverse order of removal.
9. Check for leakage in the cooling system.

D AEW OO M Y_2000
SECTION 1F2
ENGINE CONTROLS
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 other -
wise noted.
TABLE OF CONTENTS
Engine and ECM Problem Check Report 1F2 -- 2....
Specifications 1F2 -- 3............................
Engine Data Display Table 1F2 -- 3.................
Fastener Tightening Specifications 1F2 -- 4..........
Fuel System Specification 1F2 -- 5.................
Temperature vs Resistance 1F2 -- 5................
Special Tools and Equipment 1F2 -- 6..............
Special Tools Table 1F2 -- 6.......................
Schematic and Routing Diagrams 1F2 -- 7..........
ECM Wiring Diagram
(2.3L DOHC -- MSE 3.53S) 1F2 -- 7..............
Diagnosis 1F2 -- 14................................
Failure Code Diagnosis 1F2 -- 14.....................
Clearing Failure Codes 1F2 -- 14...................
Failure Codes Table 1F2 -- 14.....................
Ignition System 1F2 -- 18...........................
Ignition Coil 1F2 -- 20.............................
Crankshaft Position (CKP) Sensor 1F2 -- 22.........
Camshaft Position (CMP) Sensor 1F2 -- 26..........
Camshaft Actuator 1F2 -- 30......................
Knock Sensor (KS) 1F2 -- 32......................
Spark Plug 1F2 -- 34.............................
System Voltage 1F2 -- 38.........................
Ignition Switch 1F2 -- 39..........................
Fuel System 1F2 -- 40..............................
Fuel Pump 1F2 -- 42.............................
Fuel Injector 1F2 -- 46............................
Purge Control Valve 1F2 -- 50.....................
Fuel Rail 1F2 -- 52...............................
Fuel Pressure Regulator 1F2 -- 54.................
Induction System 1F2 -- 56..........................
Throttle Valve Actuator 1F2 -- 56...................
Hot Film Air Mass (HFM) Sensor 1F2 -- 60..........
Engine Coolant Temperature (ECT) Sensor 1F2 -- 64.
Accelerator Pedal Module 1F2 -- 68................Cooling Fan 1F2 -- 72............................
A/C Compressor Relay 1F2 -- 73...................
Cruise Control Switch 1F2 -- 74....................
Traction Control System (TCS) 1F2 -- 75............
Stop Lamp Switch 1F2 -- 76.......................
Engine RPM 1F2 -- 77............................
Exhaust System 1F2 -- 78...........................
Catalytic Converter 1F2 -- 78......................
Oxygen Sensor 1F2 -- 80.........................
Engine Control Module 1F2 -- 86.....................
Serial Data Communication 1F2--88...............
Internal Failure 1F2 -- 90..........................
Electronic Throttle Controller Safety
Malfunction 1F2 -- 92...........................
Immobilizer 1F2 -- 94.............................
Maintenance and Repair 1F2 -- 95..................
On -- Vehicle Service 1F2 -- 95........................
Discharging the Pressure in Fuel System 1F2 -- 95...
Fuel Pump 1F2 -- 95.............................
Fuel Filter 1F2 -- 96..............................
Fuel Tank 1F2 -- 97..............................
Fuel Pressure Regulator 1F2 -- 98.................
Fuel Rail and Injector 1F2 -- 99....................
Engine Coolant Temperature Sensor 1F2 -- 100......
Throttle Body (Integrated with the
Actuator) 1F2 -- 101............................
Hot Film Air Mass (HFM) Sensor 1F2 -- 102.........
Knock Sensor 1F2 -- 102..........................
Pedal Position Sensor 1F2 -- 103...................
Oxygen Sensor 1F2 -- 103........................
Purge Control Valve 1F2 -- 104....................
Canister 1F2 -- 104...............................
Camshaft Position Sensor 1F2 -- 104...............
Crankshaft Position Sensor 1F2 -- 105..............
Engine Control Module 1F2 -- 105..................

M161 ENGINE CONTROLS 1F2 -- 3
D AEW OO M Y_2000
SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
ParameterUnitVa l u e
Engine Coolant Temp.°Cgreater than 95_Cafterwarmup
Intake Air Temp.°C-- 40 ~ 130_C (varies with ambient
temp. or engine mode)
Engine RPMrpm700±50 (P/N), 600±50 (D)
Regular RPMrpm700±50 (P/N), 600±50 (D)
Engine Load%18 ~ 25 %
Mass Air Flow MeterKg/h16 ~ 25 Kg/h
Throttle Position Angle_TA0_TA(upto100_TA at the wide
open throttle)
Spark Advance_CA8_CA (6 ~ 9_CA)
Indicated Engine TorqueNmVaries with engine condition
Injection Timems3~5ms
Battery VoltageV13.5 ~ 14.1 v (engine running)
Front Axle SpeedKm/h0~265Km/h
Rear Axle SpeedKm/h0~265Km/h
Accel. Pedal Position 1V0.4~4.8V
Accel. Pedal Position 2V0.2~2.4V
Throttle Position 1V0.3~4.6V
Throttle Position 2V0.3~4.6V
Fuel Integrator0.8 ~ 1.2
Oxygen Sensormv100 ~ 900 mv
A/C S/W Condition1=ON/0=OFF--
Full Load State1=ON/0=OFF--
Shift Gear State (A/T)1=ON/0=OFF--
A/CControlState1=ON/0=OFF--
Clutch Switch (M/T)1=ON/0=OFF--
Cam Actuator State1=ON/0=OFF--
Knocking Control1=ON/0=OFF--
Protect Mission1=ON/0=OFF--
Purge Control Valve1=ON/0=OFF--
Lambda Function1=ON/0=OFF--
Catalyst Heating1=ON/0=OFF--
Overrun Fuel Cut1=ON/0=OFF--
Full Fuel Cut1=ON/0=OFF--
Brake Switch1=ON/0=OFF--
Cruise Control Status1=ON/0=OFF--
* Condition : Warmed up, idle, P/N or neutral

1F2 -- 4 M161 ENGINE CONTROLS
D AEW OO M Y_2000
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-FtLb-In
Camshaft Position Sensor Retaining Bolts10--89
Canister Mounting Bolts6--53
Coolant Temperature Sensor3022--
Crankshaft Position Sensor Retaining Bolt10--89
Engine Control Module (ECM) Mounting Bracket Nuts10--89
Fuel Filter Mounting Bracket Bolt6--53
Fuel Filter Lines2821--
Fuel Pressure Test Connector2518--
Fuel Rail Assembly Bolts2518--
Fuel Return And Supply Lines2317--
Fuel Tank Retaining Nuts3828--
Knock Sensor Mounting Bolt2518--
Oxygen Sensor5541--
Pedal Position Censor Mounting Bolts And Nut6--53
Throttle Body Bolts12--106

1F2 -- 14 M161 ENGINE CONTROLS
D AEW OO M Y_2000
DIAGNOSIS
FAILURE CODE DIAGNOSIS
CLEARING FAILURE CODES
Notice:To prevent Engine Control Module (ECM) damage, the key must be OFF when disconnecting or reconnecting
the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.)
Parameters listed in the table may not be exactly the same as your reading due to the type of instrument or other
factors. If a failure code is displayed during the “TROUBLE CODE” in scan tool check mode, check the circuit for the
code listed in the table below. For details of each code, turn to the page referred to under the “See Page” for the re-
spective “Failure Code” in the below table.
Failure codes should be cleared after repairs have been completed.
FAILURE CODES TABLE
Failure
codeSee
PageDescription
001F2 -- 66Engine coolant temperature sensor low voltage
011F2 -- 66Engine coolant temperature sensor high voltage
021F2 -- 66Engine coolant temperature sensor plausibility
031F2 -- 62Intake air temperature sensor low voltage
041F2 -- 62Intake air temperature sensor high voltage
051F2 -- 62Intake air temperature sensor plausibility
061F2 -- 66Engine coolant temperature insufficient for closed loop fuel control
081F2 -- 38System voltage too low
091F2 -- 62Mass air flow sensor plausibility
101F2 -- 62Mass air flow sensor low voltage
111F2 -- 62Mass air flow sensor high voltage
171F2 -- 23Crankshaft position sensor signal failure (no engine revolution signal)
181F2 -- 23Crankshaft position sensor signal failure (rpm > max. value)
191F2 -- 27Camshaft position senosr signal : No.1 cylinder recognition failure
201F2 -- 23Crankshaft position sensor signal failure (gap recognition failure)
211F2 -- 90Transmission coding failure
231F2 -- 88CAN communication failure : ASR/MSR
241F2 -- 88CAN communication failure : ABS
251F2 -- 94Communication with transponder missing
261F2 -- 88CAN communication failure : TCU (A/T only)
291F2 -- 89CAN communication failure : ID 200h not plausible
301F2 -- 89CAN communication failure : ID 208h not plausible
311F2 -- 89CAN communication failure : communication initialization failure
321F2 -- 77Engine rpm output circuit short circuit to battery
331F2 -- 77Engine rpm output circuit short circuit to ground or open
341F2 -- 43Fuel pump relay short circuit to battery
351F2 -- 43Fuel pump relay short circuit to ground or open

1F2 -- 40 M161 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL SYSTEM
The function of the fuel metering system is to deliver the correct amount of fuel to the engine under all operating condi-
tions. The fuel is delivered to the engine by the individual fuel injectors mounted into the intake manifold near each
cylinder.
The main fuel control sensors are the Mass Air Flow (MAF) sensor and the oxygen (O2) sensors.
The MAF sensor monitors the mass flow of the air being drawn into the engine. An electrically heated element is
mounted in the intake air stream, where it is cooled by the flow of incoming air. Engine Control Module (ECM) modu-
lates the flow of heating current to maintain the temperature differential between the heated film and the intake air at a
constant level. The amount of heating current required to maintain the temperature thus provides an index for the
mass air flow. This concept automatically compensates for variations in air density, as this is one of the factors that
determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located
between the air filter and the throttle valve.
Under high fuel demands, the MAF sensor reads a high mass flow condition, such as wide open throttle. The ECM
uses this information to enrich the mixture, thus increasing the fuel injector on-- time, to provide the correct amount of
fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by
the ECM, which then decreases the fuel injector on-- time due to the low fuel demand conditions.
The O2 sensors are located in the exhaust pipe before catalytic converter. The O2 sensors indicate to the ECM the
amount of oxygen in the exhaust gas, and the ECM changes the air/fuel ratio to the engine by controlling the fuel
injectors. The best air/fuel ratio to minimize exhaust emissions is 14.7 to 1, which allows the catalytic converter to
operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system
is called a “closed loop” system.
The ECM uses voltage inputs from several sensors to determine how much fuel to provide to the engine. The fuel is
delivered under one of several conditions, called ‘‘modes”.
Starting Mode
When the ignition is turned ON, the ECM turns the fuel pump relay on for 1 second. The fuel pump then builds fuel
pressure. The ECM also checks the Engine Coolant Temperature (ECT) sensor and the Throttle Position (TP) sensor
and determines the proper air/fuel ratio for starting the engine. This ranges from 1.5 to 1 at -- 36°C(--33°F) coolant
temperature to 14.7 to 1 at 94°C (201°F) coolant temperature. The ECM controls the amount of fuel delivered in the
starting mode by changing how long the fuel injector is turned on and off. This is done by ‘‘pulsing” the fuel injectors for
very short times.
Run Mode
The run mode has two conditions called ‘‘open loop” and ‘‘closed loop”.
Open Loop
When the engine is first started and it is above 690 rpm, thesystem goes into “open loop” operation. In “open loop”, the
ECM ignores the signal from the HO2S and calculates the air/fuel ratio based on inputs from the ECT sensor and the
MAF sensor. The ECM stays in “open loop” until the following conditions are met:
DThe O2 has a varying voltage output, showing that it is hot enough to operate properly.
DThe ECT sensor is above a specified temperature (22.5°C).
DA specific amount of time has elapsed after starting the engine.
Closed Loop
The specific values for the above conditions vary with different engines and are stored in the Electronically Erasable
Programmable Read -- Only Memory (EEPROM). When these conditions are met, thesystem goes into “closed loop”
operation. In “closed loop”, the ECM calculates the air/fuel ratio (fuel injector on-- time) based on the signals from the
O2 sensors. This allows the air/fuel ratio to stay very close to 14.7 to 1.
Acceleration Mode
The ECM responds to rapid changes in throttle position and airflow and provides extra fuel.
Deceleration Mode
The ECM responds to changes in throttle position and airflow and reduces the amount of fuel. When deceleration is
very fast, the ECM can cut off fuel completely for short periods of time.

1F2 -- 50 M161 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

1F2 -- 56 M161 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

1F2 -- 58 M161 ENGINE CONTROLS
D AEW OO M Y_2000
Failure
CodeDescriptionTrouble AreaMaintenance Hint
126
Throttle position sensor
1 not plausible with
Throttle position sensor
2
When difference between
TPS 1 and TPS 2DMonitoring the actual values through
scan tool
DIns
pection the ECMpin 84, 85, 87,
127High permanent throttle
signalWhen failure of wiring
harness or actuator
DInspectiontheECMpin84,85,87,
112, 67, 68 about short circuit or open
with bad contact
Itiththttlltt
185
Mass air flow sensor
and throttle position
sensor failureWhen difference between
MAF and TPS signal
DInspection the throttle valve actuator
DInspection the ECM
Circuit Description
The ECM supplies a 5 volt reference signal and a ground to the TP sensor. The TP sensor sends a voltage signal back
to the ECM relative to the throttle plate opening. The voltage signalwill vary from approximately 0.3 ~ 0.9 volts at
closed throttle, to over 4.0 ~ 4.6 volts at Wide Open Throttle (WOT).
The TP sensors serve for engine load control according to the drive pedal command. Load adjustments independent of
the drive pedal command can be implemented; such functions are, for instance, idle control, speed control, drive slip
control, load shock damping, and similar functions.
When the actuator current fails, the throttle valve is returned to emergency operating position by a spring. The throttle
valve position, thereby the actuator drive position checkback is provided by two potentiometers. The motor positions
the throttle valve against the return spring force. Motor and return spring are two separate energy sources. Each of
them is able to position the throttle valve in emergency position alone. Throttle valve position checkback and monitor-
ing is provided by two actual value potentiometers connected to the engine control electronics.
Throttle Actuator Inspection
1. Turn the ignition switch to “ON” position.
2. Measure the TPS 1 signal voltage at the ECM pin No. 87 and TPS 2 signal voltage at the ECM pin No. 85.
Pedal PositionSpecified Value
TPS1Closed0.3 ~ 0.9 vTPS1Opened4.0 ~ 4.6 v
TPS2Closed4.0 ~ 4.6 vTPS2Opened0.3 ~ 0.9 v
Throttle Actuator DC Motor Inspection
1. Turn the ignition switch to “ON” position.
2. Measure the signal voltage between the ECM pin No. 67 and No. 68.
Application
Specified Value
Ignition “ON”0.8 ~ 2.3 v
Engine StatusIdling1.0 ~ 2.5 v
(Coolant temperature is over 70°C)
Throttle Actuator DC Motor Resistance
1. Turn the ignition switch to “OFF” position.
2. Measure the resistance between the ECM pin No. 67 and No. 68.
Specified Value
<10Ω

M161 ENGINE CONTROLS 1F2 -- 63
D AEW OO M Y_2000
Mass Air Flow Sensor Input Voltage Inspection
1. Turn the ignition switch to “ON” position.
2. Measure the signal voltage between the ECM pin No. 103 and No. 104.
Application
Specified Value
Ignition “ON”0.9 ~ 1.1 v
Engine StatusIdling1.3 ~ 1.7 v
(Coolant temperature is over 70°C)
Notice:If the measured value is not within the specified value, the possible cause may be in cable or MAF sensor in
itself. Perform the 5 volt power supply inspection procedures.
Mass Air Flow Sensor 5 volt Power Supply Inspection
1. Turn the ignition switch to “OFF” position.
2. Disconnect the HFM sensor connector.
3. Turn the ignition switch to “ON” position.
4. Measure the voltage between the ECM pin No. 108 and MAF sensor connecter terminal No. 3.
Specified Value
4.7~5.2v
Notice:If the measured value is not within the specified value, the possible cause may be in cable or ECM coupling.
5. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 4.
Specified Value
4.7~5.2v
Notice:If the measured value is not within the specified value, the possible cause may be in cable or ECM coupling.
Mass Air Flow Sensor 12 volt Power Supply Inspection
1. Turn the ignition switch to “OFF” position.
2. Disconnect the HFM sensor connector.
3. Turn the ignition switch to “ON” position.
4. Measure the voltage between the ECM pin No. 105 and MAF sensor connecter terminal No. 2.
Specified Value
11 ~ 14 v
Notice:If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage
Protection Relay (OVPR).