ECU SSANGYONG KORANDO 1997 Service Repair Manual

0B -- 10 GENERAL INFORMATION
D AEW OO M Y_2000
Chassis and Body
MAINTENANCE ITEMMAINTENANCE INTERVAL
Kilometers or time in months, whichever comes first
x1,000 km1153045607590105120
Months--1224364860728496
Exhaust pipes & mountings--IIIIIIII
Brake/Clutch fluid (3)(4)--IRIRIRIR
Parking brake/Brake pads F & R (5)--IIIIIIII
Brake line & connections (including booster)IIIIIIIII
Manual transmission oil (3)IIIRIIRII
Clutch & brake pedal free play--IIIIIIII
Front & Rear Differential Fluid (3)IIIRIIRII
Transfer case fluidIIIRIIRII
Automatic transmission fluid
(MB W4A040) (6)IIIRIIIII
Automatic transmission fluid (BTRA M74)IIIIIIIII
Chassis & underbody bolts & nuts tight/secureIIIIIIIII
Tire condition & inflation pressureIIIIIIIII
Wheel alignment (7)Inspect & adjust when abnormal condition is noted
Steering wheel & linkage--IIIIIIII
Power steering fluid & lines* (3)--IIIIIIII
Drive shaft boots--IIIIIIII
Seat belts, buckles & anchorsIIIIIIIII
Lubricate locks, hinges & bonnet latch--IIIIIIII
Chart Symbols:
I -- Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R -- Replace or change.
(3) Refer to “Recommended fluids and lubricants”.
(4) Change the brake / clutch fluid every 15,000 km if the vehicle is mainly driven under severe conditions:
-- Driving in hilly or mountainous terrain, or
-- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, fre-
quent low -- speed operation in stop-- and-- go traffic or driving in dusty condition.
(6) Change automatic transaxle fluid and filter every 75,000 km if the vehicle is mainly driven under severe condi-
tions.
-- In heavy city traffic where the outside temperature regularly reaches 32°C(90°F) or higher, or
-- In hilly or mountainous terrain, or
-- When doing frequent trailer towing, or
-- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

0B -- 12 GENERAL INFORMATION
D AEW OO M Y_2000
Chassis and Body
MAINTENANCE ITEMMAINTENANCE INTERVAL
Kilometers or time in months, whichever comes first
x1,000 km1102030405060708090100
Months--6121824303642485460
Exhaust pipes & mountings--IIIIIIIIII
Brake/clutch fluid (3) (4)IIIRIIRIIRI
Parking brake/Brake pads (F & R) (5)--IIIIIIIIII
Brake line & connections (including
booster)--IIIIIIIIII
Manual transmission fluid (3)--IIIIRIIIIR
Clutch & brake pedal free play--IIIIIIIIII
F & R Differential fluid (3)IIIIIRIIIIR
Transfer case fluid (3)--IIIIRIIIIR
Automatic transmission
fluid (BTRA M74) (6)--IIIIIIIIII
Chassis & underbody bolts & nuts
tight/secureIIIIIIIIIII
Tire condition & inflation pressureIIIIIIIIIII
Wheel alignment (7)Inspect & adjust when abnormal condition is noted
Steering wheel & linkage--IIIIIIIIII
Power steering fluid & lines* (3)--IIIIIIIIII
Drive shaft bootsIIIIIIIIIII
Seat belts, buckles & anchorsIIIIIIIIIII
Lubricate locks, hinges & bonnet latchIIIIIIIIIII
Chart Symbols:
I -- Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R -- Replace or change.
(3) Refer to “Recommended fluids and lubricants”.
(4) Change the brake / clutch fluid more regularly if the vehicle is mainly driven under severe conditions :
-- Driving in hilly or mountainous terrain, or
-- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, fre-
quent low
-- speed operation in stop-- and-- go traffic or driving in dusty condition.
(6) Change automatic transmission fluid every 70,000 km if the vehicle is mainly driven under severe conditions.
-- In heavy city traffic where the outside temperature regularly reaches 32°C(90°F) or higher, or
-- In hilly or mountainous terrain, or
-- When doing frequent trailer towing, or
-- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

1B1 -- 44 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and re-
move the bearing cap.
Installation Notice
Tightening Torque
40 NSm (30 lb-ft) + 90°
DMake sure that the upper and lower bearing shells
do not change each other.
DCoat the bearing shell with engine oil.
DInstall the bearing cap according to the consecu-
tive number.
Part No. : 601 030 00 62 2.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
2. Unscrew the crankshaft bearing cap bolts and sepa-
rate the upper and lower bearing shells and thrust
washers.
Installation Notice
Tightening Torque
55 NSm (41 lb-ft) + 90°
DRemove the bearing cap from front (pulley side) to
rear.
DMake sure that the upper and lower bearing shells
do not change each other and coat with engine oil.
DThe oil grooves (arrows) in the thrust washers
must face outward and insert the thrust bearing
into the bearing cap.
DThere are five kinds of thrust washers by thick-
ness. Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in
the reverse order.
5. After completion of the installation, check for the ro-
tating condition of the crankshaft.
Installation Notice
DMake sure the crankshaft bearing cap properly
seated in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the left
side (intake manifold side).
DAssemble so that the projected part of the cap and
crankcase face the same direction.

1B1 -- 60 M162 ENGINE MECHANICAL
D AEW OO M Y_2000
Tools Required
DW110 -- 120 Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turn-
ing the crankshaft.
Notice:When the OT mark on vibration damper is
aligned with timing gear case cover, the intake and ex-
haust cam of cylinderwill make the slope to the center
and will face up. In this way, the adjustment hole of the
intake and exhaust camshaftwill match in line with the
cylinder head upper end, at 3 o’clock, and 9 o’clock di-
rection each other.
2. Check the timing as below procedure;
-- Check if the camshaft adjustment hole is posi-
tioned to 3 o’clock direction at the intake side and
to 9 o’clock direction at the exhaust side, respec-
tively and align with the cylinder head mating sur-
face.
-- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear
case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30°.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole
with the cylinder head upper surface.
DIntake Side : 3 o’clock direction
DExhaust Side : 9 o’clock direction
5. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin
DW110-- 120 into the holes.
6. Secure the intake and exhaust camshaft.
7. Position the piston of No.1 cylinder at TDC (OT) by
turning the crankshaft.
8. Turn the camshaft adjuster of the intake camshaft to
the left as much as possible (cam adjuster ‘retarded’
position).
9. Install the chain to the intake camshaft sprocket.
Notice:Timing chain must be placed on the guide rail in
gear case cover.

1E 1 -- 10 M162 ENGINE ELECTRICAL
D AEW OO M Y_2000
Circuit Diagram
Inspection & Maintenance Procedure (for
MSE)
1. While the ignition switch is in ’OFF’ position, remove
the wiring connectors (1 and 15) from ignition coil and
measure the primary resistance between terminal
No.1 and No.15.
Specified Value
0.9 -- 1.6Ω(20°C)
Notice:If out of specified value, replace the ignition coil.
2. During engine cranking, measure primary voltage
(T1/1) between ECU terminal No. 71 and No. 69.
Specified Value
200 -- 350 V
Notice
DMeasure remaining cables.
-- T1/2 : No. 72 and 69.
-- T1/3 : No. 70 and 69.
DIf out of specified value, check ignition cable and
ECU.
3. Using a multi-- tester, measure the secondary coil re-
sistance between 5a and 5b.
Specified Value
6--8.5kΩ

1F1 -- 16 M162 ENGINE CONTROLS
D AEW OO M Y_2000
FAILURE CODES TABLE (Cont’d)
Failure
codeSee
PageDescription
1031F1 -- 83Bank 1 system learning control failure (lean, high load)
1041F1 -- 57Throttle position sensor 1 low voltage
1051F1 -- 57Throttle position sensor 1 high voltage
1081F1 -- 57Throttle position sensor 2 low voltage
1091F1 -- 57Throttle position sensor 2 high voltage
1101F1 -- 92Throttle actuator learning data fault
1161F1 -- 57Throttle actuator learning control failure
1171F1 -- 92Exceed fuel-- cut safety time
1191F1 -- 57Throttle valve return spring failure
1201F1 -- 92Cruise control interruption memory failure
1211F1 -- 57Throttle actuator failure
1221F1 -- 69Accelerator pedal position sensor signal failure
1231F1 -- 57Different Mass air flow sensor signal with throttle position sensor
1251F1 -- 57Both throttle position sensors failure
1261F1 -- 58Throttle position sensor 1 not plausible with throttle position sensor 2
1271F1 -- 58High permanent throttle signal
1291F1 -- 74Cruise control “OFF” due to message counter failure
1301F1 -- 74Vehicle speed signal failure
1311F1 -- 74Vehicle speed signal failure
1321F1 -- 74Cruise control lever failure
1331F1 -- 74Cruise control acceleration failure
1341F1 -- 74Cruise control deceleration failure
1351F1 -- 77Stop lamp switch failure
1361F1 -- 90ECU failure (RAM)
1371F1 -- 90ECU failure (EPROM)
1381F1 -- 92Call monitoring
1391F1 -- 92Servo motor control output interruption memory failure
1401F1 -- 92Servo motor open/short
1411F1 -- 94Unprogramed ECU with immobilizer
1421F1 -- 90Uncoded/unprogramed ECU
1431F1 -- 90ECU failure (EEPROM/Flash -- EPROM checksum failure)
1441F1 -- 90ECU failure (coding ID checksum failure)
1451F1 -- 90ECU failure (coding checksum failure)
1461F1 -- 90ECU failure (programing checksum failure)
1501F1 -- 75TCS input signal short circuit to battery
1511F1 -- 75TCS input signal short circuit to ground or open
1601F1 -- 69Accelerator pedal position sensor 1 low voltage
1611F1 -- 69Accelerator pedal position sensor 1 high voltage
1621F1 -- 69Accelerator pedal position sensor 2 low voltage
1631F1 -- 69Accelerator pedal position sensor 2 high voltage
1641F1 -- 69Accelerator pedal position sensor 1 not plausible with pedal position sensor 2

M162 ENGINE CONTROLS 1F1 -- 17
D AEW OO M Y_2000
FAILURE CODES TABLE (Cont’d)
Failure
codeSee
PageDescription
1671F1 -- 69Both setpoint accelerator pedal position sensor defective
1851F1 -- 58Mass air flow sensor and throttle position sensor failure
1861F1 -- 92ECU failure (incompatible CPU)
1871F1 -- 92ECU failure (CPUs communication failure)
1881F1 -- 92ECU failure (CPU 2 configuration failure)
1891F1 -- 92ECU failure (CPU 2 fault)
1901F1 -- 92ECU failure (CPU run time failure between CPUs)
1921F1 -- 48No.5 injector short circuit to battery
1931F1 -- 48No.5 injector short circuit to ground or open
1941F1 -- 48No.6 injector short circuit to battery
1951F1 -- 48No.6 injector short circuit to ground or open
1981F1 -- 76Resonance flap short circuit to battery
1991F1 -- 76Resonance flap short circuit to ground or open
2261F1 -- 31Camshaft actuator short circuit to battery
2271F1 -- 31Camshaft actuator short circuit to ground or open
2281F1 -- 73A/C compressor relay short circuit to battery
2291F1 -- 73A/C compressor relay short circuit to ground or open
2311F1 -- 92ECU failure (CPU 2 cruise control message counter failure)
2321F1 -- 92Over decceleration limit (CPU 2)
2331F1 -- 92Over acceleration limit (CPU 2)
2341F1 -- 92Cruise control lever dual operation (CPU 2)
2351F1 -- 92Cruise control lever safety terminal failure (CPU 2)
2361F1 -- 92Unusual pedal position variation (CPU 2)
2371F1 -- 92Unusual throttle position variation (CPU 2)
2381F1 -- 92Unusual throttle controller monitor data comparison fault (CPU 2)
2391F1 -- 93Unusual accelerator pedal position sensor comparison fault (CPU 2)
2401F1 -- 93Throttle potentiometer comparision fault (CPU 2)
2411F1 -- 93Unusual CPU communication (CPU 2)
2421F1 -- 93Unusual CPU configuration (CPU 2)
2431F1 -- 93A/D converter failure (CPU 2)
2441F1 -- 93Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2
2451F1 -- 93Position controller setpoint fault between CPU 1 and CPU 2
2461F1 -- 93MSR setpoint fault between CPU 1 and CPU 2
2471F1 -- 93Idle control setpoint fault between CPU 1 and CPU 2
2481F1 -- 93A/Dconverteroverflow(CPU2)
2491F1 -- 93ROM fault (CPU 2)
2501F1 -- 93RAM fault (CPU 2)
2511F1 -- 93Cycle monitor fault (CPU 2)

M162 ENGINE CONTROLS 1F1 -- 105
D AEW OO M Y_2000
4. Check the O-ring for damage and replace it if neces-
sary.
5. Installation should follow the removal procedure in
the reverse order.
KAA1F160
CRANKSHAFT POSITION SENSOR
Removal and installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the crankshaft
position sensor.
3. Remove the crankshaft position sensor retaining bolt.
Installation Notice
Tightening Torque
10 NSm (89 lb-in)
4. Installation should follow the removal procedure in
the reverse order.
KAA1F200
ENGINE CONTROL MODULE
Removal and installation Procedure
1. Disconnect the negative battery cable.
2. Remove the cowl side trim form passenger side. Re-
fer toSection 9G, Interior trim.
3. Remove the four securing nuts for the Engine Control
Module (ECM) from the mounting bracket.
Installation Notice
Tightening Torque
10 NSm (89 lb-in)
4. Pull out the ECM from the bracket.
5. Disconnect the vehicle side coupling.
6. Installation should follow the removal procedure in
the reverse order.

1G1 -- 10 M162 ENGINE INTAKE & EXHAUST
D AEW OO M Y_2000
Function Description
A pneumatically actuated resonance flap (5) is located
on the intake manifold, and will be opened and closed by
load, which operates resonance flap according to engine
and controlled by ECU and rpm.
1. Resonance flap closed (at idle/partial load : less
than 3,800/rpm)
The switch valve (7) will be adjusted by ECU and res-
onance flapwill be closed. By increasing air flow pas-
sage through dividing intaking air flow toward both air
collection housing (8). This leads to a signficant in-
crease in the torque in the lower speed range.
2. Resonance flap open (at full load:over 3,800/rpm)
The switch valve (7) will not be adjusted by ECU and
resonance flap (5) will beopen. The colllected air in
the air collection housing (8)will not be divided and
intaking air passage will be shorten.

1B2 -- 48 M161 ENGINE MECHANICAL
D AEW OO M Y_2000
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and re-
move the bearing cap.
Installation Notice
Tightening Torque
40 NSm (30 lb-ft) + 90°
DMake sure that the upper and lower bearing shells
do not change each other.
DCoat the bearing shell with engine oil.
DInstall the bearing cap according to the consecu-
tive number.
Part No. : 601 030 00 62 2.15 mm
Part No. : 601 030 01 62 2.20 mm
Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
2. Unscrew the crankshaft bearing cap bolts and sepa-
rate the upper and lower bearing shells and thrust
washers.
Installation Notice
Tightening Torque
55 NSm (41 lb-ft) + 90°
DRemove the bearing cap from front (pulley side) to
rear.
DMake sure that the upper and lower bearing shells
do not change each other and coat with engine oil.
DThe oil grooves (arrows) in the thrust washers
must face outward and insert the thrust bearing
into the bearing cap.
DThere are five kinds of thrust washers by thick-
ness. Select the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in
the reverse order.
5. After completion of the installation, check for the ro-
tating condition of the crankshaft.
Installation Notice
DMake sure the crankshaft bearing cap properly
seated in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the left
side (intake manifold side).
DAssemble so that the projected part of the cap and
crankcase face the same direction.