heater SSANGYONG KORANDO 1997 Service Repair Manual

1D1 -- 10 M162 ENGINE COOLING
D AEW OO M Y_2000
THERMOSTAT
1 Thermostat Cover
2 Thermostat
3O--ring
4 Thermostat Cover Bracket5 Bolt (M6 X 25, 3 pieces)
9--11 NSm (80-- 97 lb-in) .....................
6 Hose Mounting Clamp
7HeaterHose
Removal & Installation Procedure
1. Drain the coolant from the radiator.
2. Loosen the hose mounting clamp (6) and remove the
heater hose (7).
3. Unscrew the three bolts (5) and remove the thermo-
stat cover bracket, thermostat cover and the thermo-
stat in order.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
Do not separate the thermostat cover and thermo-
stat.
4. Replace the O -- ring if necessary.
5. Check the leakage in the cooling system.

M162 ENGINE CONTROLS 1F1 -- 15
D AEW OO M Y_2000
FAILURE CODES TABLE (Cont’d)
Failure
codeSee
PageDescription
401F1 -- 51Purge control valve short circuit to battery
411F1 -- 51Purge control valve short circuit to ground or open
441F1 -- 72Cooling fan (HI) relay short circuit to power
451F1 -- 72Cooling fan (HI) relay short circuit to ground or open
541F1 -- 51Purge control circuit malfunction
561F1 -- 33No.1 knock sensor signal failure
571F1 -- 33No.2 knock sensor signal failure
581F1 -- 27Camshaft position sensor signal : No.1 cylinder synchronization failure
591F1 -- 89CAN communication failure : MSR data transmission not plausible
601F1 -- 89CAN communication failure : ASR data transmission not plausible
621F1 -- 71Clutch switch defective
641F1 -- 21No ignition voltage output (No.1 ignition coil)
651F1 -- 21No ignition voltage output (No.2 ignition coil)
661F1 -- 21No ignition voltage output (No.3 ignition coil)
671F1 -- 23Crankshaft position sensor adaptation failure
681F1 -- 35Random/Multiple Misfire
711F1 -- 39Starter signal recognition failure
721F1 -- 47No.1 injector short circuit to battery
731F1 -- 47No.1 injector short circuit to ground or open
741F1 -- 47No.2 injector short circuit to battery
751F1 -- 47No.2 injector short circuit to ground or open
761F1 -- 47No.3 injector short circuit to battery
771F1 -- 48No.3 injector short circuit to ground or open
781F1 -- 48No.4 injector short circuit to battery
791F1 -- 48No.4 injector short circuit to ground or open
801F1 -- 82Oxygen sensor high voltage
811F1 -- 83Bank 1 system short term fuel trim adaptation below lean threshold
821F1 -- 82Oxygen sensor no activity detected
831F1 -- 82Oxygen sensor not lean after overrun fuel shut -- off
841F1 -- 82Oxygen sensor slow response
851F1 -- 82Oxygen sensor heater failure
861F1 -- 82Oxygen sensor heater short circuit to battery
871F1 -- 82Oxygen sensor heater short circuit to ground or open
891F1 -- 82Oxygen sensor low voltage
931F1 -- 83Bank 1 system short term fuel trim adaptation above rich threshold
961F1 -- 83Bank 1 system short term fuel trim at rich stop
971F1 -- 83Bank 1 system short term fuel trim at lean stop
981F1 -- 83Bank 1 system idle adaptation failure (above rich threshold)
991F1 -- 83Bank 1 system idle adaptation failure (below lean threshold)
1001F1 -- 83Bank 1 system learning control failure (rich, low load)
1011F1 -- 83Bank 1 system learning control failure (lean, low load)
1021F1 -- 83Bank 1 system learning control failure (rich, high load)

1F1 -- 62 M162 ENGINE CONTROLS
D AEW OO M Y_2000
KAB1F250
Failure
CodeDescriptionTrouble AreaMaintenance Hint
03Intake air temperature
sensor low voltageIAT sensor short circuit to
ground or openDMonitoring the actual air temperature
throu
gh scan tool
04Intake air temperature
sensor high voltageIAT sensor short circuit to
power
throughscantool
DInspection the ECM pin 80, 79 about
short circuit or open with bad contact
05Intake air temperature
sensor plausibilityMalfunction in recognition of
IAT
When functional problem
p
DInspection the IAT sensor (integrated
in HFM sensor)
DInspection the ECM
09Mass air flow sensor
plausibilityMalfunction in recognition of
MAF
When air mass not plausibleDMonitoring the actual air mass flow
through scan tool
DIns
pection the ECMpin 81, 105 about
10Mass air flow sensor low
voltageMAF sensor short circuit to
ground or open
DInspectiontheECMpin81,105about
short circuit or open with bad contact
DInspection the MAF sensor (integrated
iHFM)
11Mass air flow sensor
high voltageMAF sensor short circuit to
powerin HFM sensor)
DInspection the ECM
Circuit Description
The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the
other elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The
separation of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal
decoupling between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is
located on a single layer. The voltage at the heater provides the index for the mass air flow. The MAF’s electronic
circuitry then converts the voltage to a level suitable for processing in the ECM. This device does not need a burn off
process to maintain its measuring precision over an extended period. In recognition of the fact that most deposits
collect on the sensor element’s leading edge, the essential thermal transfer elements are located downstream on the
ceramic layer. The sensor element is also design to ensure that depositswill not influence the flow pattern around the
sensor.
The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a
ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltagewill be high. If the
intake air is warm, resistance is low; therefore the IAT signal voltagewill be low.

1F1 -- 82 M162 ENGINE CONTROLS
D AEW OO M Y_2000
KAB1F340
Failure
CodeDescriptionTrouble AreaMaintenance Hint
80Oxygen sensor high
voltage
When recognition the output
that more than nominal
threshold, malfunction of
sensing voltage.
89Oxygen sensor low
voltage
When recognition the output
that more than nominal
threshold, malfunction of
sensing voltage.DMonitoring the actual output signal
through scan tool
DInspection the ECM pin 16, 17 about
htiitithbdtt
82Oxygen sensor no
activity detectedWhen recognition the output
that not active the sensor etc.short circuit or open with bad contact
DInspection the oxygen sensor
DInspectiontheECM
83
Oxygen sensor not lean
after overrun fuel
shut -- offWhen recognition the output
that no lean signal after
overrun fuel shut -- offDInspectiontheECM
84Oxygen sensor slow
responseWhen slow response of
sensor signal
85Oxygen sensor heater
failureWhen recognition the heating
circuitDMonitoring the heating status through
scantool
86Oxygen sensor heater
short circuit to battery
When recognition the heating
currents that more or less
than set values (less than 0.2
Aormorethan2A)scantool
DInspection the ECM pin 9 about short
circuit or open with bad contact
DInspection the heating power source
DInspectiontheheatingcircuitof
87
Oxygen sensor heater
short circuit to ground or
openWhen recognition the heating
voltages than less than set
values (less than 2 v)DInspectiontheheating circuitof
oxygen sensor
DInspection the ECM

M161 ENGINE COOLING 1D2 -- 9
D AEW OO M Y_2000
WAT E R P U M P
Preceding Work: Removal of viscous clutch
1 Bolt (M6 X 45, 1 piece)
9--11 NSm (80-- 97 lb-in) .....................
2 Bolt (M6 X 95, 1 piece)
9--11 NSm (80-- 97 lb-in) .....................
3 Bolt (M6 X 25, 4 piece)
9--11 NSm (80-- 97 lb-in) .....................
4 Bolt (M8 X 85, 2 piece)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............5 Water Pump Housing
6 Bolt (M6 X 16, 4 piece)
9--11 NSm (80-- 97 lb-in) .....................
7 Water Pump Pulley
8 Coolant Inlet Hose
9HeaterHose
10 Coolant Bypass Hose
11 Gasket

M161 ENGINE CONTROLS 1F2 -- 15
D AEW OO M Y_2000
FAILURE CODES TABLE (Cont’d)
Failure
codeSee
PageDescription
401F2 -- 51Purge control valve short circuit to battery
411F2 -- 51Purge control valve short circuit to ground or open
441F2 -- 72Cooling fan (HI) relay short circuit to power
451F2 -- 72Cooling fan (HI) relay short circuit to ground or open
541F2 -- 51Purge control circuit malfunction
561F2 -- 33No.1 knock sensor signal failure
581F2 -- 27Camshaft position sensor signal : No.1 cylinder synchronization failure
591F2 -- 89CAN communication failure : MSR data transmission not plausible
601F2 -- 89CAN communication failure : ASR data transmission not plausible
641F2 -- 21No ignition voltage output (No.1 ignition coil)
651F2 -- 21No ignition voltage output (No.2 ignition coil)
671F2 -- 23Crankshaft position sensor adaptation failure
681F2 -- 35Random/Multiple Misfire
711F2 -- 39Starter signal recognition failure
721F2 -- 47No.1 injector short circuit to battery
731F2 -- 47No.1 injector short circuit to ground or open
741F2 -- 47No.2 injector short circuit to battery
751F2 -- 47No.2 injector short circuit to ground or open
761F2 -- 47No.3 injector short circuit to battery
771F2 -- 48No.3 injector short circuit to ground or open
781F2 -- 48No.4 injector short circuit to battery
791F2 -- 48No.4 injector short circuit to ground or open
801F2 -- 82Oxygen sensor high voltage
811F2 -- 83Bank 1 system short term fuel trim adaptation below lean threshold
821F2 -- 82Oxygen sensor no activity detected
831F2 -- 82Oxygen sensor not lean after overrun fuel shut -- off
841F2 -- 82Oxygen sensor slow response
851F2 -- 82Oxygen sensor heater failure
861F2 -- 82Oxygen sensor heater short circuit to battery
871F2 -- 82Oxygen sensor heater short circuit to ground or open
891F2 -- 82Oxygen sensor low voltage
931F2 -- 83Bank 1 system short term fuel trim adaptation above rich threshold
961F2 -- 83Bank 1 system short term fuel trim at rich stop
971F2 -- 83Bank 1 system short term fuel trim at lean stop
981F2 -- 83Bank 1 system idle adaptation failure (above rich threshold)
991F2 -- 83Bank 1 system idle adaptation failure (below lean threshold)
1001F2 -- 83Bank 1 system learning control failure (rich, low load)
1011F2 -- 83Bank 1 system learning control failure (lean, low load)
1021F2 -- 83Bank 1 system learning control failure (rich, high load)

1F2 -- 62 M161 ENGINE CONTROLS
D AEW OO M Y_2000
KAB1F250
Failure
CodeDescriptionTrouble AreaMaintenance Hint
03Intake air temperature
sensor low voltageIAT sensor short circuit to
ground or openDMonitoring the actual air temperature
throu
gh scan tool
04Intake air temperature
sensor high voltageIAT sensor short circuit to
power
throughscantool
DInspection the ECM pin 80, 79 about
short circuit or open with bad contact
05Intake air temperature
sensor plausibilityMalfunction in recognition of
IAT
When functional problem
p
DInspection the IAT sensor (integrated
in HFM sensor)
DInspection the ECM
09Mass air flow sensor
plausibilityMalfunction in recognition of
MAF
When air mass not plausibleDMonitoring the actual air mass flow
through scan tool
DIns
pection the ECMpin 81, 105 about
10Mass air flow sensor low
voltageMAF sensor short circuit to
ground or open
DInspectiontheECMpin81,105about
short circuit or open with bad contact
DInspection the MAF sensor (integrated
iHFM)
11Mass air flow sensor
high voltageMAF sensor short circuit to
powerin HFM sensor)
DInspection the ECM
Circuit Description
The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the
other elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The
separation of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal
decoupling between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is
located on a single layer. The voltage at the heater provides the index for the mass air flow. The MAF’s electronic
circuitry then converts the voltage to a level suitable for processing in the ECM. This device does not need a burn off
process to maintain its measuring precision over an extended period. In recognition of the fact that most deposits
collect on the sensor element’s leading edge, the essential thermal transfer elements are located downstream on the
ceramic layer. The sensor element is also design to ensure that depositswill not influence the flow pattern around the
sensor.
The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a
ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltagewill be high. If the
intake air is warm, resistance is low; therefore the IAT signal voltagewill be low.

1F2 -- 82 M161 ENGINE CONTROLS
D AEW OO M Y_2000
KAB1F340
Failure
CodeDescriptionTrouble AreaMaintenance Hint
80Oxygen sensor high
voltage
When recognition the output
that more than nominal
threshold, malfunction of
sensing voltage.
89Oxygen sensor low
voltage
When recognition the output
that more than nominal
threshold, malfunction of
sensing voltage.DMonitoring the actual output signal
through scan tool
DInspection the ECM pin 16, 17 about
htiitithbdtt
82Oxygen sensor no
activity detectedWhen recognition the output
that not active the sensor etc.short circuit or open with bad contact
DInspection the oxygen sensor
DInspectiontheECM
83
Oxygen sensor not lean
after overrun fuel
shut -- offWhen recognition the output
that no lean signal after
overrun fuel shut -- offDInspectiontheECM
84Oxygen sensor slow
responseWhen slow response of
sensor signal
85Oxygen sensor heater
failureWhen recognition the heating
circuitDMonitoring the heating status through
scantool
86Oxygen sensor heater
short circuit to battery
When recognition the heating
currents that more or less
than set values (less than 0.2
Aormorethan2A)scantool
DInspection the ECM pin 9 about short
circuit or open with bad contact
DInspection the heating power source
DInspectiontheheatingcircuitof
87
Oxygen sensor heater
short circuit to ground or
openWhen recognition the heating
voltages than less than set
values (less than 2 v)DInspectiontheheating circuitof
oxygen sensor
DInspection the ECM

OM600 ENGINE MECHANICAL 1B3 -- 37
D AEW OO M Y_2000
CYLINDER HEAD
1 Fuel Injection Pipe 18N∙m (13 lb-ft) ..........
2 Cylinder Head
3 Gasket Replace..........................
4 Bolt 25N∙m (18 lb-ft) ......................
5 Washer
6 Clamp
7 Heater Feed Pipe
8Bolt
9 Washer
10 Bolt
11 Nozzle Washer Replace...................
12 Fuel Injection Nozzle 35 -- 40 N∙m(26--30 lb-ft)
13 Hexagon Socket Bolt 25 N∙m (18 lb-ft) ......
14 Washer
15 Bolt 25 N∙m (18 lb-ft) .....................
16 Cylinder Head Bolt See Table..............
17 Cylinder Head Cover
18 Bolt 10 N∙m (89 lb-in) .....................
19 Gasket
20 Camshaft21 Camshaft Drive Sprocket Replace...........
22 Washer
23 Bolt(12-- Sided) 25N∙m (18 lb-ft) + 90_ .......
24 Sliding Rail
25 Sliding Rail Pin
26 Sliding Rail Pin
27 Chain Tensioner 80 N∙m (59 lb-ft) ...........
28 Gasket Replace..........................
29 Cooling Fan Check.......................
30 Hexagon Socket Bolt 45 N∙m (33 lb-ft) ......
31 Tensioning Lever
32 Bolt 25 N∙m (18 lb-ft) .....................
33 Bolt
34 Nut 23 N∙m (17 lb-ft) ......................
35 Fuel Filter
36 Turbo Charger
37 Intake Duct
38 Gasket Replace..........................
39 Intake Manifold

1B3 -- 44 OM600 ENGINE MECHANICAL
D AEW OO M Y_2000
22. Remove the cable channel.
23 .Disconnect the cables from the glow plug sensor
and coolant temperature sensor.
24. Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe for-
ward and then pull out the pipe.