1997 SSANGYONG KORANDO ignition

D AEW OO M Y_2000
SECTION 1E3
OM600 ENGINE ELECTRICAL
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
Specifications 1E3 -- 1............................
General Specifications 1E3-- 1....................
Maintenance and Repair 1E3 -- 2...................
On-- Vehicle Service 1E3-- 2.........................Glow Plug 1E3-- 2...............................
Generator 1E3-- 6...............................
Starter Motor 1E3-- 8............................
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Generator12V -- 75A
Starter12V -- 2.2kW
Glow Plug11. 5 V

D AEW OO M Y_2000
SECTION 1F3
OM600 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
Specifications 1F3 -- 1............................
Fastener Tightening Specifications 1F3 -- 1..........
Maintenance and Repair 1F3 -- 2...................
On -- Vehicle Service 1F3 -- 2.........................
Fuel System 1F3 -- 2.............................
Fuel Injection Pump Coding 1F3 -- 3................
Fuel Tank 1F3 -- 4...............................
Vacuum Control System Test 1F3 -- 5..............
Vacuum Pump Test 1F3 -- 10......................
Vacuum Pump 1F3 -- 12..........................
Vacuum Unit Replacement 1F3 -- 14...............
Idle Speed Adjustment 1F3 -- 15...................Fuel Pump Test 1F3 -- 17.........................
Fuel Pump 1F3 -- 20.............................
Injection Nozzle Test 1F3-- 21.....................
Injection Nozzles 1F3-- 24........................
Injection Nozzle Repair 1F3 -- 26...................
Removal and Installation of
Injection Timing Device 1F3 -- 29.................
Injection Timing Device 1F3 -- 34...................
StartofDeliveryTest
(Position Sensor, RIV Method) 1F3 -- 36..........
Fuel Injection Pump 1F3 -- 45.....................
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationN∙mLb-- FtLb-In
Fuel Tank Mounting Nut28 -- 4721 -- 35--
Fuel Pump Pressure Line1310--
Fuel Injection Nozzle35 -- 4026 -- 30--
Fuel Injection Pipe1813--
Nozzle Tensioning Nut8059--
Screw Plug3022--
Left -- Hand Thread Bolt4634--

OM600 ENGINE CONTROLS 1F3 -- 5
D AEW OO M Y_2000
VACUUM CONTROLSYSTEM TEST
1 Ventilation (To Passenger Compartment)
2 Engine Cut -- Off Valve (Ignition Key Switch)
3 Auto-- locking Hub Solenoid Valve
4 Engine Stop Valve Unit
5 PLA Vacuum Unit (Idle Speed Adjustment)6Engine
7 Vacuum Pump
830_Thermovalve
9 Fuel Injection Pump
Test Data
Idle Speed IncreaseAt least 100 rpm at approx. 500mbr
Permissible Pressure Drop of System400 -- 500mbar approx. 1 min.

SECTION 4A
HYDRAULIC BRAKES
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 otherwise noted.
TABLE OF CONTENTS
Description and Operation...................................4A-2
General Description.............................................4A-2
Diagnostic Information and Procedures..............4A-3
Brake System Testing ..........................................4A-3
Brake Hose Inspection.........................................4A-3
Brake Warning Lamp Circuit Description..............4A-4
Brake Warning Lamp Diagnosis...........................4A-5
LCRV (Load Conscious Reducing Valve)..............4A-8
Repair Instructions..............................................4A-10On-Vehicle Service...............................................4A-10
Manual Bleeding The Brakes.............................4A-10
Front Brake Hose...............................................4A-13
Rear Brake Hose...............................................4A-13
Stoplamp Switch................................................4A-14
Brake Pedal.......................................................4A-14
Specifications.....................................................4A-15
General Specification .........................................4A-15
Fastener Tightening Specifications.....................4A-16

SSAMGYONG MY2002
4A-4 HYDRAULIC BRAKES
KAA4A010
BRAKE WARNING LAMP CIRCUIT DESCRIPTION
Diagnostic Aids
The BRAKE lamp glows brightly when the ignition is
ON and either the parking brake lever switch or the
brake fluid level switch is closed.
If neither switch is closed, the BRAKE lamp receives
a ground through the generator, and it glows dimly
when the ignition is ON and the engine is off. When
the engine starts, the generator creates voltage. With
voltage on both sides of the lamp, the lamp turns off.
Test Description
The numbers below refer to steps in the diagnostic
table.
1. This step begins the test sequence for a BRAKE
warning lamp that stays on when the engine is run-
ning.
2. This step begins the test sequence for a BRAKE
warning lamp that never turns on.

SSAMGYONG MY2002
4A-6 HYDRAULIC BRAKES
Action
1. Turn the ignition ON.
2. Apply the parking brake.
Does the BRAKE warning lamp turn on?
Check fuse F30.
Is fuse F30 blown?
Check for a short circuit and repair it, if necessary.
Replace fuse F30.
1. Turn the ignition ON.
2. Check the voltage at F30.
Is the voltage equal to the specified value?
Repair the power supply to fuse F30.
Is the repair complete?
1. Disconnect terminal A1 of the instrument cluster.
2. Turn the ignition ON.
3. Use a voltmeter to check the voltage at terminal A1.
Is the voltage equal to the specified value?
Repair the open circuit between terminal A1 of the
instrument cluster and fuse F30.
Is the repair complete?
1. Reconnect terminal A1 of the instrument cluster.
Turn the ignition ON.
2. Use a voltmeter to backprobe terminal D10 of the
instrument cluster.
Is the voltage equal to the specified value?
1. Remove the BRAKE warning lamp from its socket.
2. Test the Brake warning lamp.
Is the BRAKEwarning lamp OK?
Replace the instrument cluster.
Is the repair complete?
Replace the BRAKE warning lamp.
Is the repair complete?
1. Disconnect terminal C10 of the STICS.
2. Connect a jumper wire between terminal C10 and
ground.
3. Turn the ignition ON.
Is the BRAKE warning lamp on?
Replace the STICS.
Is the repair complete?
1. Disconnect the STICS connector.
2. Connect a jump wire between terminal C19 and
ground.
3. Turn the ignition ON.
Is the BRAKE warning lamp on?
Replace the brake warning lamp switch.
Is the repair complete?
Repair the open circuit between the brake warning
lamp switch and terminal C19 of the STICS
BRAKE LAMP WARNING CIRCUIT (Cont’d)
Yes
Go To Step 31
Go To Step 17
System OK
Go To Step 20
System OK
Go To Step 22
System OK
Go To Step 26
Go To Step 24
System OK
System OK
Go To Step 27
System OK
Go To Step 29
System OK
System OKNO
Go To Step 16
Go To Step 18
-
Go To Step 19
-
Go To Step 21
-
Go To Step 23
Go To Step 25
-
-
Go To Step 28
-
Go To Step 30
-
-Step
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30Value
-
-
-
11 - 14 v
-
11 - 14 v
-
11 - 14 v
-
-
-
-
-
-
-
-

SSANGYONG MY2002
4F-4 ABS AND TCS
Pressure Modulation
Depending on the control deviation and the wheel accel-
eration of the spinning wheel, pressure increase, hold
and decrease are made.
The pressure modulation is done with the conventional
control with the valves. Prime valve, pilot valve, inlet
valve and outlet valve according to the following table:
Speed Range
TCS is available in the speed range ≤ 60 kph.
Above 60 kph vehicle speed, TCS is passive.
It is possible to initiate TCS operation up to a vehicle
speed of 55 kph.
Prime Valve
Pilot Valve
Inlet Valve
Outlet Valve
Increase
Open
Closed
Open
ClosedHold
Open
Closed
Closed
ClosedDecrease
Open
Closed
Closed
Open
System Failure (EBD,
ABS or TCS are Not
Distinguished)
ABS Warning
LampIgnition ONABS
OperationTCS
OperationTCS Passive Due to
Temperature Model
2 second on
for lamp
checkOFF OFF ON OFF
TCS Info
Lamp2 second on
for lamp
checkOFFBlinking
(FLASHING)OFF ON
EBD Warning
Lamp2 second on
for lamp
checkEBD
operation/OFFOFF ON OFF
Temperature Model
TCS operation is a high thermal load for the brakes.
To avoid any damages at the brakes, the disk tempera-
ture is calculated with a mathematical model for each
driven wheel separately. After ignition on, the
calculation starts with 30°C and then three different
phases are evaluated separately and added:
TCS operation, braking and coling phase.
If the temperature is highter than 500°C, TCS is dis-
abled for this wheel.
It is permitted again, if the model has calculated down
the 350°C.
Lamp Concepts
The system is equipped with an TCS information lamp,
which is blinking during TCS operation.
The activation of the EBD, TCS warning lamp and the
TCS info lamp issummarized in thefollowing table:

ABS AND TCS 4F-5
SSANGYONG MY2002
EBD (ELECTRONIC BRAKE
FORCE DISTRIBUTION) SYSTEM
System Description
As an add-on logic to the ABS base algorithm, EBD
works in a range in which the intervention thresholds
for ABS control are not reached yet.
EBD ensures that the rear wheels are sensitively
monitored for slip with respect to the front axle. If slip
is detected, the inlet valves for the rear wheels are
switched to pressure hold to prevent a further increase
in pressure at the rear-wheel breaks, thus electronically
reproducing a pressure-reduction function at the rear-
wheel brakes.
ABS features an enhanced algorithm which includes
control of the brake force distribution between the front
and rear axles. This is called Electronic Brake
Distribution. In an unloading car condition the brake
efficiency is comparable to the conventional system
but for a fully loaden vehicle the efficiency of the EBD
system is higher due to the better use of rear axle
braking capability.
The Benefits of EBD
Elimination of conventional proportioning valve EBD
utilizes the existing rear axle wheel speed sensor
to monitor rear wheel slip.
Based on many variables in algorithm a pressure
hold, increase and/or decrease pulsetrain may be
triggered at the rear wheels insuring vehicle
stability.
Vehicle approaches the ideal brake force
distribution (front to rear).
Constant brake force distribution during vehicle
lifetime.
EBD function is monitored via ABS safety logic
(conventional proportioning valves are not
monitorable).
“Keep alive” function.Service Precautions
Observe the following general precautions during any
ABS/TCS service. Failure to adhere to these
precautions may result in ABS/TCS system damage.
1. Disconnect the EBCM harness connector before
performing the electric welding procedures.
2. Carefully note the routing of the ABS/TCS wiring
and wring components during removal. The ABS/
TCS components are extremely sensitive to EMI
(eletromagnetic interference). Proper mounting is
critical during component service.
3. Disconnect the EBCM connector with the ignition
OFF.
4. Do not hang the suspension components from the
wheel speed sensor cables. The cables may be
damaged.
5. Do not use petroleum based fluids in the master
cylinder. Do not use any containers previously used
for petroleum based fluids. Petroleum causes
swelling and distortion of the rubber components
in the hydraulic brake system, resulting in water
entering the system and lowering the fluid boiling
point.
KAA4F020