1997 SSANGYONG KORANDO bar

M162 ENGINE MECHANICAL 1B1 -- 103
D AEW OO M Y_2000
4. Enlarge the oil gallery at the rear of the cylinder
head to be diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery
using the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth
8mm.
8. Make a screw hole at the oil gallery using M10 x 1
thread.
9. All the oil gallery should be cleaned with the com-
pressed air.
10. Apply the Loctite 270 to new plug and press in using
a suitable drift (arrow).
11. Tighten the screw plug with the seal (arrow).

1D1 -- 2 M162 ENGINE COOLING
D AEW OO M Y_2000
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Cooling TypeWater Cooling Forced Circulation
RadiatorCirculation TypeDouble Cross Flow
Radiation Capability70,000 kcal/h
Dimension(Width x Height x Thickeness)580 x 482 x 45 mm
Cooling Fanφ460, Six Blades
Anti-- Freeze AgentALUTEC -- P78
Mixing Ratio of Anti-- Freeze Agen with Water (Anti-- Freeze Agent : Water)50 : 50
Coolant Capacity11. 3 L
Reservoir Capacity3.4 L
Cap Operating Pressure (Reservoir Tank Pressure Cap)1.4 bar
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb-FtLb-In
Coolant Drain Plug3022--
Engine Hanger Bracket and Coolant Outlet
Port Bolt22.5 -- 27.516.6 -- 20.3--
Thermostat Cover Bracket Bolts9--11--80 -- 97
Oil Cooler Pipe Line Bolts9--11--80 -- 97
Cooling Fan Bolts9--11--80 -- 97
Viscous Clutch Mounting Bolts40.5 -- 49.529.8 -- 36.5--
Automatic Transmission Fluid Cooler Pipe2015--
Cooling Fan Shroud Bolts3--7--27 -- 62
Automatic Transmission Radiator Tube
Assembly Mounting Bolt7--62
Radiator Bracket Mounting Bolts3--7--27 -- 62

1D1 -- 4 M162 ENGINE COOLING
D AEW OO M Y_2000
DIAGNOSIS
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test Procedure
1. Loosen the cap a little and release pressure and re-
move the cap.
Notice:For the risk of scalding, cap must not be opened
unless the coolant temperature is below 90°C.
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the special tool to the reservoir filler cap and
apply 1.4 bar of pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at
the all coolant hoses and pipes and each connec-
tions. Replace or retighten if necessary.

1F1 -- 42 M162 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL PUMP
YAA1F380
Requirements for Fuel Pump
ItemSpecified ValueItemSpecified Value
System Pressure3.8 barMinimum Delivery at 8V30 Litre/Hr
Maximum Pressure8.5 bar (12 V)Operating Voltage8V
Minimum Pressure5.0 bar (12 V)Maximum Allowable
Current7.5 A
Nominal Voltage12 VAmbient Temperature-- 30 ~ +70°C
Minimum Amount
of Fuel Supply114 Liter/Hr (12 V, 3.8 bar,
-- 30 ~ +70°C)Maximum Amount
of Fuel Supply165 Liter/Hr (12V, 3.8 bar,
-- 3 0 ~ + 7 0°C)

M162 ENGINE CONTROLS 1F1 -- 51
D AEW OO M Y_2000
KAB1F230
Failure
CodeDescriptionTrouble AreaMaintenance Hint
40Purge control valve
short circuit to batteryWhen short circuit to power
sourceDInspection the ECM pin 34 about short
circuitoropenwithbadcontact
41
Purge control valve
short circuit to ground or
openWhen short circuit to ground or
open
circuitor open withbadcontact
DInspection the source power of valve
DInspection the purge control solenoid
vale
54Purge control circuit
malfunctionWhen malfunction of purge
control : not workvale
DInspection the ECM
Test
YAA1F460
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECM terminal No. 11 and No. 34 and
check for normal operation through the output waves
using oscilloscope.Notice:Test during purge control valve operation after
the minimum of 1 minute after the engine turned on.
3. Connect the ECM terminal No. 34 and No.10 and
check for current consumption during the ignition
switch ON.
Specified Value
0.3 ~ 0.5 A
4. Remove the line to canister and measure the pres-
sure with the vacuum pressure gauge.
Specified Value
> 500 mbar
(after approx. 1 min.)
purge control valve operates
at this time
Notice:Test while at normal temperature and at idling
state by operating the engine.

M162 ENGINE CONTROLS 1F1 -- 53
D AEW OO M Y_2000
Fuel Pressure Test
Tools Required
103 589 00 21 00 Fuel Pressure Gauge
1. Turn the ignition switch to “OFF” position.
2. Remove the fuel pressure test connector.
KAA1F430
3. Connect the fuel pressure gauge to the fuel pressure test connector.
4. Test the fuel pressure at idling by operating the engine using the fuel pressure gauge 103 589 00 21 00.
Vacuum Hose Connected (bar)
3.2~3.6
Vacuum Hose Disconnected (bar)3.7~4.2
5. Replace the pressure regulator diaphragm if out of the specification.
Internal Leakage Test
1. Connect the fuel pressure gauge 103 589 00 21 00 to
the fuel pressure test connector.
KAA1F420
2. Stop the engine for approximately 30 minutes and then check the fuel pressure changes.
Pressure change
Fuel pressure drops slowlyDFuel leakage at the injector
DFaulty fuel pressure regulator ’s diaphragm and O-ring
Fuel pressure drops rapidlyDFaulty check valve in the fuel pump
3. If there is no change in fuel pressure and maintain the following pressure over 30minutes, it is normal.
Fuel pressure (bar)
≥2.5

1F1 -- 54 M162 ENGINE CONTROLS
D AEW OO M Y_2000
FUEL PRESSURE REGULATOR
YAA1F480
Function of the Fuel Pressure Regulator
The fuel pressure regulator maintains the fuel pressure
in the fuel line with the pressure of 3.2 bars to 3.8 bars
according to the intake manifold pressure. This operat-
ing pressure cannot be changed, and the fuel injection
volume will be only determined by the injection time.
Over supplied fuel returns to the fuel tank through the
return line.

There is no negative pressure applied to the spring
chamber (9) during the full load, and it is separated from
the fuel chamber (8) by the diaphragm (5).
When the fuel pressure goes up, the diaphragm forces
the compression spring (6) in the direction of compres-
sion . At this moment, the valve (3) sticks to the dia-
phragm by the fuel pressure, and the fuel return line (2)
opens. The fuel over supplied returns to the fuel tank
through the return line.
YAA1F490
2. Fuel return line
3. Valve
5. Diaphragm
6. Compression Spring
8. Fuel Chamber
9. Spring Chamber
A. Valves Closed
B. Valves Opened

M162 ENGINE CONTROLS 1F1 -- 55
D AEW OO M Y_2000
The pressure difference between the fuel pressure and
the intake manifold is about 3.8 bars during the full load.
YAA1F500
1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return (to fuel tank)
4. Fuel Supply (from fuel pump)
5. Fuel Pressure (approx. 3.8 bars)
6. Intake Manifold Negative Pressure (0 bar)

The spring chamber (9) is connected to the intake man-
ifold with the vacuum hose at the intake pipe connection
(7). The negative pressure generated in the intake man-
ifold activates the diaphragm, and thus the fuel pressure
gets reduced to the rate of the operating extent of the
diaphragm by the intake manifold’s negative pressure.
YAA1F510
Consequently, the fuel pressure in the fuel distributor
changes by the intake manifold’s negative pressure, and
the injector ’s fuel pressure gets reduced independentlyto the throttle valve’s position. Thus, the fuel injection
volume can only be determined according to the injec-
tor’s injecting duration.
The pressure difference between the fuel pressure and
the intake manifold is approx. 3.2 bars during idling.
YAA1F520
1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return (to fuel tank)
4. Fuel Supply (from fuel pump)
7. Fuel Pressure (approx. 3.2 bars)
8. Intake Manifold Negative Pressure (0.6 bars)

YAA1F530
A. Fuel pressure
B. Intake Manifold Negative Pressure
LL. Idling
TL. Partial load
VL. Full load