engine SSANGYONG MUSSO 2003 Service Manual

1F1-6 M162 ENGINE CONTROLSDIAGNOSIS
SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS
1 Ground
2 Ignition 1
3 Battery Power Supply (Fuse NO.17)
4 REKES :PIN 6
5 Engine Speed Signal :MSE PIN 60
6 TCCU(Part-time)
7 STICS(PIN 26) 8- 9-
10 Air Bag(PIN 20) 11 Remote Engine Start Unit(PIN 10)
12 -
13 Brake System (ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46)
14 MSE 3.62S/3.53S(ECU Data Output:PIN 58)
15 TOD(PIN 20)
1 6 Immobilizer
17 -
18 TCU(PIN 23)
19 -
2 0 K-LINE(ECS:PIN 23)

M162 ENGINE CONTROLS 1F1-7
41 44455657 58 59606264 65 66677172 73 74757677 78 79808182 83 86 8789
0001 02 0304 05 08091011 17 1819 20 21 2324 25 26272930 31 34 3540
Failure
code Description
Coolant temperature sensor open Coolant temperature sensor shortCoolant temperature sensor signal failureIntake temperature sensor openIntake temperature sensor short Intake temperature sensor signal failure Low battery voltageHFM sensor signal failureHFM sensor signal failure(Low)HFM sensor signal failure(High) Crankshaft position sensor signal failure (no engine revolution signal)Crankshaft position sensor signal failure(rpm > max. value)No.1 cylinder recognition failure Crankshaft position sensor signal failure (gab recognition failure)
Transmission coding failureCAN communication failure : ASR-
Transponder signal failure CAN communication failure : TCU(A/T only)CAN communication failure : TOD(E32 only)-- CAN communication failure : communication initialization failureFuel pump relay short(PWR)Fuel pump relay open/short(GND)Purge valve short
Fa
ilure
code Description
Purge valve open/short Condenser fan(HI) relay short(PWR)Condenser fan(HI) relay short(GND)No.1 knock sensor signal failureNo.2 knock sensor signal failure No.1 cylinder synchronization failure --Cluster S/W defectaveNo ignition voltage output(No.1 ignition coil) No ignition voltage output(No.2 ignition coil) No ignition voltage output(No.3 ignition coil)Crankshaft position sensor adaptation failureStart signal recognition failureNo.1 injector short(PWR) No.1 injector open/short(GND) No.2 injector short(PWR)No.2 injector open/short(GND)No.3 injector short(PWR)No.3 injector open/short(GND) No.4 injector short(PWR) No.4 injector open/short(GND)High oxygen sensor voltageLow oxygen sensor amplifying voltageOxygen sensor operating failure Not excessive lean indication in oxygen sensor(during coasting)Oxygen sensor heater short(PWR)Oxygen sensor heater open/short(GND)Low oxygen sensor voltage
SELF DIAGNOSIS FAILURE CODE

1F1-8 M162 ENGINE CONTROLSCruise control acceleration failure Cruise control deceleration failureECU failure(RAM)ECU failure(EPROM) Servo motor control output inter-ruption memory failureServo motor open/shortUnprogramed ECU with Immobilizer Uncoded ECU ECU failure(NVRAM checksum failure) ECU failure(coding ID checksum failure)ECU failure(coding checksum failure)ECU failure(programing checkusm failure)ABD input signal short(power) ABD input signal short(GND) Low pedal valve sensor SP1 voltageHigh pedal valve sensor SP1 voltageLow pedal valve sensor SP2 voltageHigh pedal valve sensor SP2 voltageDifferent pedal valve sensor signal(1,2) Pedal valve sensor 1,2 failure
HFM sensor, and throttle position sensorfailureECU failure(incompatible CPU)ECU failure(CPUs communication failure) ECU failure(CPU(2) configuration failure) ECU failure(CPU(2) fault)ECU failure(CPU run time failure betweenCPUs)No.5 injector short(PWR)
93969798 99
100 101 102 103 104 105108 109 11 0
11 6
11 7
11 9
120 121 122123125126 127 129130131132 Short learning control failureLambda control failure (rich stop)Lambda control failure (lean stop) Lambda idle adaptation failure(above rich threshold) Lambda idle adaptation failure(below lean threshold)learning control failure(rich, low load)learning control failure(lean, low load) learning control failure(rich, high load) learning control failure(lean, high load)Low throttle position sensor(IP1) voltageHigh throttle position sensor(IP1) voltageLow throttle position sensor(IP2) voltage High throttle position sensor(IP2) voltage Throttle actuator learning data faultThrottle actuator learning control failureExceed fuel-cut safety timeThrottle valve return spring failureCruise control interruption memory failure Throttle actuator failure Pedal module position sensor signal failureDifferent HFM signal with throttle potentiometerBoth throttle potentiometer(IP1&IP2) failureIPS1 with IPS2 High permanent throttle signal Message counter failure
cruise control ’OFF ’
Vehicle speed signal failure
Vehicle speed signal failureCruise control lever failure 133134 136 137 139 140 141142 143 144145146150 151 160161162163164 167 185 186 187 188 189190 192
Failure
code DescriptionFailure
code Description

M162 ENGINE CONTROLS 1F1-9
234 235236237 238 239240241 242 243
No.5 injector open/short(GND) No.6 injector short(PWR)No.6 injector open/short(GND)
Variable intake air valve short(PWR)
Variable intake air valve open/short(GND) Cam actuator short(PWR)Cam actuator open/short(GND)A/C compressor relay short(PWR)A/C compressor relay open/short(GND) Over acceleration limit Over acceleration limit(CPU2)
193194195198 199 226227228229 232 233
Failure
code Description Failure
code Description
Control lever dual operation(CPU2) Control lever safety terminal failure(CPU2)Unusual pedal position variation(CPU2)Unusal throttle position variation(CPU2) Unusal throttle control data(CPU2) Unusal pedal position sensor(CPU2)Throttle potentiometer fault(CPU2)
Unusual CPU communication(CPU2)Unusual CPU configuration(CPU2) AD converter failure(CPU2)

1F1-10 M162 ENGINE CONTROLS
TEST BOX CONNECTION
1 ECU
2 Test Coupling(No.1 - 60)
3 Test Coupling(No.61 - 120)
4 Multi-tester0 1 Test Box
02 ECU Test Cable
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 ECU Test Cable

M162 ENGINE CONTROLS 1F1-11
FUEL INJECTION SYSTEM TEST (MSE3.62)
Failurecode Item

1.0
Checking method
 Ignition:ON
Test stepRequirementSpecified
value Possible cause
10 12 11 -14V



ECU:power
supply - terminal 30(TM.30)
2.2 


Power
supply:
- terminal 87(TM.87) 
Ignition:ON 
Power supply cable
 OVPR
08,

1.1
 1.2
1.1 
Ignition:ON
10 2 11 -14V



Ground
cable:- Battery ground
 Ground cable
 Ground condition
Diagnosis socket
69 2
Diagnosis socket
1.2 
Ignition:ON
11 2 11 -14V



Power
supply: - terminal 30(TM.30)
 Power supply cable
Diagnosis socket
2.0 
Ignition:ON
51 1 11 -14V



ECU:power
supply - terminal 87(TM.87)
08, 
1.1
 2.1
2.1 
Ignition:ON 11 -14V



Ground
cable - Electronic ground 
Ground cable
52
Diagnosis socket
11 1
Diagnosis
socket Ignition:OFF
11 -14V
< 1V
3.0 
Engine:in Cranking
52 
Cable
 Ignition switch
11 -14
(during engine cranking)



Start signal:
- terminal 50(TM.50)

1F1-12 M162 ENGINE CONTROLS
Failurecode Item
09, 10,11,
Checking method
Te s t
stepRequirementSpecified value Possible cause
4.0 


HFM sensor
signal 105 81
 Ignition:ON 0.9 - 1.1V
4.1 - 4.3
 Cable
 External air inflow
 HFM sensor

Engine:in Idle
(Coolant temperature : > 70 °C )
: voltage value isincreased whenengine rpm isincreased 1.3 - 1.7V
4.1
105 4
 Ignition:ON
 HFM sensor
connector removed 4.7 - 5.2V

Cable
 ECU coupling



HFM sensor:
- 5V power supply HFM
sensor
4.2
3 108
 Ignition:ON
 HFM sensor
connector removed 4.7 - 5.2V

4.3
 Cable



HFM sensor:
- 5V power supply HFM
sensor
4.3
104 2
 Ignition:ON
 HFM sensor
connector removed 11 - 14V

Cable
 OVPR



HFM sensor:
- 12V power supply HFM
sensor
03, 04,05,
5.0 


Intake air
temperature sensor:- Voltage 105 80
Ignition:ON 
5.1
 ECU
± 5%
5.1 
Ignition:OFF
 No.2 ECU coupling
removed
105 80 
Cable
 HFM sensor



Intake air
temperature sensor:- Resistance° C
10 2030405060 ± 5%
3600242016621166 853600
°
C
102030405060 V
3.1
2.652.181.76 1.41.1

M162 ENGINE CONTROLS 1F1-13
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause
6.1 
Ignition:ON 0.1 - 0.3A
Cable
 Fuel pump relay
 ECU



Fuel pump
relay: - Current consumption
00, 01, 02, 06,
7.0 


Coolant
temperature sensor:- Voltage 79 78
Ignition:ON °CV
20 3.57
80 1.22
100 0.78 
7.1
 ECU
± 5%

6.0 
Ignition:ON
(Fuel pump relay will operate for 1 - 2seconds when theignition switch isturned to "ON" afterstopping the engine)
 Engine:cranking
33 11

Cable
 Fuel pump relay



Fuel pump
relay:- Operation
34, 11 - 14V
(approx.1- 2sec.)
11 - 14V
(Cranking or driving)
53 3
7.1 
Ignition:OFF
(Remove the No.2 coupling from ECU)
79 78 
7.2
 Cable



Coolant
temperature sensor:- Resistance & cable °
C
20 2500 80 322
100 185
± 5%
7.2 


Coolant
temperature sensor:- Resistance Coolant temperature
sensor:
14 Remove the
connector from coolant temperaturesensor and measurethe resistancebetween No.1 andNo.2 pin withmultimeter. 
refer to
specifiedresistancevalue of 7.1 
Coolant
temperaturesensor
34, 35,

1F1-14 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Test
stepRequirementSpecified value Possible cause
9.0 
Keep the engine run
above 2 minutes in over 80 °C of coolant
temperature. 6.0 - 7.0 V
 ECU
 Cable
 Oxygen sensor



Oxygen
sensor:- Signal
80, 81,82,83,89, 56
0
8.0 
Engine:in cranking or
idle
56 0 
Cable
 ECU



ECU:
- RPM signal output32, 33, refer to figure
2
10.0 
Keep the engine run
above 2 minutes in over 80 °C of coolant
temperature.



Oxygen
sensor:- Heating functionoperated
11.0 


No.1 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms
Cable
 ECU
 No.1 Injector
 Coolant
temperature sensor
 Oxygen sensor
 Intake air
temperature sensor
- Voltage 
Engine:in cranking
or idle (above 5V in idling)
16 17
59
91 1

Ignition:ON 11 - 14 V

ECU
 Cable
 Oxygen sensor
- Current consumption 0.2 - 2.0 A
72, 73, 63 11
 When the coolant
temperature is approx. 80 °C:
- Engine:at idling speed
- Engine:at sharp acceleration(fullthrottle)
(refer to figure 3 and 4) approx.
2.7 - 5.0ms approx.14ms
There will be a
voltage
fluctuation in the range of - 0.2 -1.0V
85, 86,87,

M162 ENGINE CONTROLS 1F1-15
Failurecode ItemChecking method
Test stepRequirementSpecified
value Possible cause

Ignition:OFF(injector
temperature is 20 °C) 14 - 17

- Internal
resistance (No.1 injector) 63 11

12.0 


No.2 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms
Cable
 ECU
 No.2 Injector
 Coolant
temperaturesensor
 Oxygen sensor
 Intake airtemperaturesensor
74, 75,
61 11
 When the coolant
temperature is approx. 80 °C:
- Engine:at idling speed
- Engine:at sharp acceleration(fullthrottle)
(refer to figure 3 and 4) approx.
2.7 - 5.0ms approx.14ms
 Ignition:OFF(injector
temperature is 20 °C) 14 - 17

- Internal
resistance (No.2injector) 61 11

13.0 


No.3 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms
Cable
 ECU
 No.3 Injector
 Coolant
temperature sensor
 Oxygen sensor
 Intake airtemperature sensor
76, 77,
66 11
 When the coolant
temperature is approx. 80 °C:
- Engine:at idling speed
- Engine:at sharp acceleration(full throttle)
(refer to figure 3 and 4) approx.
2.7 - 5.0ms approx.14ms