engine SSANGYONG MUSSO 2003 Service Manual

1F1-16 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Te s t
stepRequirementSpecified
value Possible cause

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

- Internal
resistance (No.3injector) 66 11

14.0 


No.4
cylinder injector: - Operating & injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms
Cable
 ECU
 No.4 Injector
 Coolant
temperature sensor
 Oxygen sensor
 Intake airtemperature sensor
78, 79,
62 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
 Ignition:OFF(injector
temperature is 20 °C) 14 - 17

- Internal
resistance (No.4 injector) 62 11
192, 193,
15.0 


No.5
cylinder injector:- Operating & injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms

Cable
 ECU
 No.5 Injector
 Coolant
temperature sensor
 Oxygen sensor
 Intake airtemperature sensor
65 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

M162 ENGINE CONTROLS 1F1-17
Failurecode ItemChecking method
Test
stepRequirementSpecified value Possible cause

17.0 


Variable
intake air valve(resonanceflap switchvalve)- Operating 
Engine:in cranking/
below 3500rpm 
ECU
 Cable
 Variable intake air
valve< 1V
 Ignition:ON 0.4 - 0.6A
- Current
consumption
198, 199, 
Ignition:OFF(injector
temperature is 20 °C) 14 - 17

- Internal
resistance(No.5 injector) 65 11

16.0 


No.6 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms 
Cable
 ECU
 No.6 Injector
 Coolant
temperature sensor
 Oxygen sensor
 Intake air
temperature sensor
194, 195,
64 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
 Ignition:OFF(injector
temperature is 20 °C) 14 - 17

- Internal
resistance (No.6 injector) 64 11
97 11
69 97

Engine:rpm > above
3500rpm 11 - 15V



Camshaft actuator:Currentconsumption
12 Camshaft actuator
1 - 1.5 A

ECU
 18.1
 19.0
18.0
226, 227, 
Engine : in idling- Coolant temperature
: above 70 °C
- Engine rpm : increase up to 2000rpm

1F1-18 M162 ENGINE CONTROLS
Failurecode Item

18.1
Checking method
Test
stepRequirementSpecified
value Possible cause
73 2 8 - 12




Camshaft
actuator: Solenoidresistance
21.0 


Purge
control valve:- Vacuum control 
Engine:in idling/
normal operatingtemperature 
Vacuum line
 Purge control valve

Cable
 Camshaft actuator
Diagnosis socket
19.0
73 69 Engine is
unstable or stopped



Camshaft
actuator:MechanicalActuation
 Mechanical failure of
camshaft actuator
20.0 
Engine:in idling
34 11 The purge
control valve should be
operated after approx.
1minute.
(refer to figure 5)



Purge
control valve:- Operating226, 227,
 ECU
 Cable
 Purge control valve
 Ignition:ON 0.3 - 0.5 A
- Current
consumption
10 34
Creating
above 50mbar of vacuum
after approx. 1 minute
22.0 
Ignition:OFF
38 37 
Data bus
 22.1
 22.2
55 - 65




CAN data
bus
 Ignition:OFF

Engine:in idling
- connect the bridge to the test box for approx. 10 seconds
40, 41,54,
Connect the vacuum gauge between thecontrol valve andcanister
22,23, 24,26,27,29,30,31,59,60,

M162 ENGINE CONTROLS 1F1-19
Failurecode Item

22.1
Checking method
Test stepRequirementSpecified
value Possible cause
38 37 115 - 125




CAN module
resistance in ABS, ABD,ASR controlunit
 Cable
 ABS, ABD, ASR
control unit Ignition:OFF
- disconnect the coupling "No.1" from ECU.
22.2
38 37 115 - 125




CAN module
resistance inECU controlunit
 ECU Ignition:OFF
- disconnect the coupling "No.1" from ECU.
23.0
558 11 - 14 V



Diagnosis
cable operating ECU
 Cable

Ignition:ON
22,23, 24,26,27,29,30,31,59,60,

1F1-20 M162 ENGINE CONTROLS Reference Figures Figure2. RPM Sgnal OutputFigure 3. Injection Valve Wave(at idle speed)
Figure 4. Injection Valve Wave(at sharp acceleration) Figure 5. Purge Control Valve Operationg Wave

M162 ENGINE CONTROLS 1F1-21
Failurecode ItemChecking 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
IGNITION SYSTEM TEST
08, 
1.1
 1.2
1.1 
Ignition:ON
10 2 11 - 14V



Ground
cable:- Battery ground
 Ground cable
 Ground condition
(figure 1)
Diagnosis
socket
69 2
Diagnosis socket
1.2 
Ignition:ON
11 2 11 - 14V



Power
supply: - terminal 30(TM.30)
 Power supply cable
 Fuse No.8
Diagnosis socket
2.0 
Ignition:ON
51 1 11 -14V



ECU:power
supply - terminal 87(TM.87)
08, 
2.1
 2.2
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 
Ignition:ON
69 71 11 - 14 V



Ignition
coil(T1/1) - No.2,5 Cylinder64, 
Cable
 Ignition coil(T1/1)
 Fuse No.17
 Engine:in cranking > 10 V

1F1-22 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause

6.1 


Crankshaft
position sensor:- Resistance 
Ignition:OFF
- Disconnect the coupling "NO.2"from ECU 
Cable
 Crankshaft position
sensor

6.0 
Engine:in cranking
99 100 Measure the
signal (refer to figure 6)



Crankshaft
positionsensor:- Signal
17, 18,20,67, 
6.1
 Increament failure in
driven plate
> 5 V -
99 100
99 100
1050 - 1400

7.0 
Engine:in cranking
104 106 
7.1
 Cable
 Camshaft position
sensor
Measure the
signal(refer to figure 7)



Camshaft
position sensor:- Signal
4.0 
Ignition:ON
69 72 11 -14 V



Ignition
coil(T1/2) - No.3,4 Cylinder65, 
Cable
 Ignition coil(T1/2)
 Fuse No.17
 Engine:in cranking > 10 V

Engine:in idling
- Voltage (alternating) 
Engine:in cranking
 Engine: in idling > 2.5 V -
19, 58,

5.0 
Ignition:ON
69 70 11 -14 V



Ignition
coil(T1/3) - No.1,6 Cylinder66, 
Cable
 Ignition coil(T1/3)
 Fuse No.17
 Engine:in cranking > 10 V
17, 18,20,67, Voltage value
is increased
when engine rpm is
increased

M162 ENGINE CONTROLS 1F1-23
Failurecode ItemChecking method
Te s t stepRequirementSpecified
value Possible cause
106 11 The value will
be changed in 1.2 - 1.7 V
- Voltage
(alternating)
0.9 - 1.6
71 11
71 72

Engine:in cranking
7.1 
Ignition:ON
- Remove the connector from the Camshaft positionsensor betweenNo.1 terminal andNo.3 terminal.
13
11 -14 V



Camshaft
positionsensor(E23 only)- Power supply
 Cable
 OVPR



Ignition
coil(T1/1) - primary coil voltage(No.2 and 5 cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 %(using engine tester)
 Ignition:OFF 200 - 350 VCamshaft position
sensor
64, 8.0
8.1
8.1 


Connecting
resistance of ignition coilbetween T1/1 and T1/2 
Cable
 Ignition coil T1/1
 Ignition coil T1/2
72 11



Ignition
coil(T1/2) - primary coil voltage(No.3 and 4cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 %(using engine tester) 200 - 350 V
65, 9.0
9.1
0.9 - 1.6
72 71
 Ignition:OFF 9.1 


Connecting
resistance of ignition coilbetween T1/2 and T1/1 
Cable
 Ignition coil T1/1
 Ignition coil T1/2
The
resistance of
ignition coil at 20°C is
approached 0.6
The
resistance of
ignition coil at 20°C is
approached 0.6

1F1-24 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Test
stepRequirementSpecified
value Possible cause
8 - 20 KV



Ignition coil
(T1/1, T1/2, T1/3)
- Secondary ignition voltage
> 10 M
117 118
 Engine:in cranking - Select the ignition
coil in order of T1/1,T1/2
- Measuring range: 20KV
- Time range:100 %
 Ignition:OFF
- Disconnect the coupling "No.2" fromECU.
12.0 


Knock
sensor 1 - Resistance (cylinder No1, 2, 3) 
Connecting
condition
 Cable
 ECU

11.0
64,65,66, Engine tester

11.1
 Ignition plug
 ECU
 High tension cable
6 - 8.5 K



Ignition coil
(T1/1, T1/2, T1/3)
- Secondary coilresistance 
Remove the high
tension cable of T1/1, T1/2, T1/3.

11.1 Ignition coil
(T1/1, T1/2, T1/3) 
Ignition coil T1/1
 Ignition coil T1/2
 Ignition coil T1/3
TM.4a TM.4b
56,
11



Ignition
coil(T1/3) - primary coil voltage(No.1 and 6cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 % 200 - 350 V
66, 10.0
10.1
0.9 - 1.6
70 72
 Ignition:OFF 10.1 


Connecting
resistance of ignition coilbetween T1/3 and T1/2 
Cable
 Ignition coil T1/3
 Ignition coil T1/2
> 10 M
114 115 Ignition:OFF
- Disconnect the coupling "No.2" from ECU. 13.0 


Knock
sensor 2 - Resistance (cylinder No.4, 5, 6) 
Connecting
condition
 Cable
 ECU
57,
The
resistance of
ignition coil at 20°C is
approached 0.6

M162 ENGINE CONTROLS 1F1-25
Reference Figures Figure 6. Crankshaft Position Sensor Signal
a Voltage
b Identifying the No.1 - 2 Missing TeethFigure 7. Camshaft Position Sensor Signal
Figure 8. Signal Function
1 Crank Angle
2 Cylinder
3 Crankshaft Position Sensor Signal
4 Camshaft Position Sensor Signal
5 RPM Signal