SSANGYONG MUSSO 2003 Service Manual

M162 ENGINE CONTROLS 1F1-39
Engine Connector
Pin No.Abbreciation
Decription
61 62636465666768697071727374757677787980 EV5EV6EV1EV4EV2EV3
M+M-
TM.31
ZSC16 ZSA25ZSB34 NWS ----
MT
GND LT
Injector-cylinder 2Injector-cylinder 4Injector-cylinder 1Injector-cylinder 6Injector-cylinder 5Injector-cylinder 3E-GAS motor plusE-GAS motor minusPower ground TM.31Ignition coil cylinder 1+6Ignition coil cylinder 2+5Ignition coil cylinder 3+4Camshaft control----Engine coolant temperature
Temperature groundIntake air temperature

1F1-40 M162 ENGINE CONTROLS
Pin No.Abbreciation
Description
81 828384858687888990919293949596979899
100101102103104105106107108109
11 0 111
11 2
11 3
11 4
11 5
11 6
11 7
11 8
11 9120 HFM
---
IP2S -
IP1S ---------
SRV -
KW-
KW+
---
NOWE- GND
NOWE+ -
V-REF.HFM ---
V-REF.DK -
GND KS2 -
GND KS1 --
Hot film air mass signal--E-GAS potentiometer groundE-GAS potentiometer 2 signal-E-GAS potentiometer 1 signal---------Intake manifold resonance flap-Crankshaft sensor groundCrankshaft sensor signal - --Camshaft sensor groundHot film air mass groundCamshaft sensor signal-Hot film air mass supply---E-GAS potentiometer supply-Knock sensor 2 groundKnock sensor 2 signal-Knock sensor 1 groundKnock sensor 1 signal--

M162 ENGINE CONTROLS 1F1-41
Application
Pin No.Description
- Starter motor TM.50- - Electronic ground--- Lambda probe 1 heating Power ground TM.31
V-BATTERY TM.87
V-BATTERY TM.30Immobilizer crypto read Immobilizer crypto write -Lambda probe 1 groundLambda probe 1 signal- - -Brake switch-- - --Air conditioning clutch relay- - -1 23 4 5678 9
10 11
12 13 14 15161718 19 20212223 24 25262728 29 30-
TM.50 - -
GND - --
LSH1
TM.31TM.87TM.30
WFS I/O WFS O
-
GND LS1 - - -
BRS -- - --
KLIKU - - - -
--
-- -





-

- - -
-- - --
- - - -
- -
- --






-

- - -
-- - --
- - -
: Standard, : Option Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

1F1-42 M162 ENGINE CONTROLS
Pin No.Description
Pedal potentiometer 1 ground Pedal potentiometer 1 supplyFuel pump relay
Tank purge valve Engine fan -CAN-LowCAN-High - - --Clutch switchAir conditioning Electronic traction signal(ABD) -Pedal potentiometer 1 signalPedal potentiometer 2 signalBrake light switchPedal potentiometer 2 ground Pedal potentiometer 2 supply Cruise accelerate/SetCruise resumeCruise decelerate/SetCruise safety contact switch - Cruise off switchDiagnostics(K-line)
Vehicle speed signalEngine speed signal31 323334 35 363738 39 40 41424344 45 4647484950 51 52535455 56 57585960GND
SP1+5V KP
TEV ML
-
CAN L
CAN H
- - --
KPL
KLIMA ETS
-
SP1SSP2S BLS
GND
SP2+2.5V
S+BWA
S-B
KSK -
AUS
DIAG
V-SIG
TN-SIG




-

- - --


-







-







-

- - --


-







-


Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

M162 ENGINE CONTROLS 1F1-43
Pin No.
61 626364 65 666768 69 70 71727374 75 7677787980 81 82838485 86 87888990
Description
Injector-cylinder 2 Injector-cylinder 4Injector-cylinder 1Injector-cylinder 6 Injector-cylinder 5 Injector-cylinder 3E-GAS motor plusE-GAS motor minus Power ground TM.31 Ignition coil cylinder 1+6 Ignition coil cylinder 2+5Ignition coil cylinder 3+4Camshaft control- - --Engine coolant temperature
Temperature groundIntake air temperature Hot film air mass signal --E-GAS potentiometer groundE-GAS potentiometer 2 signal - E-GAS potentiometer 1 signal---EV5 EV6EV1EV4 EV2 EV3M+M-
TM.31
ZSC16
ZSA25ZSB34 NWS - - --
MT
GND LT
HFM
--
GND IP2S -
IP1S ---












- - --



--

-
- - -












- - --



- -

-
--- Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

1F1-44 M162 ENGINE CONTROLS
Pin No.Description
- --- - -Intake manifold resonance flap- Crankshaft sensor ground Crankshaft sensor signal ---Camshaft sensor ground Hot film air mass ground Camshaft sensor signal-Hot film air mass supply-- - E-GAS potentiometer supply-Knock sensor 2 groundKnock sensor 2 signal - Knock sensor 1 groundKnock sensor 1 signal--91 929394 95 969798 99
100 101102103104 105 106107108109
11 0111
11 2
11 3
11 4
11 5
11 6
11 7
11 8
11 9
120- --- - -
SRV -
KW-
KW+
---
NOWE- GND
NOWE+ -
V-REF.HFM -- -
V-REF.DK -
GND KS2 -
GND KS1 - - ---- - -
-

- --


-
- - -
-

-

- - - --- - -
-

- --


-
-- -
-

-

-- Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

M162 ENGINE CONTROLS 1F1-45
Removal & Installation Procedure
when removing the ECU only
1. Turn the ignition switch to "OFF" position.
2. Disconnect the negative battery cable.
3. Disconnect the couplings from ECU.
4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket and remove the auxiliarly bracket from the bracket assembly (2). Installation Notice
5. Unscrew the four bolts (5) and disconnect the ECU (6) from the bracket assenbly. Installation Notice
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 6 - 8 Nm
5 - 7 Nm(1) (3)
Tightening Torque 5 - 7 Nm
8. Unscrew the bolts (5) and disconnect the ECU (6) from the bracket assenbly. Installation Notice

When Removing the ECU with ABS or ABS/ASR Unit
1. Turn the ignition switch to "OFF" position.
2. Disconnect the negative battery cable.
3. Disconnect the couplings from ECU.
4. Disconnect the coupling from ABS or ABS/ASR unit.
5. Unscrew the bolt (1) and the left and right flange nuts.
6. Remove the ECU with ABS or ABS/ASR unit assembly.
7. Unscrew the left and right bolt (3) on the auxiliary bracket and remove the auxiliary bracket from the bracket assembly. Installation Notice
Tightening Torque 6 - 8 Nm
Tightening Torque 5 - 7 Nm
Tightening Torque 5 - 7 Nm
9. Installation should follow the removal procedure in the reverse order.

1F1-46 M162 ENGINE CONTROLS1 Vacuum Hose
2 Circlip
3 Fuel Pressure Regulator
FUEL PRESSURE REGULATOR
4 O-ring ..................................................... replace
5 O-ring ..................................................... replace

M162 ENGINE CONTROLS 1F1-47
3. Disconnect the vacuum hose.
4. Disconnect the circlip and remove the fuel pressureregulator.
5. Apply the oil to O-ring lightly and then replace it.
6. Installation should follow the removal procedure in the reverse order.
7. Check for fuel pressure and internal leaks by operating the engine.
2. Discharge the pressure in fuel supply system by pressing
the service valve.
Removal & Installation Procedure
1. Remove the fuel pressure test connector.

1F1-48 M162 ENGINE CONTROLSA . Valves Closed
B. Valves Opened
The pressure difference between the fuel pressure and the intake manifold is about 3.8 bars during the full load. <Operating at Idle and partial load> The spring chamber(9) is connected to the intake manifold with the vacuum hose at the intake pipe connection(7). Thenegative pressure generated in the intake manifold activates the diaphragm, and thus the fuel pressure gets reduced to the rate of the operating extent of the diaphragm by the intakemanifold's negative pressure.
Consequently, the fuel pressure in the fuel distributor changes by the intake manifold's negative pressure, and the injector'sfuel pressure gets reduced independently to the throttle valve'sposition. Thus, the fuel injection volume can only be determined according to the injector's injecting duration. 2. Fuel return line
3. Valve
5. Diaphragm
6. Compression Spring
8. Fuel Chamber
9. Spring Chamber
1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return(to fuel tank)
4. Fuel Supply(form fuel pump)
5. Fuel Pressure(approx. 3.8 bars)
6. Intake Manifold Negative Pressure(0 bar)
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 tothe intake manifold pressure. This operating pressure cannotbe 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. <Operating at full load>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 compression . At thismoment, the valve(3) sticks to the diaphragm by the fuelpressure, and the fuel return line(2) opens. The fuel over supplied returns to the fuel tank through the return line.