ignition SSANGYONG MUSSO 1998 Workshop Service Manual

SECTION 1F1
M162 ENGINE CONTROLS
TABLE OF CONTENTS
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.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F1-2
Fastener Tightening Specifications . . . . . . . . 1F1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1F1-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1F1-3
Schematic and Routing Diagrams . . . . . . . 1F1-4
E32 ECU (HFM) . . . . . . . . . . . . . . . . . . . . . . 1F1-4
E32 ECU (MSE) . . . . . . . . . . . . . . . . . . . . . . 1F1-5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-6
Self Diagnosis Socket Pin Numbers and
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 1F1-6
Self Diagnosis Failure Code . . . . . . . . . . . . . 1F1-7
Test Box Connection . . . . . . . . . . . . . . . . . . 1F1-10
Fuel Injection System Test (MSE3.62) . . . . . 1F1-11
Ignition System Test . . . . . . . . . . . . . . . . . . 1F1-21
Idling Control and Electronic Pedal
System Test . . . . . . . . . . . . . . . . . . . . . . . 1F1-26
Air Conditioner Control System Test . . . . . . 1F1-28
Fuel Pressure and Internal Leakage Test . . 1F1-29
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F1-31Injector Test . . . . . . . . . . . . . . . . . . . . . . . . 1F1-33
Maintenance and Repair . . . . . . . . . . . . . 1F1-35
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F1-35
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-35
Fuel Pressure Regulator . . . . . . . . . . . . . . 1F1-46
Fuel Distributor . . . . . . . . . . . . . . . . . . . . . . 1F1-50
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-54
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-57
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-58
Purge Switchover Valve . . . . . . . . . . . . . . . 1F1-62
Vacuum System . . . . . . . . . . . . . . . . . . . . . 1F1-64
Crankshaft Position Sensor . . . . . . . . . . . . 1F1-65
Camshaft Position Sensor . . . . . . . . . . . . . 1F1-67
Hot Film Air Mass (HFM) Sensor . . . . . . . . . 1F1-69
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 1F1-72
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 1F1-74
Coolant Temperature Sensor . . . . . . . . . . . 1F1-75
Accelerator Pedal Module . . . . . . . . . . . . . . 1F1-78

1F1-6 M162 ENGINE CONTROLS
DIAGNOSIS
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 -
1 8 TCU(PIN 23)
19 -
2 0 K-LINE(ECS:PIN 23)

M162 ENGINE CONTROLS 1F1-7
41
44
45
56
57
58
59
60
62
64
65
66
67
71
72
73
74
75
76
77
78
79
80
81
82
83
86
87
89 00
01
02
03
04
05
08
09
10
11
17
18
19
20
21
23
24
25
26
27
29
30
31
34
35
40
Failure
codeDescription
Coolant temperature sensor open
Coolant temperature sensor short
Coolant temperature sensor signal failure
Intake temperature sensor open
Intake temperature sensor short
Intake temperature sensor signal failure
Low battery voltage
HFM sensor signal failure
HFM 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 failure
CAN communication failure : ASR
-
Transponder signal failure
CAN communication failure : TCU(A/T only)
CAN communication failure : TOD(E32 only)
-
-
CAN communication failure :
communication initialization failure
Fuel pump relay short(PWR)
Fuel pump relay open/short(GND)
Purge valve short
Failure
codeDescription
Purge valve open/short
Condenser fan(HI) relay short(PWR)
Condenser fan(HI) relay short(GND)
No.1 knock sensor signal failure
No.2 knock sensor signal failure
No.1 cylinder synchronization failure
-
-
Cluster S/W defectave
No 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 failure
Start signal recognition failure
No.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 voltage
Low oxygen sensor amplifying voltage
Oxygen 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

M162 ENGINE CONTROLS 1F1-11
FUEL INJECTION SYSTEM TEST (MSE3.62)
Failure
codeItem
Þ 1.0
Checking method
· Ignition:ON
Test
stepRequirementSpecified
valuePossible cause
10 1211 -14V
· ·· ·
· ECU:power
supply
- terminal
30(TM.30)
Þ 2.2· ·· ·
· Power
supply:
- terminal
87(TM.87)· Ignition:ON· Power supply cable
· OVPR 08,
·Þ 1.1
·Þ 1.2
Þ 1.1
· Ignition:ON
10 211 -14V· ·· ·
· Ground
cable:
- Battery
ground· Ground cable
· Ground conditionDiagnosis
socket
69 2
Diagnosis
socket
Þ 1.2· Ignition:ON
11211 -14V· ·· ·
· Power
supply:
- terminal
30(TM.30)· Power supply cable
Diagnosis
socket
Þ 2.0· Ignition:ON
51111 -14V· ·· ·
· ECU:power
supply
- terminal
87(TM.87)08,·Þ 1.1
·Þ 2.1
Þ 2.1
· Ignition:ON 11 -14V· ·· ·
· Ground
cable
- Electronic
ground· Ground cable
52
Diagnosis
socket
111
Diagnosis
socket· Ignition:OFF
11 -14V
< 1V
Þ 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
Failure
codeItem
09,
10,
11,
Checking method Te s t
stepRequirementSpecified
valuePossible cause
Þ 4.0· ·· ·
· HFM sensor
signal
105 81· Ignition:ON0.9 - 1.1V· Þ 4.1 - 4.3
· Cable
· External air inflow
· HFM sensor
· Engine:in Idle
(Coolant temperature
: > 70°C )
: voltage value is
increased when
engine rpm is
increased1.3 - 1.7V
Þ 4.1
105 4
· Ignition:ON
· HFM sensor
connector removed4.7 - 5.2V
· Cable
· ECU coupling
· ·· ·
· HFM sensor:
- 5V power
supplyHFM
sensor
Þ 4.2
3 108· Ignition:ON
· HFM sensor
connector removed4.7 - 5.2V
· Þ 4.3
· Cable
· ·· ·
· HFM sensor:
- 5V power
supplyHFM
sensor
Þ 4.3
104 2· Ignition:ON
· HFM sensor
connector removed11 - 14V
· Cable
· OVPR
· ·· ·
· HFM sensor:
- 12V power
supplyHFM
sensor
03,
04,
05,Þ 5.0· ·· ·
· Intake air
temperature
sensor:
- Voltage105 80· Ignition:ON· Þ 5.1
· ECU
± 5%
Þ 5.1· Ignition:OFF
· No.2 ECU coupling
removed 105 80
· Cable
· HFM sensor
· ·· ·
· Intake air
temperature
sensor:
- Resistance°C
10
20
30
40
50
60
± 5%W
3600
2420
1662
1166
853
600 °C
10
20
30
40
50
60V
3.1
2.65
2.18
1.76
1.4
1.1

M162 ENGINE CONTROLS 1F1-13
Failure
codeItemChecking method Te s t
stepRequirement
Specified
valuePossible cause
Þ 6.1· Ignition:ON0.1 - 0.3A· Cable
· Fuel pump relay
· ECU
· ·· ·
· Fuel pump
relay:
- Current
consumption
00,
01,
02,
06,Þ 7.0· ·· ·
· Coolant
temperature
sensor:
- Voltage79 78· Ignition:ON°CV
20 3.57
80 1.22
100 0.78· Þ 7.1
· ECU
±5% Þ 6.0
· Ignition:ON
(Fuel pump relay will
operate for 1 - 2
seconds when the
ignition switch is
turned to "ON" after
stopping the engine)
· Engine:cranking 33 11
· Cable
· Fuel pump relay
· ·· ·
· Fuel pump
relay:
- Operation34,11 - 14V
(approx.1-
2sec.)
11 - 14V
(Cranking or
driving)
533
Þ 7.1· Ignition:OFF
(Remove the No.2
coupling from ECU) 79 78· Þ 7.2
· Cable
· ·· ·
· Coolant
temperature
sensor:
- Resistance
& cable°CW
20 2500
80 322
100 185
±5%
Þ 7.2· ·· ·
· Coolant
temperature
sensor:
- ResistanceCoolant temperature
sensor:
14
· Remove the
connector from
coolant temperature
sensor and measure
the resistance
between No.1 and
No.2 pin with
multimeter.· Þ refer to
specified
resistance
value of 7.1· Coolant
temperature
sensor 34,
35,

1F1-14 M162 ENGINE CONTROLS
Failure
codeItemChecking method Test
stepRequirementSpecified
valuePossible cause
Þ 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:
- Signal80,
81,
82,
83,
89,560
Þ 8.0· Engine:in cranking or
idle
560· Cable
· ECU
· ·· ·
· ECU:
- RPM signal
output32,
33,refer to figure
2
Þ 10.0· Keep the engine run
above 2 minutes in
over 80°C of coolant
temperature.· ·· ·
· Oxygen
sensor:
- Heating
function
operated
Þ 11.0· ·· ·
· No.1
cylinder
injector:
- Operating &
injection
time· When the coolant
temperature is
approx. 20°C:
- Engine:in cranking8.0 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
911
· Ignition:ON11 - 14 V
· ECU
· Cable
· Oxygen sensor
- Current
consumption0.2 - 2.0 A
72,
73,
63 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 There will be a
voltage
fluctuation in
the range of
- 0.2 -1.0V
85,
86,
87,

M162 ENGINE CONTROLS 1F1-15
Failure
codeItem
Checking method Test
stepRequirementSpecified
valuePossible cause
·Ignition:OFF(injector
temperature is 20°C)14 - 17 W - Internal
resistance
(No.1
injector)63 11
Þ 12.0· ·· ·
· No.2
cylinder
injector:
- Operating &
injection
time· When the coolant
temperature is
approx. 20°C:
- Engine:in cranking8.0 ms· Cable
· ECU
· No.2 Injector
· Coolant
temperature
sensor
· Oxygen sensor
· Intake air
temperature
sensor 74,
75,
61 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 W - Internal
resistance
(No.2
injector)61 11
Þ 13.0· ·· ·
· No.3
cylinder
injector:
- Operating &
injection
time· When the coolant
temperature is
approx. 20°C:
- Engine:in cranking
8.0 ms· Cable
· ECU
· No.3 Injector
· Coolant
temperature sensor
· Oxygen sensor
· Intake air
temperature 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

1F1-16 M162 ENGINE CONTROLS
Failure
codeItemChecking method Te s t
stepRequirementSpecified
valuePossible cause
·Ignition:OFF(injector
temperature is 20°C)14 - 17 W - Internal
resistance
(No.3
injector)66 11
Þ 14.0· ·· ·
· No.4
cylinder
injector:
- Operating &
injection
time· When the coolant
temperature is
approx. 20°C:
- Engine:in cranking
8.0 ms· Cable
· ECU
· No.4 Injector
· Coolant
temperature sensor
· Oxygen sensor
· Intake air
temperature 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 W - Internal
resistance
(No.4
injector)62 11
192,
193,Þ 15.0· ·· ·
· No.5
cylinder
injector:
- Operating &
injection
time· When the coolant
temperature is
approx. 20°C:
- Engine:in cranking8.0 ms· Cable
· ECU
· No.5 Injector
· Coolant
temperature sensor
· Oxygen sensor
· Intake air
temperature sensor 65 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

M162 ENGINE CONTROLS 1F1-17
Failure
codeItemChecking method Test
stepRequirementSpecified
valuePossible cause
Þ 17.0· ·· ·
· Variable
intake air
valve
(resonance
flap switch
valve)
- 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 W - Internal
resistance
(No.5 injector)65 11
Þ 16.0· ·· ·
· No.6
cylinder
injector:
- Operating &
injection
time· When the coolant
temperature is
approx. 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 W
- Internal
resistance
(No.6 injector)64 11
97 11
69 97
· Engine:rpm > above
3500rpm11 - 15V
· ·· ·
· Camshaft
actuator:
Current
consumption
12
Camshaft actuator1 - 1.5 A· ECU
· Þ 18.1
· Þ 19.0
Þ 18.0 226,
227,· Engine : in idling
- Coolant temperature
: above 70°C
- Engine rpm :
increase up to 2000
rpm