electrical SSANGYONG MUSSO 2003 User Guide

M162 ENGINE ELECTRICAL 1E1-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
120 589 02 09 00
Spark Plug Wrench

1E1-4 M162 ENGINE ELECTRICALMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
ALTERNATOR Preceding Work : Removal of the drivebelt Removal & Installation Procedure
1. Disconnect the negative battery terminal.
2. Unscrew the nut and disconnect the terminal (1). Installation Notice
1 Terminal (B+)
2 Terminal (D+)
3 Combination Bolt
4 Alternator
3. Unscrew the nut and disconnect the terminal (2).Installation Notice
Tightening Torque 14 - 18 Nm
4. Unscrew the combination bolt (3). Installation Notice
Tightening Torque 4 - 5 Nm
5. Remove the alternator.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 42 - 50 Nm

M162 ENGINE ELECTRICAL 1E1-5
3 Fixing Bolt
4 Starting Motor
4. Unscrew the mounting bolts (3) of starting motor.
Installation Notice
5. Remove the starting motor.
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 35 - 48 Nm
STARTING MOTOR Removal & Installation Procedure
1. Disconnect the ground cable.
2. Unscrew the nut and disconnect the battery cable(1).
Installation Notice
1 Battery Cable
2 Engine Electric Wire
3. Unscrew the nut and disconnect the engine electric wire
(2). Installation Notice
Tightening Torque 12 - 15 Nm
Tightening Torque 6 - 7 Nm

1E1-6 M162 ENGINE ELECTRICAL
BATTERY
1 Cable Terminal (-)
2 Cable Terminal Cap (-)
3 Cable Terminal Cap (+)
4 Nut
5 Fuseblink Box
6 Terminal (+)7 Battery holddown Bracket
8 Battery Clamp Bolt
9 Battery
10 Sub Tray 11 Battery Tray
Removal & Installation Procedure Notice
Disconnect the battery negative cable first.
Insert the clamp bolt (8) into the battery tray hole (11)
from inside when installing.

M162 ENGINE ELECTRICAL 1E1-7
1 Ignition Coil Cable Cover
2 Bolt (M6 X 60, 7 pieces)......................... 9-11 Nm
3 Spark Plug
SPARK PLUG Preceding Work : Removal of intake air ductT1/1
Ignition Coil : Cylinder 2 and 5
T1/2 Ignition Coil : Cylinder 3 and 4
T1/3 Ignition Coil : Cylinder 1 and 6

1E1-8 M162 ENGINE ELECTRICAL
Tools Required 120 589 09 00 Spark Plug Wrench Replacement Procedure
1. Remove the seven bolts (2) and remove the ignition cablecover. Installation Notice
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 11 Nm
2. Remove the two bolts (M6 X 25) from each ignition cableand remove the ignition cable. Installation Notice
3. Remove the spark plug using the special tool. Installation Notice
Spark Plug Wrench 120 589 02 09 00

M162 ENGINE ELECTRICAL 1E1-9
IGNITION CABLE Preceding Work : Removal of intake air duct
1 Control Cable Connection
2 Ignition Cable
3 Spark Plug Connector
4 Coupling Plug5a, 5b Secondary Voltage Connection
E Iron Core
L1 Secondary Ignition Coil
L2 Primary Ignition Coil

1E1-10 M162 ENGINE ELECTRICAL Functions
1. Firing order : 1-5-3-6-2-4
2. The ignition cables are located on the cylinder head cover.Each ignition coil provides the high voltage to two spark
plugs simultaneously.
- T1/1 : cylinder 2 and 5
- T1/2 : cylinder 3 and 4
- T1/3 : cylinder 1 and 6
Removal & Installation Procedure
1. Disconnect the negative battery cable (1).
2. Remove the ignition cable connector from the ignition cable.
3. Disconnect the secondary spark plug connectors from the each spark plugs and remove the ignition cable. Installation Notice
3. The secondary output voltage (5a) is supplied to the No.2
cylinder spark plug through the spark plug connector. The secondary output voltage (5b) is supplied to the No.5 cylinderspark plug through the ignition cable. The guide pin (W)acts as a ground while the ignition cable is operated.
Make sure that the ignition cables are correctly routed.
Exactly install the ignition cable guide pin into the vehicle
to be grounded.
4. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm

M162 ENGINE ELECTRICAL 1E1-11
Circuit Diagram
Inspection & Maintenance Procedure (for MSE)
1. While the ignition switch is in 'OFF' position, remove thewiring connectors (1 and 15) from ignition coil and measure the primary resistance between terminal No.1 and No.15.
2. During engine cranking, measure primary voltage (T1/1) between ECU terminal No. 71 and No. 69.
Notice If out of specified value, replace the ignition coil.
Specified Value
0.9 - 1.6 (20 °C)
Specified Value 200 - 350 V
Notice
Measure remaining cables.
- T1/2 : No. 72 and 69.
- T1/3 : No. 70 and 69.
If out of specified value, check ignition cable and ECU.
3. Using a multi-tester, measure the secondary coil resistance between 5a and 5b.
Specified Value 6 - 8.5 k

1E1-12 M162 ENGINE ELECTRICALUNIT REPAIR
BATTERY
Inspection Notice
When charging the battery, do not leave the inflammable
objects around it.
When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects were found on it.
2. Check if the specific gravity of the electrolyte is within the specified value. Notice
Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
Measure the specific gravity in the approx. 20 °C
of ambient temperature.
3. Replenish the electrolyte if necessary. Battery capacity(Ah)Battery specific gravity Max. tolerance between cells
85
1.24
0.04