fuel SSANGYONG MUSSO 2003 Owner's Guide

OM600 ENGINE MECHANICAL 1B3-63
TIMING CASE COVER
Preceding Work : Removal of the cooling fanRmoval of the V-belt tensioning device Removal of the vibration damper and hub Removal of the alternator
1 Bolt............................................................ 10Nm
2 Cylinder Head Cover
3 Gasket ................................................... Replace
4 Socket Bolt ................................................ 25Nm
5 Fuel Filter
6 Square Nut
7 Oil Pan
8 Socket Bolt ................................................ 10Nm
9 Bolt .................................................... M6 : 10Nm
M8 : 23Nm 10 Power Steering Pump
11 Bolt
12 Belt Pulley 13 Bolt
............................................................ 32Nm
14 Timing Case Cover
15 Bolt ............................................................ 23Nm
16 Alternator Bracket
17 Bolt ............................................................ 45Nm
18 Bolt ............................................................ 25Nm
19 Bolt ............................................................ 10Nm
20 Closing Cover
21 Socket Bolt ................................................ 23Nm
22 Guide Pulley
23 Bolt .............................................................. 9Nm
24 Guide Pulley Bracket
25 Nut ............................................................. 23Nm

OM600 ENGINE MECHANICAL 1B3-65
11. Remove the alternator bracket (16).
9. Disconnect the pipes of power steering pump and removethe belt pulley. Notice
Be careful not to lose the key.
10. Remove the nut and pull out the bolt and then remove the power steering pump.
12. Remove the fuel filter.

1B3-66 OM600 ENGINE MECHANICAL
18. Remove the timing case cover (19) bolts and then removethe timing case cover (14). Notice Be careful not to damage the cylinder head gasket or oil pan gasket.
13. Remove the camshaft.
14. Remove the socket bolts(4) in the chain box.
Socket Wrench 115 589 03 07 00
15. Remove the injection pump. NoticeSee the ‘Removal of fuel injection pump ’.
16. Remove the oil pan bolts (8, 9) in the area of the timing case cover (14).
17. Slightly loosen the remaining oil pan bolts.

OM600 ENGINE MECHANICAL 1B3-69
10. Install the fuel filter.
11. Install the vacuum pump.
12. Install the power steering pump.
13. Install the power steering pump pulley.
Tightening Torque 25 Nm
Tightening Torque 10 Nm
Tightening Torque 23 Nm
Tightening Torque 32 Nm
14. Install the guide pulley bracket.
Tightening Torque 9 Nm

1B3-92 OM600 ENGINE MECHANICAL
28. Remove the connecting rod bearing cap.
29. Install the piston.
30. Rotate the crankshaft by hand and check whether it rotatessmoothly.
31. If the bearings are damaged,
- replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully and
replace the hose if necessary. Notice After assembling the engine, check the camshaft timing, adjust the start of fuel injection and check the TDC sensorbracket setting.
32. Fill oil and run the engine and then check the oil pressure and oil level. Notice Install the original oil filter element and then change the engine oil and oil filter element after 1,000 - 1,500km.
27. Measure the radial clearance (L) of the connecting rod
bearing. Example) Measured value ‘J’ = 47.700mm
Measured value ‘K’ = 47.653mm
Clearance ‘L’ = 0.047mm
Radial Clearance ‘L’0.026 - 0.068mm
Notice If the clearance is out of standard, adjust the radial clearance of connecting rod bearing by replacing theconnecting rod bearing shells.
26. Measure connecting rod bearing journal diameter (K).
Notice Refer to measurement of the crankshaft bearing journal
diameter.
24. Insert the new connecting rod bearing shells into theconnecting rod and connecting rod bearing cap and tighten
the 12-sided stretch bolts (11).
25. Measure inner diameter of connecting rod bearing.
Tightening Torque 40 Nm + 90 °

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 cablewill help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
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 andDescriptions . . . . . . . . . . . . . . . . . . . . . . . . 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

1F1-2 M162 ENGINE CONTROLSSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Return and Supply Line Fuel Distributor Assembly Bolt
Pressure Test ConnectorFuel Inlet and Outlet LineFuel Filter Mounting Bracket Bolt Crankshaft Position Sensor Bolt Camkshaft Position Sensor BoltKnock Sensor Mounting Bolt
Coolant Temperature BoltN m
25 - 30
22.5 - 27.5 21.6 - 26.4 25 - 304 - 8
9 - 11
9 - 11
22.5 - 27.5 18 - 22

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 1F1-11
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)