SSANGYONG MUSSO 2003 Service Manual

M162 ENGINE CONTROLS 1F1-9
234 235236237 238 239240241 242 243
No.5 injector open/short(GND) No.6 injector short(PWR)No.6 injector open/short(GND)
Variable intake air valve short(PWR)
Variable intake air valve open/short(GND) Cam actuator short(PWR)Cam actuator open/short(GND)A/C compressor relay short(PWR)A/C compressor relay open/short(GND) Over acceleration limit Over acceleration limit(CPU2)
193194195198 199 226227228229 232 233
Failure
code Description Failure
code Description
Control lever dual operation(CPU2) Control lever safety terminal failure(CPU2)Unusual pedal position variation(CPU2)Unusal throttle position variation(CPU2) Unusal throttle control data(CPU2) Unusal pedal position sensor(CPU2)Throttle potentiometer fault(CPU2)
Unusual CPU communication(CPU2)Unusual CPU configuration(CPU2) AD converter failure(CPU2)

1F1-10 M162 ENGINE CONTROLS
TEST BOX CONNECTION
1 ECU
2 Test Coupling(No.1 - 60)
3 Test Coupling(No.61 - 120)
4 Multi-tester0 1 Test Box
02 ECU Test Cable
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 ECU Test Cable

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)

1F1-12 M162 ENGINE CONTROLS
Failurecode Item
09, 10,11,
Checking method
Te s t
stepRequirementSpecified value Possible cause
4.0 


HFM sensor
signal 105 81
 Ignition:ON 0.9 - 1.1V
4.1 - 4.3
 Cable
 External air inflow
 HFM sensor

Engine:in Idle
(Coolant temperature : > 70 °C )
: voltage value isincreased whenengine rpm isincreased 1.3 - 1.7V
4.1
105 4
 Ignition:ON
 HFM sensor
connector removed 4.7 - 5.2V

Cable
 ECU coupling



HFM sensor:
- 5V power supply HFM
sensor
4.2
3 108
 Ignition:ON
 HFM sensor
connector removed 4.7 - 5.2V

4.3
 Cable



HFM sensor:
- 5V power supply HFM
sensor
4.3
104 2
 Ignition:ON
 HFM sensor
connector removed 11 - 14V

Cable
 OVPR



HFM sensor:
- 12V power supply HFM
sensor
03, 04,05,
5.0 


Intake air
temperature sensor:- Voltage 105 80
Ignition:ON 
5.1
 ECU
± 5%
5.1 
Ignition:OFF
 No.2 ECU coupling
removed
105 80 
Cable
 HFM sensor



Intake air
temperature sensor:- Resistance° C
10 2030405060 ± 5%
3600242016621166 853600
°
C
102030405060 V
3.1
2.652.181.76 1.41.1

M162 ENGINE CONTROLS 1F1-13
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause
6.1 
Ignition:ON 0.1 - 0.3A
Cable
 Fuel pump relay
 ECU



Fuel pump
relay: - Current consumption
00, 01, 02, 06,
7.0 


Coolant
temperature sensor:- Voltage 79 78
Ignition:ON °CV
20 3.57
80 1.22
100 0.78 
7.1
 ECU
± 5%

6.0 
Ignition:ON
(Fuel pump relay will operate for 1 - 2seconds when theignition switch isturned to "ON" afterstopping the engine)
 Engine:cranking
33 11

Cable
 Fuel pump relay



Fuel pump
relay:- Operation
34, 11 - 14V
(approx.1- 2sec.)
11 - 14V
(Cranking or driving)
53 3
7.1 
Ignition:OFF
(Remove the No.2 coupling from ECU)
79 78 
7.2
 Cable



Coolant
temperature sensor:- Resistance & cable °
C
20 2500 80 322
100 185
± 5%
7.2 


Coolant
temperature sensor:- Resistance Coolant temperature
sensor:
14 Remove the
connector from coolant temperaturesensor and measurethe resistancebetween No.1 andNo.2 pin withmultimeter. 
refer to
specifiedresistancevalue of 7.1 
Coolant
temperaturesensor
34, 35,

1F1-14 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Test
stepRequirementSpecified value Possible cause
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:- Signal
80, 81,82,83,89, 56
0
8.0 
Engine:in cranking or
idle
56 0 
Cable
 ECU



ECU:
- RPM signal output32, 33, refer to figure
2
10.0 
Keep the engine run
above 2 minutes in over 80 °C of coolant
temperature.



Oxygen
sensor:- Heating functionoperated
11.0 


No.1 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 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
91 1

Ignition:ON 11 - 14 V

ECU
 Cable
 Oxygen sensor
- Current consumption 0.2 - 2.0 A
72, 73, 63 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
There will be a
voltage
fluctuation in the range of - 0.2 -1.0V
85, 86,87,

M162 ENGINE CONTROLS 1F1-15
Failurecode ItemChecking method
Test stepRequirementSpecified
value Possible cause

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

- Internal
resistance (No.1 injector) 63 11

12.0 


No.2 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms
Cable
 ECU
 No.2 Injector
 Coolant
temperaturesensor
 Oxygen sensor
 Intake airtemperaturesensor
74, 75,
61 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
 Ignition:OFF(injector
temperature is 20 °C) 14 - 17

- Internal
resistance (No.2injector) 61 11

13.0 


No.3 cylinderinjector:- Operating &
injectiontime 
When the coolant
temperature isapprox. 20 °C:
- Engine:in cranking 8.0 ms
Cable
 ECU
 No.3 Injector
 Coolant
temperature sensor
 Oxygen sensor
 Intake airtemperature 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
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,