ignition SSANGYONG MUSSO 2003 Workshop Manual

M162 ENGINE CONTROLS 1F1-23
Failurecode ItemChecking method
Te s t stepRequirementSpecified
value Possible cause
106 11 The value will
be changed in 1.2 - 1.7 V
- Voltage
(alternating)
0.9 - 1.6
71 11
71 72

Engine:in cranking
7.1 
Ignition:ON
- Remove the connector from the Camshaft positionsensor betweenNo.1 terminal andNo.3 terminal.
13
11 -14 V



Camshaft
positionsensor(E23 only)- Power supply
 Cable
 OVPR



Ignition
coil(T1/1) - primary coil voltage(No.2 and 5 cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 %(using engine tester)
 Ignition:OFF 200 - 350 VCamshaft position
sensor
64, 8.0
8.1
8.1 


Connecting
resistance of ignition coilbetween T1/1 and T1/2 
Cable
 Ignition coil T1/1
 Ignition coil T1/2
72 11



Ignition
coil(T1/2) - primary coil voltage(No.3 and 4cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 %(using engine tester) 200 - 350 V
65, 9.0
9.1
0.9 - 1.6
72 71
 Ignition:OFF 9.1 


Connecting
resistance of ignition coilbetween T1/2 and T1/1 
Cable
 Ignition coil T1/1
 Ignition coil T1/2
The
resistance of
ignition coil at 20°C is
approached 0.6
The
resistance of
ignition coil at 20°C is
approached 0.6

1F1-24 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Test
stepRequirementSpecified
value Possible cause
8 - 20 KV



Ignition coil
(T1/1, T1/2, T1/3)
- Secondary ignition voltage
> 10 M
117 118
 Engine:in cranking - Select the ignition
coil in order of T1/1,T1/2
- Measuring range: 20KV
- Time range:100 %
 Ignition:OFF
- Disconnect the coupling "No.2" fromECU.
12.0 


Knock
sensor 1 - Resistance (cylinder No1, 2, 3) 
Connecting
condition
 Cable
 ECU

11.0
64,65,66, Engine tester

11.1
 Ignition plug
 ECU
 High tension cable
6 - 8.5 K



Ignition coil
(T1/1, T1/2, T1/3)
- Secondary coilresistance 
Remove the high
tension cable of T1/1, T1/2, T1/3.

11.1 Ignition coil
(T1/1, T1/2, T1/3) 
Ignition coil T1/1
 Ignition coil T1/2
 Ignition coil T1/3
TM.4a TM.4b
56,
11



Ignition
coil(T1/3) - primary coil voltage(No.1 and 6cylinder) 
Engine:in cranking
(starter operating)- Measuring range: 400 V
- Time range: 100 % 200 - 350 V
66, 10.0
10.1
0.9 - 1.6
70 72
 Ignition:OFF 10.1 


Connecting
resistance of ignition coilbetween T1/3 and T1/2 
Cable
 Ignition coil T1/3
 Ignition coil T1/2
> 10 M
114 115 Ignition:OFF
- Disconnect the coupling "No.2" from ECU. 13.0 


Knock
sensor 2 - Resistance (cylinder No.4, 5, 6) 
Connecting
condition
 Cable
 ECU
57,
The
resistance of
ignition coil at 20°C is
approached 0.6

1F1-26 M162 ENGINE CONTROLS
IDLING CONTROL AND ELECTRONIC PEDAL SYSTEM TEST
2.1 
Ignition:ON
50 51 2.25 - 2.75 V



Pedal valve
sensor: - Power supply
(potentiometer 2)
Cable
 ECU
Failure
code Item

1.0
Checking method
 Ignition:ON
 Position of
accelerator pedal: - Closed throttle position
- Full throttle with kick down
Test
stepRequirement
Specified value Possible cause
31 47 0.3 - 0.7 V



Pedal valve
sensor: - Signal
(potentiometer 1)
160, 161,164,167,
4.3 - 4.8 V 
1.1
 Cable
 Pedal valve sensor
1.1 
Ignition:ON
31 32 4.75 - 5.25 V



Pedal valve
sensor: - Power supply
(potentiometer 1)

Cable
 ECU
2.0 
Ignition:ON
 Position of
accelerator pedal: - Closed throttle position
- Full throttle with kick down
50 48
0.1 - 0.4 V



Pedal valve
sensor:- Signal
(potentiometer 2)
162, 163,164,167,
2.1 - 2.5 V
2.1
 Cable
 Pedal valve sensor
3.0 
Engine:in idling
84 87 0.3 - 0.9 V



Throttle
valveactuator:- SignalThrottle valve
potentiometer 1
104, 105,108,109,116,119,185,
4.0 - 4.6 V
3.1
 Cable
 E-GAS actuator
 Position of
accelerator pedal:- Closed throttle position
- Full throttle with kick down

M162 ENGINE CONTROLS 1F1-27
Failurecode ItemChecking method
Test
stepRequirementSpecified
value Possible cause
3.1 
Ignition:ON
84 112 4.75 - 5.25 V



Throttle
valve actuator:- Power supply(5V)
 Cable
 ECU
4.0 
Ignition:ON
68 67 0.8 - 2.3 V
The value will
be changed in 1.0 - 2.5V.



Throttle
valve actuator:- Signal Throttle valve actuatormotor voltagesupply
104, 105,108,109,116,119,185, 
ECU
 Cable
 E-GAS actuator

Engine:in idling
- Coolant temperature:
>70 °C
84 85
4.0 - 4.6 V
Throttle valve
potentiometer 2
0.3 - 0.9 V

Position of
accelerator pedal: - Closed throttle position
- Full throttle with kick down
Throttle valvepotentiometer1+2
 Ignition:OFF
< 10
Throttle valve actuatormotorresistance 68 67

M162 ENGINE CONTROLS 1F1-29
FUEL PRESSURE AND INTERNAL LEAKAGE TEST
01 Pressure Tester
02 Pressure Hose
03 Measuring Beaker
Preparation Connection of the Equipment
1. Turn the ignition switch to "OFF" position.
2. Remove the air cleaner cross pipe.
3. Remove the cap on fuel pressure test plug and connect the
pressure hose and pressure tester.
4. Prepare the beaker for measuring the amount of fuel.
Tools Required
103 589 00 21 00 Pressure Tester
119 589 04 63 00 Pressure Hose

M162 ENGINE CONTROLS 1F1-31
FUEL PUMP TEST Preparation
1 ECU
2 Test Coupling(No.1-60)
3 Test Coupling(No.61-120)
4 Stop Watch
5 Measuring Beaker
Connection of the Equipment
1. Turn the ignition switch to "OFF" position. 2. Connect the test box to the ECU. 0 3 Test Box
04 ECU Test Cable
Tools Required
103 589 00 21 00 Pressure Tester 210 589 00 99 00 Adaptor Line
129 589 00 21 00 Test Box
210 589 08 63 00 Ecu Test Cable

1F1-32 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Test
stepRequirementSpecified
value Possible cause
1 liter of fuel supply formax. 35
seconds



Fuel pump:
- Fuel supply ratio 
Ignition:ON
- Disconnect the fuel return pipe and connect the host tobeaker to collect thesupplied fuel

1.0 
2.0
 Check the fuel line
5 - 9 A



Fuel pump:
- Current consumption 
Ignition:ON
- Remove the fuel relay from the fuseand relay box inluggagecompartment andconnect theamperemeterbetween No.1 andNo.3 in relaybox(fuel pump relay removed position) for measuringcurrent consumption

2.0 
Fuel pump
53 3
Multi tester(DC current)
31

1F1-34 M162 ENGINE CONTROLS Figure 9. Shop Made CableFigure 10. Fuel Injector Normal Spary Pattern
Failure
code ItemChecking method
Test
stepRequirementSpecified value Possible cause
There should be no leaks and later
drops from
the injector



Injector:
- Leakage test 
Ignition:ON
- Remove the fuel distributor and fuel injector with a unit.

1.0
The spray
pattern of the injector most show in the figure 10.

Ignition:ON
- Connect the shop made cable to theinjector
- Collect the spraying fuel with a beaker
- Connect the shop made cable toNo.21(+) and No.3
(-) terminal in test box

2.0 
Injector
53 3



Injector:
- Function test and spray patterncheck
53 3

1F1-36 M162 ENGINE CONTROLS
Location Engine ECU is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & Installation Procedure
1. Turn the ignition switch to "OFF" position.
2. Disconnect the battery negative cable
3. Remove the cowl side trim form passenger side.
4. Unscrew four securing nuts for ECU from mounting bracket.Installation Notice
5. Pulling out the ECU from bracket.
6. Disconnect the vehicle side coupling(B).
7. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm

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