check oil SSANGYONG MUSSO 2003 Repair Manual

1F1-22 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause

6.1 


Crankshaft
position sensor:- Resistance 
Ignition:OFF
- Disconnect the coupling "NO.2"from ECU 
Cable
 Crankshaft position
sensor

6.0 
Engine:in cranking
99 100 Measure the
signal (refer to figure 6)



Crankshaft
positionsensor:- Signal
17, 18,20,67, 
6.1
 Increament failure in
driven plate
> 5 V -
99 100
99 100
1050 - 1400

7.0 
Engine:in cranking
104 106 
7.1
 Cable
 Camshaft position
sensor
Measure the
signal(refer to figure 7)



Camshaft
position sensor:- Signal
4.0 
Ignition:ON
69 72 11 -14 V



Ignition
coil(T1/2) - No.3,4 Cylinder65, 
Cable
 Ignition coil(T1/2)
 Fuse No.17
 Engine:in cranking > 10 V

Engine:in idling
- Voltage (alternating) 
Engine:in cranking
 Engine: in idling > 2.5 V -
19, 58,

5.0 
Ignition:ON
69 70 11 -14 V



Ignition
coil(T1/3) - No.1,6 Cylinder66, 
Cable
 Ignition coil(T1/3)
 Fuse No.17
 Engine:in cranking > 10 V
17, 18,20,67, Voltage value
is increased
when engine rpm is
increased

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

M162 ENGINE CONTROLS 1F1-47
3. Disconnect the vacuum hose.
4. Disconnect the circlip and remove the fuel pressureregulator.
5. Apply the oil to O-ring lightly and then replace it.
6. Installation should follow the removal procedure in the reverse order.
7. Check for fuel pressure and internal leaks by operating the engine.
2. Discharge the pressure in fuel supply system by pressing
the service valve.
Removal & Installation Procedure
1. Remove the fuel pressure test connector.

M162 ENGINE CONTROLS 1F1-55
Removal & Installation Procedure
1. Remove the O-ring.Check for damage and replace it if necessary.
2. Remove the injector bracket from the injector.
Installation Notice Exactly seat the anti-twist lock into the square groove in
injector.
3. Separate the injector from the fuel distributor. Inspection & Maintenance Inspection of the Injector operation and spray pattern
1. Connect the contact box to the ECU.
2. Connect the shop made test plug to the injector and place it into the tank.
3. Position the ignition switch to ON.
4. Connect the pin 63(+) and 69(-) of the contact box with a test cable.
5. Check the injector spray pattern.
NoticeReplace the injector if the injector spray pattern is abnormal or the fuel doesn't inject.
Injector Resistance Inspection
1. Remove the injector connector.
2. Measure the injector coil resistance using a resistance tester. Notice Replace the injector if the measured values is out of the specified values. Check the connector and wire connectionbetween the ECU and the injector if the measured valuesare normal.
Specified Value 14 - 17

1F3-30 OM600 ENGINE CONTROLS
REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE Preceding Work : Removal of vacuum pump
1 Cylinder Head Cover
2 Bolt ............................................................ 10Nm
3 Gasket ................................................... Replace
4 Fuel Injection Pump
5 Seal ....................................................... Replace
6 Screw Plug ................................................. 30Nm
7 Oil Pan
8 Locking Pin
9 Injection Timing Device 10 Washer
11 Bolt (Left-Hand Thread) .............................46Nm
12 Camshaft Sprocket
13 Washer
14 12-Sided Stretch Bolt ............Check, 25Nm + 90 °
15 Timing Chain
16 Seal
17 Chain Tensioner ......................................... 80Nm

1F3-38 OM600 ENGINE CONTROLS
Tools Required 617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel.
2. Install the position sensor (1) into the governor housing of
the injection pump to be the guide pin of the position sensor facing up.
3. Connect the battery terminal of position sensor (1) to positive terminal (+) of battery.
Position Sensor 617 589 08 21 00
4. Rotate the crankshaft by hand (in direction of engine rotation) until the lamp ‘B’ lights up. Rotate the crankshaft carefully
further until both lamps ‘A and B ’ come on. In this position,
check the Rl value on the crankshaft vibration damper. Notice If only lamp ‘A’ lights up, repeat the test and if out of
specification, adjust start of delivery.
Specification A TDC 14° - 16 °

OM600 ENGINE CONTROLS 1F3-41
With Pulse Generator
Tools Required 617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Item
Digital Tester
Without Pulse Generator Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3 Bosch, ETD 019.00Sun, DIT 9000
ALV, Diesel - Tester 875
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable vessel.
2. Install the Rl sensor into the governor housing of injection pump (1).
Rl Sensor 617 589 10 21 00
3. Connect the digital tester and TDC pulse sender unit according to connection diagram.
4. Run the engine at idle speed and check the Rl value on the digital tester Notice
If out of standard, adjust the start of delivery.
5. Stop the engine.
6. Remove the Rl sensor, digital tester and TDC pulse sender unit.
7. Replace the seal and tighten the plug.
8. Check engine oil level and adjust if necessary.
Rl value A TDC 14° - 16 °
Tightening Torque 30 Nm

SUSPENSION DIAGNOSIS 2A-3
DIAGNOSIS
GENERAL DIAGNOSIS
Checks
Loosened Mountings Damaged or Worn wheel BearingDamaged Shock Absorber
Damaged Tire Action
Retightening ReplaceReplaceReplace
Abnormal Noises
Checks
Broken Stabilizer Bar Faulty Shock Absorber Action
ReplaceReplace
Vehicle Rolling
Checks
Over Inflated Tire Faulty Shock Absorber Loosened wheel Nut Bent or Broken Coil Spring
Damaged TireWorn Bushing Action
Pressure Adjustment
Replace
Tighten as Specified ReplaceReplaceReplace
Poor Riding
Problems in the steering, the suspension, the tires, and the wheels involve several systems. Consider all systems when you diagnose a complaint. Some problems, suchas abnormal or excessive tire wear and scuffed tires,may by the result of hard driving. Always road test the
vehicle first. If possible, do this road test with the
customer. Proceed with the following preliminary checks. Correct any substandard conditions.
Checks
Incorrect Wheel Alignment Excessive Resistance of Lower Arm Ball Joint
Insufficient Tire PressureFaulty Power Steering
Action Repair
Replace Adjust
Repair or Replace
Hard Steering
Checks
Deformed Arm Assembly Worn BushingBent or Broken Coil SpringDifference Between L/H & R/H Heights Action
ReplaceReplaceReplace Adjust
Vehicle Pulls to Right or Left

2A-4 SUSPENSION DIAGNOSISChecks
Worn or Broken Coil Spring Checks
Incorrect Front wheel Alignment Worn or Loosened Lower Arm Bushing
Action
Replace
Repair or Replace
Steering Instability
Action
Replace
Vehicle Bottoming