ignition SSANGYONG MUSSO 2003 Repair Manual

M162 ENGINE CONTROLS 1F1-43
Pin No.
61 626364 65 666768 69 70 71727374 75 7677787980 81 82838485 86 87888990
Description
Injector-cylinder 2 Injector-cylinder 4Injector-cylinder 1Injector-cylinder 6 Injector-cylinder 5 Injector-cylinder 3E-GAS motor plusE-GAS motor minus Power ground TM.31 Ignition coil cylinder 1+6 Ignition coil cylinder 2+5Ignition coil cylinder 3+4Camshaft control- - --Engine coolant temperature
Temperature groundIntake air temperature Hot film air mass signal --E-GAS potentiometer groundE-GAS potentiometer 2 signal - E-GAS potentiometer 1 signal---EV5 EV6EV1EV4 EV2 EV3M+M-
TM.31
ZSC16
ZSA25ZSB34 NWS - - --
MT
GND LT
HFM
--
GND IP2S -
IP1S ---












- - --



--

-
- - -












- - --



- -

-
--- Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

M162 ENGINE CONTROLS 1F1-45
Removal & Installation Procedure
when removing the ECU only
1. Turn the ignition switch to "OFF" position.
2. Disconnect the negative battery cable.
3. Disconnect the couplings from ECU.
4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket and remove the auxiliarly bracket from the bracket assembly (2). Installation Notice
5. Unscrew the four bolts (5) and disconnect the ECU (6) from the bracket assenbly. Installation Notice
6. Installation should follow the removal procedure in the reverse order.
Tightening Torque 6 - 8 Nm
5 - 7 Nm(1) (3)
Tightening Torque 5 - 7 Nm
8. Unscrew the bolts (5) and disconnect the ECU (6) from the bracket assenbly. Installation Notice

When Removing the ECU with ABS or ABS/ASR Unit
1. Turn the ignition switch to "OFF" position.
2. Disconnect the negative battery cable.
3. Disconnect the couplings from ECU.
4. Disconnect the coupling from ABS or ABS/ASR unit.
5. Unscrew the bolt (1) and the left and right flange nuts.
6. Remove the ECU with ABS or ABS/ASR unit assembly.
7. Unscrew the left and right bolt (3) on the auxiliary bracket and remove the auxiliary bracket from the bracket assembly. Installation Notice
Tightening Torque 6 - 8 Nm
Tightening Torque 5 - 7 Nm
Tightening Torque 5 - 7 Nm
9. Installation should follow the removal procedure in the reverse order.

1F1-52 M162 ENGINE CONTROLS8. Remove the injectors and the fuel distributor carefully.
9. Installation should follow the removal procedure in the reverse order.
10. Check for fuel pressure and internal leakage by operating the engine.
Fuel Pressure Test
1. Turn the ignition switch to "OFF" position.
2. Remove the fuel pressure test connector.
Vacuum Hose Connected (bar) 3.2 - 3.6 Vacuum Hose Disconnected (bar) 3.7 - 4.2
5. Replace the pressure regulator diaphragm if out of the specification.
3. Connect the fuel pressure gauge to the fuel pressure test
connector.
4. Test the fuel pressure at idling by operating the engine.

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

1F1-56 M162 ENGINE CONTROLS
The Injector Spray Pattern Check 1. Connect the test box (129 589 00 21 00) to the ECU.
2. Disconnect the connector from connector.3. Disconnect the fuel distributor and injector with a unit fromengine without removing the fuel supply and return line. Notice Prepare the beaker for taking the poping fuel.
4. Connect either end of shop made cable to the injector.
5. Connect the other end of shop made cable to the No.21 (+:63)and No.3(-:69) terminal of the test box.
6. Turn the ignition switch to "ON" position.
7. Check the injector for normal spray pattern as shown in the figure. Check injector for leaks or later drops. Notice Refer to fuel injector test of engine diagnosis in this section for detailed information.

M162 ENGINE CONTROLS 1F1-61
Notice Replace the fuel pump relay if the measured value is over 9A.
Notice Check the fuel filter and fuel line when the fuel delivery is not within specified value.
Measure the Current Consumption of Fuel Pump
1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to "ON" position.
2. Using a multi-tester, measure the current consumption by connecting the terminal No.1 and No.3 of pump.
Measure the Fuel Delivery From the Fuel Pump
1. Disconnect the return pipe from fuel distributor and insert
the appropriate hose into it.
2 . Place the hose end into the beaker with the minimum capacity of 1Liter.
3. Turn the ignition switch to "ON" position.
4. Connect the terminal No.33 and No.5 of ECU with a service wire.
5. Measure the fuel delivery from the fuel pump.
1Liter/max.35sec.
Specifed Value
5 - 9A
Specifed Value

M162 ENGINE CONTROLS 1F1-63
4. Remove the line to canister and measure the pressure withthe vacuum pressure gauge.
Test
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECU terminal No.11 and No.34 and check for normal operation through the output waves using the
scanner. Notice
Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on.
3. Connect the ECU terminal No.34 and No.10 and check for current consumption during the ignition switch ON.
Purge switchover valve output wave
Specified Value0.3 - 0.5
Specified Value > 50mbar
(after approx. 1min.)
purge switchover valve operates at this time
Notice
Test while at normal temperature and at idling state by operating the engine.

1F1-66 M162 ENGINE CONTROLS Crankshaft Position Sensor Resistance Inspection
1. Disconnect the coupling "E" of ECU while the ignition switchis in "OFF" position.
2. Measure the resistance between the coupling terminal pin No.99 and No.100 using a multimeter. Notice Measure the insulator resistance of the crankshaft position sensor if out of the specified value.
Crankshaft Position Sensor Output Wave Inspection
1. Connect the test box to the ECU.
2. Measure the output wave between the ECU terminals No.99 and No.100 using the scanner or the oscilloscope while engine cranking (starter motor activated). Notice Check the segment or crankshaft position sensor and air gap if cannot get the output wave as shown in the figure.
Specified Value 1050 - 1400
Specified Value > 20k
Crankshaft Position Sensor Insulator Resistance Inspection
1. Disconnect the engine coupling from ECU while the ignition
switch is in "OFF" position.
2. Measure the resistance between the coupling terminal pin No.100 and No.69. Notice Measure the check and ground terminal of the crankshaft position sensor if out of the specified value.

1F1-68 M162 ENGINE CONTROLS Camshaft Position Sensor Power Supply Inspection
1. Turn the ignition switch to 'ON' position.
2. Disconnect the camshaft position sensor connector.
3. Measure the voltage between the No.1 and No.3 pin ofcamshaft position sensor while the ignition switch is in "ON" position. Notice If the measured value is not within the specified value, check the cable.
Notice The signal voltage will be changed in the range of 1.2 -
1.7V.
Camshaft Position Sensor Output Wave Inspection
1. Connect the test box to the ECU.
2. Measure the output wave between the ECU terminal No.104 and No.106 using the scanner or the oscilloscope while the engine speed is at idle. Notice Replace the camshaft position sensor if cannot get the output wave as shown in the figure.
Specified Value 11 - 14 V
Specified Value 1.2 - 1.7 V
Camshaft Position Sensor Signal Voltage Inspection
1. Connect the test box to the ECU.
2. Measure the voltage between the ECU terminal No.11 andNo.106 while the engine speed is at idle.

M162 ENGINE CONTROLS 1F1-73
Oxygen Sensor Signal Voltage Inspection
1. Measure the oxygen sensor signal voltage between the ECUterminal No.11 and No.9. Maintain the engine speed ia at idle while the coolant temperature is over 80 °C.
If the measured value is not within the specified value, thepossible cause may be in cable, oxygen sensor or ECU.
Oxygen Sensor Heating Voltage Inspection
1. Measure the oxygen sensor heating voltage between the ECU terminal No.11 and No.9. Maintain the engine speed ia at idle while the coolant temperature is over 80 °C.
If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECU.
Oxygen Sensor Heating Current Consumption
Inspection
1. Measure the oxygen sensor heating current consumption between the ECU terminal No.9 and No.5 while the ignition switch is in "ON" position. If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECU.
Specified Value 0.2 - 2.0 A
Specified Value -0.2 - 1.0 V
Specified Value 11 - 14