1998 SSANGYONG MUSSO sensor

1E3-2 OM600 ENGINE ELECTRICAL
Preheating System
General information
The preheating system consists of control, coolant temperature
sensor and glow plugs.
lControl relay - preheating time.
lCoolant temperature sensor.
lGlow plug.
GLOW PLUG
1 Wiring Harness
2 Nut .............................................................. 4 Nm3 Wire Terminal
4 Glow Plug
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE

OM600 ENGINE ELECTRICAL 1E3-3
1. Preheating time - control relay.
Control relay functions as followings :
lSwitching of preheating current.
lIndication of preheating finish.
lControl of preheating sequence.
lIndication of fault.
2. Coolant temperature sensor.
Coolant temperature sensor senses coolant’s temperature
and signals it to the preheating relay continuously.
3. Glow plug
The glow plug parts are housing with M12 ´ 1.25 thread
and heating pin in housing. It is connected in a parallel circuit
with the specified voltage of 11.5V.
The heating element has a heating coil and a control coil
and they are connected in series.
1. Control Coil
2. Heater Coil
4. Current and temperature of glow plug
lCurrent of glow plug
While the preheating system operates, current of about
30A flows in each glow plug and temperature of heating
coil rises very fast.
Due to the rise of temperature, the resistance of control
coil increases therefore the current is controlled to
about 8~15A and that protects the glow plug from over-
heating.
lTemperature of glow plug
The temperature of the glow plug reaches up to 900°C
after about 9 seconds and up to 1,050°C after 30
seconds.

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 cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
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 and
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 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 CONTROLS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Return and Supply Line
Fuel Distributor Assembly Bolt
Pressure Test Connector
Fuel Inlet and Outlet Line
Fuel Filter Mounting Bracket Bolt
Crankshaft Position Sensor Bolt
Camkshaft Position Sensor Bolt
Knock Sensor Mounting Bolt
Coolant Temperature BoltN·m
25 - 30
22.5 - 27.5
21.6 - 26.4
25 - 30
4 - 8
9 - 11
9 - 11
22.5 - 27.5
18 - 22

M162 ENGINE CONTROLS 1F1-7
41
44
45
56
57
58
59
60
62
64
65
66
67
71
72
73
74
75
76
77
78
79
80
81
82
83
86
87
89 00
01
02
03
04
05
08
09
10
11
17
18
19
20
21
23
24
25
26
27
29
30
31
34
35
40
Failure
codeDescription
Coolant temperature sensor open
Coolant temperature sensor short
Coolant temperature sensor signal failure
Intake temperature sensor open
Intake temperature sensor short
Intake temperature sensor signal failure
Low battery voltage
HFM sensor signal failure
HFM 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 failure
CAN communication failure : ASR
-
Transponder signal failure
CAN communication failure : TCU(A/T only)
CAN communication failure : TOD(E32 only)
-
-
CAN communication failure :
communication initialization failure
Fuel pump relay short(PWR)
Fuel pump relay open/short(GND)
Purge valve short
Failure
codeDescription
Purge valve open/short
Condenser fan(HI) relay short(PWR)
Condenser fan(HI) relay short(GND)
No.1 knock sensor signal failure
No.2 knock sensor signal failure
No.1 cylinder synchronization failure
-
-
Cluster S/W defectave
No 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 failure
Start signal recognition failure
No.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 voltage
Low oxygen sensor amplifying voltage
Oxygen 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 CONTROLS
Cruise control acceleration failure
Cruise control deceleration failure
ECU failure(RAM)
ECU failure(EPROM)
Servo motor control output inter-ruption
memory failure
Servo motor open/short
Unprogramed 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 voltage
High pedal valve sensor SP1 voltage
Low pedal valve sensor SP2 voltage
High pedal valve sensor SP2 voltage
Different pedal valve sensor signal(1,2)
Pedal valve sensor 1,2 failure
HFM sensor, and throttle position sensor
failure
ECU 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 between
CPUs)
No.5 injector short(PWR) 93
96
97
98
99
100
101
102
103
104
105
108
109
11 0
11 6
11 7
11 9
120
121
122
123
125
126
127
129
130
131
132Short learning control failure
Lambda 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) voltage
High throttle position sensor(IP1) voltage
Low throttle position sensor(IP2) voltage
High throttle position sensor(IP2) voltage
Throttle actuator learning data fault
Throttle actuator learning control failure
Exceed fuel-cut safety time
Throttle valve return spring failure
Cruise control interruption memory failure
Throttle actuator failure
Pedal module position sensor signal failure
Different HFM signal with throttle potentiometer
Both throttle potentiometer(IP1&IP2) failure
IPS1 with IPS2
High permanent throttle signal
Message counter failure® cruise control ’OFF’
Vehicle speed signal failure
Vehicle speed signal failure
Cruise control lever failure133
134
136
137
139
140
141
142
143
144
145
146
150
151
160
161
162
163
164
167
185
186
187
188
189
190
192
Failure
codeDescriptionFailure
codeDescription

M162 ENGINE CONTROLS 1F1-9
234
235
236
237
238
239
240
241
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) 193
194
195
198
199
226
227
228
229
232
233
Failure
codeDescriptionFailure
codeDescription
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)

1F1-12 M162 ENGINE CONTROLS
Failure
codeItem
09,
10,
11,
Checking method Te s t
stepRequirementSpecified
valuePossible cause
Þ 4.0· ·· ·
· HFM sensor
signal
105 81· Ignition:ON0.9 - 1.1V· Þ 4.1 - 4.3
· Cable
· External air inflow
· HFM sensor
· Engine:in Idle
(Coolant temperature
: > 70°C )
: voltage value is
increased when
engine rpm is
increased1.3 - 1.7V
Þ 4.1
105 4
· Ignition:ON
· HFM sensor
connector removed4.7 - 5.2V
· Cable
· ECU coupling
· ·· ·
· HFM sensor:
- 5V power
supplyHFM
sensor
Þ 4.2
3 108· Ignition:ON
· HFM sensor
connector removed4.7 - 5.2V
· Þ 4.3
· Cable
· ·· ·
· HFM sensor:
- 5V power
supplyHFM
sensor
Þ 4.3
104 2· Ignition:ON
· HFM sensor
connector removed11 - 14V
· Cable
· OVPR
· ·· ·
· HFM sensor:
- 12V power
supplyHFM
sensor
03,
04,
05,Þ 5.0· ·· ·
· Intake air
temperature
sensor:
- Voltage105 80· Ignition:ON· Þ 5.1
· ECU
± 5%
Þ 5.1· Ignition:OFF
· No.2 ECU coupling
removed 105 80
· Cable
· HFM sensor
· ·· ·
· Intake air
temperature
sensor:
- Resistance°C
10
20
30
40
50
60
± 5%W
3600
2420
1662
1166
853
600 °C
10
20
30
40
50
60V
3.1
2.65
2.18
1.76
1.4
1.1