2003 SSANGYONG MUSSO engine coolant

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 cablewill help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
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 andDescriptions . . . . . . . . . . . . . . . . . . . . . . . . 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 CONTROLSSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Return and Supply Line Fuel Distributor Assembly Bolt
Pressure Test ConnectorFuel Inlet and Outlet LineFuel Filter Mounting Bracket Bolt Crankshaft Position Sensor Bolt Camkshaft Position Sensor BoltKnock Sensor Mounting Bolt
Coolant Temperature BoltN m
25 - 30
22.5 - 27.5 21.6 - 26.4 25 - 304 - 8
9 - 11
9 - 11
22.5 - 27.5 18 - 22

M162 ENGINE CONTROLS 1F1-7
41 44455657 58 59606264 65 66677172 73 74757677 78 79808182 83 86 8789
0001 02 0304 05 08091011 17 1819 20 21 2324 25 26272930 31 34 3540
Failure
code Description
Coolant temperature sensor open Coolant temperature sensor shortCoolant temperature sensor signal failureIntake temperature sensor openIntake temperature sensor short Intake temperature sensor signal failure Low battery voltageHFM sensor signal failureHFM 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 failureCAN communication failure : ASR-
Transponder signal failure CAN communication failure : TCU(A/T only)CAN communication failure : TOD(E32 only)-- CAN communication failure : communication initialization failureFuel pump relay short(PWR)Fuel pump relay open/short(GND)Purge valve short
Fa
ilure
code Description
Purge valve open/short Condenser fan(HI) relay short(PWR)Condenser fan(HI) relay short(GND)No.1 knock sensor signal failureNo.2 knock sensor signal failure No.1 cylinder synchronization failure --Cluster S/W defectaveNo 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 failureStart signal recognition failureNo.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 voltageLow oxygen sensor amplifying voltageOxygen 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

1F1-12 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