2003 SSANGYONG MUSSO check engine

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

1F1-28 M162 ENGINE CONTROLS
AIR CONDITIONER CONTROL SYSTEM TEST
2.0 
Engine:In idling
 Air conditioner
switch : ON/OFF Air conditionerswitch : OFFAir conditionerswitch : ONCoolant temperature:above 105 °C
10 35
11 - 14 V 11 - 14 V
< 1 V



Condenser
fan(HI) control: Condenser fan
relay
 Fan motor
 ECU
Failure
code Item

1.0
Checking method
 Engine:In idling
 Air conditioner
switch : ON/OFF
Air conditioner switch : OFFAir conditionerswitch : ON
Te s t
stepRequirement
Specified value Possible cause
10 44 < 1 V



Air
conditioner signal:- Input signal (input signalfrom thermoamplifier)
44, 45,
11 - 14 V
5.1
 Cable
 Thermo amp
 Auto amp
 Dual pressure
switch
 Air conditioner
control panel
1.1 
Engine:In idling
 Air conditioner
switch : ON/OFFAir conditionerswitch : OFFAir conditionerswitch:ON
10 27
< 1 V



Air
conditionercompressor:- Output signal
11 - 14 V 
Thermo amp
 Auto amp
 Dual pressure
switch
 Air conditioner
control panel
 ECU

1F1-30 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause
3.2 - 3.6 bar



Fuel
pressure:in idling speed- When the vacuum isapplied 
Engine:in idling
- Close the valve screw on pressuretester
1.0 Connect the fuel
pressure test plug tothe pressure tester
(refer to the flgure on previous page). 
Fuel pump test
 Fuel pressure
regulator
3.7 - 4.2 bar



Fuel
pressure:in idling speed- When the vacuum isnot applied 
Engine:in idling
- Close the valve screw on pressuretester

2.0 Connect the fuel
pressure test plug tothe pressure tester
(refer to the flgure on previous page). 
Fuel pressure
regulator
> 3.0 bar



Fuel system
internalleakage: 
Engine:stop
3.0 Connect the fuel
pressure test plug tothe pressure tester
(refer to the flgure on previous page). 
The pressure drops
rapidly:non-returnvalve in fuel pump
> 2.5 bar

After 30 minutes from
engine stop 
The pressure drops
slowly: - Injector test- Fuel pressure regulator
- O-ring

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

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 1F1-51
Removal & Installation Procedure
1. Discharge the fuel pressure from the fuel pressure testconnector.
2. Disconnect the battery ground cable.
3. Disconnect the vacuum hose from the fuel pressure regulator.
4. Remove the cable guide.
5. Remove the fuel return and supply line.
Notice
For removal, cover around parts with cloths not to be
stained by fuel.
In case of checking the injector only, do not remove the
fuel return and supply line.
Installation Notice
6. Remove the six injector connectors.
7. Remove the two left and two right bolts and one center bolt of the fuel distributor assembly from the intake manifold. Installation Notice
Tightening Torque 25 - 30 Nm
Tightening Torque 22.5 - 27.5 Nm