2003 SSANGYONG MUSSO Service Manual

M161 ENGINE ELECTRICAL 1E2-9
IGNITION CABLE Preceding Work : Removal of intake air duct
1 Control Cable Connection
2 Ignition Cable
3 Spark Plug Connector
4 Coupling Plug5a, 5b Secondary Voltage Connection
E Iron Core
L1 Secondary Ignition Coil
L2 Primary Ignition Coil

1E2-10 M161 ENGINE ELECTRICAL Ignition Cable and Cable Lay-out
1. Firing Order : 1-3-4-2
2. T1/1 : Connect the cylinder 1 + 4
3. T1/2 : Connect the cylinder 2 + 3
Removal & Installation Procedure
1. Disconnect the battery negative cable.
2. Unscrew the 3 screws and remove the ignition cable ductcover. Installation Notice
3. Seperate the cable from the ignition cable and the spark plug.
4. Remove the 2 bolts from each ignition cable and remove the ignition cables. Installation Notice Install the ignition cable to the cylinder 2 and 4 and connect the cable from 1 to 4, and from 2 to 3. - T1/1 : Cylinder 1 and 4- T1/2 : Cylinder 2 and 3
5. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm
Tightening Torque 9 - 11 Nm

M161 ENGINE ELECTRICAL 1E2-11
Inspection & Maintenance (for E2.3 MSE)
1. Measure the primary resistance between the cable terminals1 and 15 after removing the ignition cable wiring connector
(1 and 15) with ignition switch OFF. Notice Replace the ignition coil if out of the specified resistance.
T1/2 : between No.71 and No.69
Notice Check the ignition cable and the ECU if out of the
specified value.
3. Measure the secondary cable resistance between the ignition coil 5a and 5b using a multimeter.
2. Measure the primary voltage(T1/1) between the ECU
terminals No.72 and No.69 during the engine cranking (starter motor activated).
Specified Value 6 - 8.5 K
Specified Value0.9 - 1.6
Specified Value 200 - 350 V

1E2-12 M161 ENGINE ELECTRICALUNIT REPAIR
BATTERY
Inspection Notice
When charging the battery, do not leave the inflammable
objects around it.
When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects were found on it.
2. Check if the specific gravity of the electrolyte is within the specified value. Notice
Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
Measure the specific gravity in the approx. 20 °C
of ambient temperature.
3. Replenish the electrolyte if necessary. Battery Capacity(Ah)Battery Specific Gravity
Max. Tolerance between Cells
75
1.24
0.04

SECTION 1E3
OM600 ENGINE ELECTRICAL
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1E3-1General Specifications . . . . . . . . . . . . . . . . . 1E3-1
Maintenance and Repair . . . . . . . . . . . . . . 1E3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1E3-2
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 otherwisenoted.
Application
Alternator Starter Glow Plug
Description 12V - 75A
12V - 2.2kW
11.5V
SPECIFICATIONS
GENERAL SPECIFICATIONS
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3-2
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E3-6
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . 1E3-8

1E3-2 OM600 ENGINE ELECTRICAL
Preheating System General information The preheating system consists of control, coolant temperature sensor and glow plugs.
Control relay - preheating time.
Coolant temperature sensor.
Glow plug.
GLOW PLUG
1 Wiring Harness
2 Nut .............................................................. 4 Nm 3 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 :
Switching of preheating current.
Indication of preheating finish.
Control of preheating sequence.
Indication 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 Current 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.
Temperature 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.

1E3-4 OM600 ENGINE ELECTRICAL
Preheating System Operation
1. Preheating before start.Preheating time is different by coolant temperature and it is on until the glow indicator light goes off.
2. Preheating after start. Preheating continues for max. 60 seconds to rise in characteristic of warming-up on engine after starting too.
3. Monitoring on glow plug. Glow plugs are monitored by low current by the microprocessor in control relay respectively while running theengine. If glow indicator comes on after starting for about one minute,
it indicates on or several plugs are faulty.
Possible Cause
- One or several glow are faulty
Problem
Glow indicator does not come on in preheating time and comes on after starting the engine. Glow indicator does not come on while preheating and after starting engine. Glow indicator does not come on and engine
’s
starting is difficult or does not start at all. Glow indicator comes on after starting for about one minute.1 2 3 4 - Faulty glow indicator
- Faulty circuit of glow indicator
- Faulty control relay
- Circuits short in one or several glow plugs
- Faulty preheating circuits
- Faulty control relay
- One or several glow plugs are faulty