2003 SSANGYONG MUSSO ignition

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

1F1-36 M162 ENGINE CONTROLS
Location Engine ECU is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & Installation Procedure
1. Turn the ignition switch to "OFF" position.
2. Disconnect the battery negative cable
3. Remove the cowl side trim form passenger side.
4. Unscrew four securing nuts for ECU from mounting bracket.Installation Notice
5. Pulling out the ECU from bracket.
6. Disconnect the vehicle side coupling(B).
7. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm

M162 ENGINE CONTROLS 1F1-39
Engine Connector
Pin No.Abbreciation
Decription
61 62636465666768697071727374757677787980 EV5EV6EV1EV4EV2EV3
M+M-
TM.31
ZSC16 ZSA25ZSB34 NWS ----
MT
GND LT
Injector-cylinder 2Injector-cylinder 4Injector-cylinder 1Injector-cylinder 6Injector-cylinder 5Injector-cylinder 3E-GAS motor plusE-GAS motor minusPower ground TM.31Ignition coil cylinder 1+6Ignition coil cylinder 2+5Ignition coil cylinder 3+4Camshaft control----Engine coolant temperature
Temperature groundIntake air temperature

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