engine SSANGYONG MUSSO 2003 Service Manual

1F1-56 M162 ENGINE CONTROLS
The Injector Spray Pattern Check 1. Connect the test box (129 589 00 21 00) to the ECU.
2. Disconnect the connector from connector.3. Disconnect the fuel distributor and injector with a unit fromengine without removing the fuel supply and return line. Notice Prepare the beaker for taking the poping fuel.
4. Connect either end of shop made cable to the injector.
5. Connect the other end of shop made cable to the No.21 (+:63)and No.3(-:69) terminal of the test box.
6. Turn the ignition switch to "ON" position.
7. Check the injector for normal spray pattern as shown in the figure. Check injector for leaks or later drops. Notice Refer to fuel injector test of engine diagnosis in this section for detailed information.

M162 ENGINE CONTROLS 1F1-57
FUEL FILTER
1 Fuel Filter
2 Outlet
Removal & Installation Procedure
1. Open the fuel tank cap and remove the fuel tank pressure.
2. Remove the fuel at (2) and in (3). Installation Notice Notice Place the fuel pump pad. There may be a corrosion due to the contact between the fuel filter and the bracket.
4. Check for leaks by operating the engine.
Notice Installation should follow the removal procedure in the
reverse order.
3. Remove the mounting bracket bolt (4) and remove the fuel
filter (1). Installation Notice 3 Inlet
Tightening Torque
25 - 30 Nm
Tightening Torque 4 - 8 Nm

1F1-58 M162 ENGINE CONTROLS
FUEL PUMP
Requirements for Fuel Pump
ItemSpecified ValueItemSpecified Value
System Pressure3.8 bar
Minimum Delivery at 8V 30 Litre/Hr
Maximum Pressure 8.5 bar (12 V)
Minimum Amount of Fuel Supply 114 Liter/Hr (12 V, 3.8 bar, -
30 ~ +70 °C)
Minimum Pressure 5.0 bar (12 V) Maximum Allowable Current
7.5 A
Nominal Voltage12 VAmbient Temperature -30 ~ +70°C
1 Reservoir Tank
2 Fuel Sensor (float/arm)
3 Resistance
4 Wiring Connector
5 Fuel Supply Pipe
7 Float
10 Flange and Harness Assembly 11 Fuel Pump
12 Spring
13 Thermister Housing
14 Thermister
15 Resistor Card and Wiper
16 Float Arm
Operating Voltage 8 V
Maximum Amount of Fuel Supply 165 Liter/Hr (12V, 3.8 bar,
-30 ~ +70 °C)

M162 ENGINE CONTROLS 1F1-59
1 2 3 4
1 Fuel Pump Connector Wiring
2 Fuel Return Pipe
3 Fuel Supply Pipe
4 Bolts5 Fuel Return Pipe
6 Fuel Supply Pipe
7 Float
8 Ground Stud (Sender "-")
COLOR
Pump "+"
Thermister "+"
Ground
Sender Unit "+" USE
Harness Location & Connector
A B
CD
2.0 BR 0.5 W
2.0 B
0.5 RY

1F1-60 M162 ENGINE CONTROLS
Tools Required 661 589 00 46 00 Cap Remover Removal & Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the harness connector (1).
3. Disconnect the fuel supply (6) and return (5) pipes.
4. Using a special tool, Unscrew the eight fuel retaining boltsand remove the pump from fuel tank. Notice
Check the condition of the seal and replace if necessary. Drain the fuel before removing the pump.

M162 ENGINE CONTROLS 1F1-61
Notice Replace the fuel pump relay if the measured value is over 9A.
Notice Check the fuel filter and fuel line when the fuel delivery is not within specified value.
Measure the Current Consumption of Fuel Pump
1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to "ON" position.
2. Using a multi-tester, measure the current consumption by connecting the terminal No.1 and No.3 of pump.
Measure the Fuel Delivery From the Fuel Pump
1. Disconnect the return pipe from fuel distributor and insert
the appropriate hose into it.
2 . Place the hose end into the beaker with the minimum capacity of 1Liter.
3. Turn the ignition switch to "ON" position.
4. Connect the terminal No.33 and No.5 of ECU with a service wire.
5. Measure the fuel delivery from the fuel pump.
1Liter/max.35sec.
Specifed Value
5 - 9A
Specifed Value

1F1-62 M162 ENGINE CONTROLS
PURGE SWITCHOVER VALVE
1 Purge Switchover Valve
2 Line to Engine
3 Line to Canister
4 Canister
Functions The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. Thefuel vaporized gas that is accumulated in the canister abstractsthrough the purge switchover valve purification during the engine combustion (except the decreasing mode) and coolant temperature of over 80 °C. For this reason, the ECU transacts
the engine speed, air inflow quantity, coolant temperature, andintake temperature. The purge switchover valve is activated by the ECU frequency according with the engine rotating speed to adjust the purification rate. The purification rate is determined by the continuous valve opening interval. The purge switchover valve is activated by the ECU for the following conditions :
Coolant temperature of over 80 °C
Engine speed of over 1000rpm
2 Minutes after starting
When the fuel cut-off mode is not activated

M162 ENGINE CONTROLS 1F1-63
4. Remove the line to canister and measure the pressure withthe vacuum pressure gauge.
Test
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECU terminal No.11 and No.34 and check for normal operation through the output waves using the
scanner. Notice
Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on.
3. Connect the ECU terminal No.34 and No.10 and check for current consumption during the ignition switch ON.
Purge switchover valve output wave
Specified Value0.3 - 0.5
Specified Value > 50mbar
(after approx. 1min.)
purge switchover valve operates at this time
Notice
Test while at normal temperature and at idling state by operating the engine.

1F1-64 M162 ENGINE CONTROLS
VACUUM SYSTEM1 Purge Control Valve
2 Molded Hose
3 Insulator
4 Fuel Tube
5 Molded Hose
6 Idle Regulator
7 Resonance Flap
8 Intake Manifold
9 Fuel Pressure Regulator
10 Vacuum Line Rubber Hose11 Vacuum Tube(Gray, 270mm)
12 Molded Hose
13 Rubber Cap
18 Rubber Hose
19 Vacuum Tube(Brown or Black, 770mm)
20 Rubber Hose A To Canicter

M162 ENGINE CONTROLS 1F1-65
1 Crankshaft Position Sensor
2 Bolt (M6 X 14)........................................ 9 -11Nm
CRANKSHAFT POSITION SENSOR
Removal & Installation Procedure
1. Disconnect the wiring connector at the crankshaft position
sensor.
2. Unscrew the bolt and remove the crankshaft position sensor unit. Installation Notice
3. Installation should follow the removal procedure in the reverse order. 3 Segment
4 Flywheel
Tightening Torque 9 -11Nm