SSANGYONG MUSSO 2003 Service Manual

M162 ENGINE CONTROLS 1F1-79
Accelerator Pedal Sensor Connector(Sensor Side)
Potentiometer 1.Pin no. 3 :Red
Pin no. 1 :YellowPin no. 5 :Brown
Potentiometer 2. Pin no. 6 :VioletPin no. 4 :GreenPin no. 2 :White
Accelerator Pedal Sensor Connector(Vehicle Side)
Potentiometer 1.Pin no. 3 :Red-Black Pin no. 1 :Blue-Green
Pin no. 5 :Yellow-Green
Potentiometer 2. Pin no. 6 :GreenPin no. 4 :Blue-RedPin no. 2 :LightGreen
Function Potentiometer 1, Power Supply(+)
Potentiometer 1, Signal
Potentiometer 2, Ground
Potentiometer 2, Power Supply(+)
Pin no. 3 Pin no. 1 Pin no. 5 Pin no. 6
Pin no. 4 Pin no. 2Potentiometer 2, SignalPotentiometer 2, Ground
Circuit Diagram
Potentiometer 1. Potentiometer 2.

SECTION 1F3
OM600 ENGINE CONTROLS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F3-1Fastener Tightening Specifications . . . . . . . . 1F3-1
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15Idle Speed Adjustment . . . . . . . . . . . . . . . .
1F3-16
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F3-18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-21
Injection Nozzle Test . . . . . . . . . . . . . . . . . . 1F3-22
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . 1F3-25
Injection Nozzle Repair . . . . . . . . . . . . . . . . 1F3-27
Removal and Installation of Injection Timing Device . . . . . . . . . . . . . . 1F3-30
Injection Timing Device . . . . . . . . . . . . . . . . 1F3-35
Start of Delivery Test (Position Sensor, RIV Method) . . . . . . . . . 1F3-37
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 1F3-46
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.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Tank Mounting Nut Fuel Pump Pressure Line Fuel Injection NozzleFuel Injection Pipe
Nozzle Tensioning NutScrew Plug Left-Hand Thread Bolt
N· m
28 - 47 13
35 - 40 18 8030 46

1F3-2 OM600 ENGINE CONTROLS
FUEL SYSTEM
1 Fuel Injection Pump
2 Fuel Feed Pump
3 Overflow Valve
4 Injection Nozzle
5 Pre-filter 6 Fuel Return Hose
7 Injection Line
8 Fuel Tank
9 Fuel Filter
10 Choke Orifice
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE

OM600 ENGINE CONTROLS 1F3-3
FUEL INJECTION PUMP CODING Model Code
PES 4M 55C 320 RS 167 PES 5M 55C 320 RS 168
Fuel Injection Pump Code Example) PES 5M 55C 320 RS 168
P Pump
E Self-Driven
S End Flange Mounting
5 Number of Cylinders (5EA)
M Pump Size
55 Element Diameter
C Modification Letter
320 Assembly Number
R Direction of Rotation (clockwise)
S188 Special Version
RSF Governor
R Governor
S Coil Spring
F Drive Governor
Component Location
1. Fuel Injection Pump
2. Vacuum Unit (Stop Unit)
3. Control Lever
4. PLA Vacuum Unit (Idle Speed Adjustment)
5. Governor
6. Fuel Pump
OM661 LA Engine OM662 LA Engine

1F3-4 OM600 ENGINE CONTROLS
FUEL TANK
1 Fuel Tank
2 The Sender of Fuel Tank
3 2-way Check Valve
4 Pre Filter
5 Front Fuel Filler Neck
6 Rear Fuel Filler Neck
7 Fuel Supply Tube 8 Fuel Return Tube
9 Filter Hose
10 Fuel Tank Hose
11 Fuel Filler Cap
12 Clip
13 Clip

OM600 ENGINE CONTROLS 1F3-5
VACUUM CONTROL SYSTEM TEST
2 Engine Cut-Off Valve (Ignition Key Switch)
3 Auto-locking Hub Solenoid Valve
4 Engine Stop Valve Unit
5 PLA Vacuum Unit (Idle Speed Adjustment)
6 Engine
7 Vacuum Pump830
° Thermovalve
9 Fuel Injection Pump
10 Filter with Restriction
11 Check V alve
12 Modulating Pressure Line (Automatic T/M)
Test Data
Idle Speed Increase Permissible Pressure Drop of System At least 100 rpm at approx. 500mbr
400 - 500mbar approx. 1 min.

1F3-6 OM600 ENGINE CONTROLSTemperature measuring instrument with test probe WB24
Digital tester
Tools Required
001 589 73 21 00 Vacuum Pump
201 589 13 21 00 Vacuum Tester
667 589 00 21 00 TDC pulse generator
Commercial Tools
e.g. Bosch MOT 001.03
Sun DIT 9000
e.g. Ahlborn, Therm 2263-2
Eichenfeldstrabe 1 - 3D-8150 Holzkirchen
Tester Connection
11 TDC Pulse Sender Unit
12 Digital Tester

OM600 ENGINE CONTROLS 1F3-7
Vacuum 500 mbar
Lines and connections leaking. Faulty PLA vacuum unit.
Test step 1
Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run engine at idle speed.YES NO
(Remove the connection hose from vacuum pump)
Connect vacuum pump (14) direct to PLA vacuum unit(5) and pressurize with vacuum.
Vacuum is built up and idle speed increases approx. 150-200 rpm
YES NO
Faulty PLA vacuum unit
(Coolant Temperature 30 °C)
Stop the engine Seal the air admission line with plug. Connect the vacuum pump to line to thermovalve andpressurize the line with vacuum.
Vacuum is built up.
YES NO
Lines and connectors leaking. Faulty thermovalve.
=
>

1F3-8 OM600 ENGINE CONTROLS
Detach line downstream of air admission filter (13).Vacuum drops.
Faulty thermovalve
Fit the line onto air admission filter. Built up vacuum with vacuum pump. Detach the plug from air admission line. Vacuum drops.
Faulty filter with restriction.
Go to test step 2.
YES
NO
YES NO

OM600 ENGINE CONTROLS 1F3-9
Test step 2
Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run the engine at idle speed.
Vacuum drops to ‘0’ at approx. 30 °C of the thermovalve.
Faulty thermovalve.
Defective filter with restriction.
Stop the engine. Detach the filter with restriction. Filter with restriction is clear.
Defective filter with restriction.
YES
NO
YES NO