engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1F2-58 M161 ENGINE CONTROLS
FUEL PUMP
Requirements for Fuel Pump
ItemSpecified ValueItemSpecified Value
System pressure
3.8 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 pressure5.0 bar (12 V)
Maximum allowable current 7.5 A
Nominal voltage
12 V
Ambient 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 supply165 Liter/Hr (12V, 3.8 bar,
-30 ~ +70°C)

M161 ENGINE CONTROLS 1F2-59
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
C
D
2.0 BR
0.5 W
2.0 B
0.5 RY

1F2-60 M161 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 bolts
and remove the pump from fuel tank.
Notice
Check the condition of the seal and replace if necessary.
Drain the fuel before removing the pump.

M161 ENGINE CONTROLS 1F2-61
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

1F2-62 M161 ENGINE CONTROLS
PURGE SWITCHOVER VALVE
1 Purge Control 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. The
fuel vaporized gas that is accumulated in the canister abstracts
through 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, and
intake 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 :
lCoolant temperature of over 80°C
lEngine speed of over 1000rpm
l2 Minutes after starting
lWhen the fuel cut-off mode is not activated

M161 ENGINE CONTROLS 1F2-63
4. Remove the line to canister and measure the pressure with
the 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 Value
0.3 - 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.

1F2-64 M161 ENGINE CONTROLS
1 Purge Switchover Valve
2 Molded Hose
3 Fuel Tube (270 mm)
4 Clamp
5 Molded Hose
6 Intake Manifold
7 Throttle Body
VACUUM SYSTEM
Manual Transmission
8 Fuel Pressure Regulator
9 Vacuum Line Rubber Hose (40 mm)
10 Vacuum Tube (Gray, 540 mm)
11 Rubber Cap
12 Molded Hose
13 Vacuum Tube (Brown)
14 Connector

M161 ENGINE CONTROLS 1F2-65
15 Manual Transmission
16 Distributor
Automatic Transmission
A. To Canister
B. To Auto Locking Hub

1F2-66 M161 ENGINE CONTROLS
1 Crankshaft Position Sensor (connector)
2 Bolt (M6 X 14)........................................ 9-11 Nm
CRANKSHAFT POSITION SENSOR
Removal & Installation Procedure
1. Disconnect the wiring connector at the crankshaft position
sensor.
2. Unscrew the bolt (2) and remove the crankshaft position
sensor unit (3).
Installation Notice
3. Installation should follow the removal procedure in the
reverse order.3 Sensor Unit
Tightening Torque 9 - 11 Nm

M161 ENGINE CONTROLS 1F2-67
Crankshaft Position Sensor Resistance
Inspection
1. Disconnect the coupling "E" of ECU while the ignition switch
is in "OFF" position.
2. Measure the resistance between the coupling terminal pin
No.99 and No.100 using a multimeter.
Notice
Measure the insulator resistance of the crankshaft position
sensor if out of the specified value.
Crankshaft Position Sensor Output Wave
Inspection
1. Connect the test box to the ECU.
2. Measure the output wave between the ECU terminals No.99
and No.100 using the scanner or the oscilloscope while
engine cranking (starter motor activated).
Notice
Check the segment or crankshaft position sensor and air
gap if cannot get the output wave as shown in the figure.
Specified Value 1050 - 1400 W
Specified Value > 20kW
Crankshaft Position Sensor Insulator Resistance
Inspection
1. Disconnect the engine coupling from ECU while the ignition
switch is in "OFF" position.
2. Measure the resistance between the coupling terminal pin
No.100 and No.69.
Notice
Measure the check and ground terminal of the crankshaft
position sensor if out of the specified value.