Fuel pump SSANGYONG MUSSO 2003 Owner's Manual

M162 ENGINE CONTROLS 1F1-13
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause
6.1 
Ignition:ON 0.1 - 0.3A
Cable
 Fuel pump relay
 ECU



Fuel pump
relay: - Current consumption
00, 01, 02, 06,
7.0 


Coolant
temperature sensor:- Voltage 79 78
Ignition:ON °CV
20 3.57
80 1.22
100 0.78 
7.1
 ECU
± 5%

6.0 
Ignition:ON
(Fuel pump relay will operate for 1 - 2seconds when theignition switch isturned to "ON" afterstopping the engine)
 Engine:cranking
33 11

Cable
 Fuel pump relay



Fuel pump
relay:- Operation
34, 11 - 14V
(approx.1- 2sec.)
11 - 14V
(Cranking or driving)
53 3
7.1 
Ignition:OFF
(Remove the No.2 coupling from ECU)
79 78 
7.2
 Cable



Coolant
temperature sensor:- Resistance & cable °
C
20 2500 80 322
100 185
± 5%
7.2 


Coolant
temperature sensor:- Resistance Coolant temperature
sensor:
14 Remove the
connector from coolant temperaturesensor and measurethe resistancebetween No.1 andNo.2 pin withmultimeter. 
refer to
specifiedresistancevalue of 7.1 
Coolant
temperaturesensor
34, 35,

1F1-30 M162 ENGINE CONTROLS
Failurecode ItemChecking method
Te s t
stepRequirementSpecified value Possible cause
3.2 - 3.6 bar



Fuel
pressure:in idling speed- When the vacuum isapplied 
Engine:in idling
- Close the valve screw on pressuretester
1.0 Connect the fuel
pressure test plug tothe pressure tester
(refer to the flgure on previous page). 
Fuel pump test
 Fuel pressure
regulator
3.7 - 4.2 bar



Fuel
pressure:in idling speed- When the vacuum isnot applied 
Engine:in idling
- Close the valve screw on pressuretester

2.0 Connect the fuel
pressure test plug tothe pressure tester
(refer to the flgure on previous page). 
Fuel pressure
regulator
> 3.0 bar



Fuel system
internalleakage: 
Engine:stop
3.0 Connect the fuel
pressure test plug tothe pressure tester
(refer to the flgure on previous page). 
The pressure drops
rapidly:non-returnvalve in fuel pump
> 2.5 bar

After 30 minutes from
engine stop 
The pressure drops
slowly: - Injector test- Fuel pressure regulator
- O-ring

M162 ENGINE CONTROLS 1F1-31
FUEL PUMP TEST Preparation
1 ECU
2 Test Coupling(No.1-60)
3 Test Coupling(No.61-120)
4 Stop Watch
5 Measuring Beaker
Connection of the Equipment
1. Turn the ignition switch to "OFF" position. 2. Connect the test box to the ECU. 0 3 Test Box
04 ECU Test Cable
Tools Required
103 589 00 21 00 Pressure Tester 210 589 00 99 00 Adaptor Line
129 589 00 21 00 Test Box
210 589 08 63 00 Ecu Test Cable

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

1F1-38 M162 ENGINE CONTROLS
Pin No.Abbreciation
Decription
21 222324252627282930313233343536373839404142434445464748495051525354555657585960 BRS
-----
KLIKU ---
GND
SP1+5V KP
TEV ML -
CAN L
CAN H -- - -
KPI
KLIMAKLIMA -
SP1SSP2S BLS
GND
SP2+2.5V S+BWA
S-B
KSK -
AUS
DIAG
V-SIG
TN-SIG
Brake switch-----Air conditioning clutch relay---Pedal potentiometer 1 groundPedal potentiometer 1 supplyFuel pump relay
Tank purge valveEngine fan (H1)-CAN-LowCAN-High-- - -Clutch switchAir conditioningElectronic traction signal-Pedal potentiometer 1 signalPedal potentiometer 2 signalBrake light switchPedal potentiometer 2 groundPedal potentiometer 2 supplyCruise accelerate/SetCruise resumeCruise decelerate/SetCruise safety contact switch-Cruise off switchDiagnostics (k-line)
Vehicle speed signalEngine speed signal

1F1-42 M162 ENGINE CONTROLS
Pin No.Description
Pedal potentiometer 1 ground Pedal potentiometer 1 supplyFuel pump relay
Tank purge valve Engine fan -CAN-LowCAN-High - - --Clutch switchAir conditioning Electronic traction signal(ABD) -Pedal potentiometer 1 signalPedal potentiometer 2 signalBrake light switchPedal potentiometer 2 ground Pedal potentiometer 2 supply Cruise accelerate/SetCruise resumeCruise decelerate/SetCruise safety contact switch - Cruise off switchDiagnostics(K-line)
Vehicle speed signalEngine speed signal31 323334 35 363738 39 40 41424344 45 4647484950 51 52535455 56 57585960GND
SP1+5V KP
TEV ML
-
CAN L
CAN H
- - --
KPL
KLIMA ETS
-
SP1SSP2S BLS
GND
SP2+2.5V
S+BWA
S-B
KSK -
AUS
DIAG
V-SIG
TN-SIG




-

- - --


-







-







-

- - --


-







-


Remarks
Abbreviation E32 ENG,
5speed M/T
E32 ENG,
4speed A/T (BTRA)

1F1-48 M162 ENGINE CONTROLSA . Valves Closed
B. Valves Opened
The pressure difference between the fuel pressure and the intake manifold is about 3.8 bars during the full load. The spring chamber(9) is connected to the intake manifold with the vacuum hose at the intake pipe connection(7). Thenegative pressure generated in the intake manifold activates the diaphragm, and thus the fuel pressure gets reduced to the rate of the operating extent of the diaphragm by the intakemanifold's negative pressure.
Consequently, the fuel pressure in the fuel distributor changes by the intake manifold's negative pressure, and the injector'sfuel pressure gets reduced independently to the throttle valve'sposition. Thus, the fuel injection volume can only be determined according to the injector's injecting duration. 2. Fuel return line
3. Valve
5. Diaphragm
6. Compression Spring
8. Fuel Chamber
9. Spring Chamber
1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return(to fuel tank)
4. Fuel Supply(form fuel pump)
5. Fuel Pressure(approx. 3.8 bars)
6. Intake Manifold Negative Pressure(0 bar)
Function of the Fuel Pressure Regulator The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3.2 bars to 3.8 bars according tothe intake manifold pressure. This operating pressure cannotbe changed, and the fuel injection volume will be only determined by the injection time. Over supplied fuel returns to the fuel tank through the return line. There is no negative pressure applied to the spring chamber(9) during the full load, and it is separated from the fuel chamber(8)by the diaphragm(5). When the fuel pressure goes up, the diaphragm forces the compression spring(6) in the direction of compression . At thismoment, the valve(3) sticks to the diaphragm by the fuelpressure, and the fuel return line(2) opens. The fuel over supplied returns to the fuel tank through the return line.

M162 ENGINE CONTROLS 1F1-49
The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. 1. Fuel Pressure Regulator
2. Intake Manifold
3. Fuel Return(to fuel tank)
4. Fuel Supply(from fuel pump)
7. Fuel Pressure(approx. 3.2 bars)
8. Intake Manifold Negative Pressure(0.6 bars)
A . Fuel pressure
B. Intake Manifold Negative Pressure
LL. Idling
TL. Partial load
V L . Full load

M162 ENGINE CONTROLS 1F1-53
3. If there is no change in fuel pressure and maintain thefollowing pressure over 30 minutes, it is normal.
Internal Leakage Test
1. Connect the fuel pressure gauge to the fuel pressure test
connector.
2. Stop the engine for approx. 30 minutes and then check the fuel pressure changes.
Fuel pressure
drops slowly 
Fuel leakage at the injector
 Faulty fuel pressureregulator'sdiaphragm and O- ring.
Fuel pressure
drops rapidly 
Faulty check valve in the fuel pump.
Possible Cause
Pressure Change
Fuel Pressure(bar) 2.5
Discharging the pressure in fuel system
1. Remove the fuel pressure test connector. Installation Notice
2. Remove the fuel pressure in fuel system by pressing the service valve with a clean, pointy tool. Notice Place a cloth so that the fuel doesn't stain around.
Tightening Torque 22.5 - 27.5 Nm

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