fuel SSANGYONG MUSSO 2003 Workshop 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,

M162 ENGINE CONTROLS 1F1-29
FUEL PRESSURE AND INTERNAL LEAKAGE TEST
01 Pressure Tester
02 Pressure Hose
03 Measuring Beaker
Preparation Connection of the Equipment
1. Turn the ignition switch to "OFF" position.
2. Remove the air cleaner cross pipe.
3. Remove the cap on fuel pressure test plug and connect the
pressure hose and pressure tester.
4. Prepare the beaker for measuring the amount of fuel.
Tools Required
103 589 00 21 00 Pressure Tester
119 589 04 63 00 Pressure Hose

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

M162 ENGINE CONTROLS 1F1-33
Connection of the Equipment
1. Connect the test box to the ECU as shown in the figure.
2. Remove the 2-pin coupling from injector.
3. Remove the fuel distributor and injector with a unit. At thistime, do not remove the supply and return line.
4. Connect the shop made cable to the injector with a firing order.
5. Collect the fuel from injector.
INJECTOR TEST
1 ECU
2 Test Coupling(No.1-60)
3 Test Coupling(No.61-120)
4 Measuring Beaker
5 Shop Made Cable
Preparation
0 3 Test Box
04 ECU Test Cable
Tools Required
129 589 00 21 00 Test Box
210 589 08 63 00 Ecu Test Cable

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

1F1-38 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




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

1F1-46 M162 ENGINE CONTROLS1 Vacuum Hose
2 Circlip
3 Fuel Pressure Regulator
FUEL PRESSURE REGULATOR
4 O-ring ..................................................... replace
5 O-ring ..................................................... replace