engine SSANGYONG MUSSO 2003 Service Manual

1F1-76 M162 ENGINE CONTROLS 2. Measure the resistance between the coolant temperaturesensor terminal No.1 and No.4 with the coolant temperature sensor disconnected.
Inspection 1. Measure the coolant sensor input voltage between the ECU
terminal No.79 and No.78 while the ignition switch in "ON" position. Notice Replace wiring and coolant temperature sensor if out of specified value. allowable error :
±5%
allowable error : ±5%
Voltage (V)
3.57 1.220.78
Temperature (
°C)
203040
Resistance (W) 2,500322 185
Temperature (
°C)
203040

M162 ENGINE CONTROLS 1F1-77
Service Data Resistance characteristic curve according to the coolant temperatureTemperature(
°C) Resistance(W) Voltage(V) Temperature( °C) Resistance(W) Voltage(V)
-40 48,550 4.8991 60 594 1.8632
-30 27,000 4.8214 70 434 1.5132
-20 15,670 4.7001 80 322 1.2179
-10 9,450 4.5215 90 243 0.9775 0 5,890 4.4273 100 185 0.7806
10 3,790 3.9562 110 143 0.6255
20 2,500 3.5714 120 111.6 0.5020
30 1,692 3.1426 130 88.0 0.4044
40 1,170 2.6959 140 71.2 0.3323 50 826 2.2618 - - -

1F1-78 M162 ENGINE CONTROLS
ACCELERATOR PEDAL MODULE1 Accelerator pedal
2 Accelerator pedal Sensor
3 Bolts (2 Pieces) ....................................... 4-8 Nm
Removal and Installation Procedure
1. Disconnect the 6-pin connector(arrow).
2. Unscrew the 2 bolts (3) / 1 nut (6) and remove the pedal
and sensor assembly. Installatoin Notice
Tightining Torque 4 - 8 Nm
2. Installation should follow the removal procedure in thereverse order. 4 6-Pin Connector
5 Kick down Switch
6 Nut (1 piece)
............................................ 4-8 Nm

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