1998 SSANGYONG MUSSO Workshop Repair Manual

M162 ENGINE CONTROLS 1F1-55
Removal & Installation Procedure
1. Remove the O-ring.
Check for damage and replace it if necessary.
2. Remove the injector bracket from the injector.
Installation Notice
Exactly seat the anti-twist lock into the square groove in
injector.
3. Separate the injector from the fuel distributor.
Inspection & Maintenance
Inspection of the Injector operation and spray pattern
1. Connect the contact box to the ECU.
2. Connect the shop made test plug to the injector and place
it into the tank.
3. Position the ignition switch to ON.
4. Connect the pin 63(+) and 69(-) of the contact box with a
test cable.
5. Check the injector spray pattern.
Notice
Replace the injector if the injector spray pattern is abnormal
or the fuel doesn't inject.
Injector Resistance Inspection
1. Remove the injector connector.
2. Measure the injector coil resistance using a resistance
tester.
Notice
Replace the injector if the measured values is out of the
specified values. Check the connector and wire connection
between the ECU and the injector if the measured values
are normal.
Specified Value
14 - 17 W

1F1-56 M162 ENGINE CONTROLS
The Injector Spray Pattern Check
1. Connect the test box (129 589 00 21 00) to the ECU.
2. Disconnect the connector from connector.
3. Disconnect the fuel distributor and injector with a unit from
engine without removing the fuel supply and return line.
Notice
Prepare the beaker for taking the poping fuel.
4. Connect either end of shop made cable to the injector.
5. Connect the other end of shop made cable to the No.21
(+:63)and No.3(-:69) terminal of the test box.
6. Turn the ignition switch to "ON" position.
7. Check the injector for normal spray pattern as shown in the
figure. Check injector for leaks or later drops.
Notice
Refer to fuel injector test of engine diagnosis in this section
for detailed information.

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 Notice3 Inlet
Tightening Torque
25 - 30 Nm
Tightening Torque
4 - 8 Nm

1F1-58 M162 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)

M162 ENGINE CONTROLS 1F1-59
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

1F1-60 M162 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.

M162 ENGINE CONTROLS 1F1-61
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

1F1-62 M162 ENGINE CONTROLS
PURGE SWITCHOVER VALVE
1 Purge Switchover 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