2003 SSANGYONG MUSSO check engine

1F1-52 M162 ENGINE CONTROLS8. Remove the injectors and the fuel distributor carefully.
9. Installation should follow the removal procedure in the reverse order.
10. Check for fuel pressure and internal leakage by operating the engine.
Fuel Pressure Test
1. Turn the ignition switch to "OFF" position.
2. Remove the fuel pressure test connector.
Vacuum Hose Connected (bar) 3.2 - 3.6 Vacuum Hose Disconnected (bar) 3.7 - 4.2
5. Replace the pressure regulator diaphragm if out of the specification.
3. Connect the fuel pressure gauge to the fuel pressure test
connector.
4. Test the fuel pressure at idling by operating the engine.

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 1F1-55
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.
NoticeReplace 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 connectionbetween the ECU and the injector if the measured valuesare normal.
Specified Value 14 - 17

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 fromengine 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 Notice 3 Inlet
Tightening Torque
25 - 30 Nm
Tightening Torque 4 - 8 Nm

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 boltsand 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

M162 ENGINE CONTROLS 1F1-63
4. Remove the line to canister and measure the pressure withthe 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 Value0.3 - 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.