2003 SSANGYONG MUSSO fuel

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)

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

M162 ENGINE CONTROLS 1F1-47
3. Disconnect the vacuum hose.
4. Disconnect the circlip and remove the fuel pressureregulator.
5. Apply the oil to O-ring lightly and then replace it.
6. Installation should follow the removal procedure in the reverse order.
7. Check for fuel pressure and internal leaks by operating the engine.
2. Discharge the pressure in fuel supply system by pressing
the service valve.
Removal & Installation Procedure
1. Remove the fuel pressure test connector.

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

1F1-50 M162 ENGINE CONTROLS1 Vacuum Hose
2 Fuel Return Line ................................... 25-30Nm
3 Fuel Supply Line ................................... 25-30Nm
4 Injector Connector
FUEL DISTRIBUTOR Preceding Work : Removal of intake air duct
5 Bolt (M8 X 50)
................................ 22.5-27.5 Nm
6 Fuel Distributor
7 O-ring .................................. Replace if damaged
8 Injector

M162 ENGINE CONTROLS 1F1-51
Removal & Installation Procedure
1. Discharge the fuel pressure from the fuel pressure testconnector.
2. Disconnect the battery ground cable.
3. Disconnect the vacuum hose from the fuel pressure regulator.
4. Remove the cable guide.
5. Remove the fuel return and supply line.
Notice
For removal, cover around parts with cloths not to be
stained by fuel.
In case of checking the injector only, do not remove the
fuel return and supply line.
Installation Notice
6. Remove the six injector connectors.
7. Remove the two left and two right bolts and one center bolt of the fuel distributor assembly from the intake manifold. Installation Notice
Tightening Torque 25 - 30 Nm
Tightening Torque 22.5 - 27.5 Nm

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.