2003 SSANGYONG MUSSO sensor

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

OM600 ENGINE CONTROLS 1F3-37
START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD)1 Position Sensor
2 Battery
3 Fuel Injection Pump 4 Seal
....................................................... Replace
5 Screw Plug ................................................. 30Nm
Service Data
Start of Delivery (RIV) ATDC 14° - 16 °

1F3-38 OM600 ENGINE CONTROLS
Tools Required 617 589 08 21 00 Position Sensor
Test Procedure
1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel.
2. Install the position sensor (1) into the governor housing of
the injection pump to be the guide pin of the position sensor facing up.
3. Connect the battery terminal of position sensor (1) to positive terminal (+) of battery.
Position Sensor 617 589 08 21 00
4. Rotate the crankshaft by hand (in direction of engine rotation) until the lamp ‘B’ lights up. Rotate the crankshaft carefully
further until both lamps ‘A and B ’ come on. In this position,
check the Rl value on the crankshaft vibration damper. Notice If only lamp ‘A’ lights up, repeat the test and if out of
specification, adjust start of delivery.
Specification A TDC 14° - 16 °

OM600 ENGINE CONTROLS 1F3-39
Digital Tester, RIV Method
(Connection Diagram for Testers Without Adapter)
1 Fuel Injection Pump
2 Rl Sensor
3 Digital Tester4 TDC Pulse Sender Unit
5 Battery

1F3-40 OM600 ENGINE CONTROLSStart of Delivery (RIV) Idle Speed
(Connection Diagram for Testers With Adapter)
1 Fuel Injection Pump
2 Rl Sensor
3 Digital Tester
4 TDC Pulse Sender Unit
5 Battery
6 Rl Pulse Generator
Service Data
ATDC 14° - 16 °
OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm

OM600 ENGINE CONTROLS 1F3-41
With Pulse Generator
Tools Required 617 589 09 21 00 Rl Sensor
617 589 10 21 00 Timing Tester667 589 00 21 00 TDC Pulse Generator
Commercial Tools
Item
Digital Tester
Without Pulse Generator Tools
Bosch, MOT 001.03
Hartmann & Braun, EOMT3 Bosch, ETD 019.00Sun, DIT 9000
ALV, Diesel - Tester 875
Test Procedure
1. Remove the screw plug (7) and seal (8) collect oil in a suitable vessel.
2. Install the Rl sensor into the governor housing of injection pump (1).
Rl Sensor 617 589 10 21 00
3. Connect the digital tester and TDC pulse sender unit according to connection diagram.
4. Run the engine at idle speed and check the Rl value on the digital tester Notice
If out of standard, adjust the start of delivery.
5. Stop the engine.
6. Remove the Rl sensor, digital tester and TDC pulse sender unit.
7. Replace the seal and tighten the plug.
8. Check engine oil level and adjust if necessary.
Rl value A TDC 14° - 16 °
Tightening Torque 30 Nm