2003 SSANGYONG MUSSO service

M162 ENGINE CONTROLS 1F1-35
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
ECU Appearance
1 Cover
2 Plate
3 Connector
4 Flat Pin Vehicle Side : No. 1 - 12 Engine Side : No. 61 - 72 5 Pin
Vehicle Side : No. 13 - 60Engine Side : No. 73 - 120
A Vehicle Side Connector : Black
B Engine Side Connector : Gray

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.

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 1F1-61
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 1F1-77
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 - - -

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

1F3-16 OM600 ENGINE CONTROLSIdle Speed
750 - 850 rpm 720 - 820 rpm
EngineOM661LA EngineOM662LA Engine
Tools Required 667 589 00 21 00 TDC Pulse Generato
Commercial Tool
IDLE SPEED ADJUSTMENT Service Data
e.g. Bosch, MOT 001.03
Sun, DIT 9000
Digital Tester
Adjustment Procedure
1. Connect the digital tester (1) and TDC pulse sender unit
(11).
2. Run the engine and warm up the coolant to 60~80 °C.
TDC pulse generator 667 589 02 21 00
3. Disconnect the vacuum hose (4) from the PLA unit to check idle speed with tester.
4. Check idle speed with tester.
Notice
To adjust idle speed, loosen the locking nut (6) of PLA unit.
OM 661LA Engine 750 - 850rpm
OM 662LA Engine
720 - 820rpm