1998 SSANGYONG MUSSO fuel pressure

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
VL. Full load

M162 ENGINE CONTROLS 1F1-51
Removal & Installation Procedure
1. Discharge the fuel pressure from the fuel pressure test
connector.
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
lFor removal, cover around parts with cloths not to be
stained by fuel.
lIn 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 Torque25 - 30 Nm
Tightening Torque 22.5 - 27.5 Nm

1F1-52 M162 ENGINE CONTROLS
8. 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 the
following 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 pressure
regulator's
diaphragm 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 1F1-57
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)

1F1-64 M162 ENGINE CONTROLS
VACUUM SYSTEM
1 Purge Control Valve
2 Molded Hose
3 Insulator
4 Fuel Tube
5 Molded Hose
6 Idle Regulator
7 Resonance Flap
8 Intake Manifold
9 Fuel Pressure Regulator10 Vacuum Line Rubber Hose
11 Vacuum Tube(Gray, 270mm)
12 Molded Hose
13 Rubber Cap
18 Rubber Hose
19 Vacuum Tube(Brown or Black, 770mm)
20 Rubber Hose
A To Canicter

SECTION 1F2
M161 ENGINE CONTROLS
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 otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F2-2
Fastener Tightening Specifications . . . . . . . . 1F2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1F2-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1F2-3
Schematic and Routing Diagrams . . . . . . . 1F2-4
E23 ECU (MSE) . . . . . . . . . . . . . . . . . . . . . . 1F2-4
E23 ECU (HFM) . . . . . . . . . . . . . . . . . . . . . . 1F2-5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-6
Self Diagnosis Socket Pin Numbers and
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 1F2-6
Self Diagnosis Failure Code (for E23 ENG) . 1F2-7
Test Box Connection . . . . . . . . . . . . . . . . . . 1F2-10
Fuel Injection System Test . . . . . . . . . . . . . 1F2-11
Ignition System Test . . . . . . . . . . . . . . . . . . 1F2-20
Idling Control and Electronic Pedal
System Test . . . . . . . . . . . . . . . . . . . . . . . 1F2-25
Air Conditioner Control System Test . . . . . . 1F2-27
Fuel Pressure and Internal Leakage Test . . 1F2-28
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F2-30Injector Test . . . . . . . . . . . . . . . . . . . . . . . . 1F2-32
Maintenance and Repair . . . . . . . . . . . . . 1F2-34
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F2-34
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-34
Fuel Pressure Regulator . . . . . . . . . . . . . . 1F2-45
Fuel Distributor . . . . . . . . . . . . . . . . . . . . . . 1F2-49
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-54
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-57
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F2-58
Purge Switchover Valve . . . . . . . . . . . . . . . 1F2-62
Vacuum System . . . . . . . . . . . . . . . . . . . . . 1F2-64
Crankshaft Position Sensor . . . . . . . . . . . . 1F2-66
Camshaft Position Sensor . . . . . . . . . . . . . 1F2-68
Hot Film Air Mass (HFM) Sensor . . . . . . . . . 1F2-70
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 1F2-73
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 1F2-75
Coolant Temperature Sensor . . . . . . . . . . . 1F2-76
Accelerator Pedal Module . . . . . . . . . . . . . . 1F2-79