1998 SSANGYONG MUSSO fuel pressure

M161 ENGINE CONTROLS 1F2-49
FUEL DISTRIBUTOR
Preceding Work : Removal of intake air duct
1 Fuel Distributor
2 Circlip
3 Fuel Pressure Regulator
4 O-ring
5 Fuel Pressure Test Connector
6 Seal Ring
7 Vacuum Hose
8 Combination Bolt (M8 X 120).........22.5-27.5 Nm9 Fuel Return Line
10 Seal Ring
11 Hollow Bolt.....................................22.5-27.5 Nm
1 2 Clamp
13 Bolt (M8 X 22)........................................ 9-11 Nm
14 Injector Bracket
15 Injector
16 O-ring

1F2-50 M161 ENGINE CONTROLS
Tightening Torque
22.5 - 27.5 Nm
Tightening Torque22.5 - 27.5 Nm
Removal & Installation Procedure
1. Discharge the fuel pressure from the fuel pressure test
connector by pushing service valve (arrow).
2. Disconnect the battery ground cable.
3. Disconnect the vacuum hose from the fuel pressure
regulator.
4. Disconnect the cable from ignition coil.
5. Remove the fuel return and supply line.
Installation Notice
Notice
lFor removal, cover around parts with cloths not to
bestained by fuel.
lIn case of checking the injector only, do not remove the
fuel return and supply line.
6. Remove the four injector connectors (arrows).
7. Unscrew the two combination bolts (8).
Installation Notice

M161 ENGINE CONTROLS 1F2-51
9. Installation should follow the removal procedure in the
reverse order.
10. Check for fuel pressure and internal leakage by operating
the engine. 8. Pull out the injector from intake manifold and remove the
fuel distributor.
Notice
Replace the injector O-ring with new one.
Ignition Coil & Cable
lIgnition coil T1/1 No.1 cylinder + No.4 cylinder
lInition coil T1/2 No.1 cylinder + No.4 cylinder

1F2-52 M161 ENGINE CONTROLS
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.

M161 ENGINE CONTROLS 1F2-53
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

M161 ENGINE CONTROLS 1F2-57
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 out (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

1F2-58 M161 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)

1F2-64 M161 ENGINE CONTROLS
1 Purge Switchover Valve
2 Molded Hose
3 Fuel Tube (270 mm)
4 Clamp
5 Molded Hose
6 Intake Manifold
7 Throttle Body
VACUUM SYSTEM
Manual Transmission
8 Fuel Pressure Regulator
9 Vacuum Line Rubber Hose (40 mm)
10 Vacuum Tube (Gray, 540 mm)
11 Rubber Cap
12 Molded Hose
13 Vacuum Tube (Brown)
14 Connector