2003 SSANGYONG MUSSO fuel pressure

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.

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 1F1-57
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 Notice 3 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 Pressure3.8 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 Pressure 5.0 bar (12 V) Maximum Allowable Current
7.5 A
Nominal Voltage12 VAmbient 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 Supply 165 Liter/Hr (12V, 3.8 bar,
-30 ~ +70 °C)

1F1-64 M162 ENGINE CONTROLS
VACUUM SYSTEM1 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 Regulator
10 Vacuum Line Rubber Hose11 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 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 1F3-5
VACUUM CONTROL SYSTEM TEST
2 Engine Cut-Off Valve (Ignition Key Switch)
3 Auto-locking Hub Solenoid Valve
4 Engine Stop Valve Unit
5 PLA Vacuum Unit (Idle Speed Adjustment)
6 Engine
7 Vacuum Pump830
° Thermovalve
9 Fuel Injection Pump
10 Filter with Restriction
11 Check V alve
12 Modulating Pressure Line (Automatic T/M)
Test Data
Idle Speed Increase Permissible Pressure Drop of System At least 100 rpm at approx. 500mbr
400 - 500mbar approx. 1 min.

1F3-12 OM600 ENGINE CONTROLS
Test Procedure
1. Remove the fuel filter (1) and keep the filter not to be damaged from running engine.
2. Remove the vacuum line (2) from ancillaries connection (3).
3. Connect the vacuum tester (4) to the ancillaries connection (3).
Vacuum Tester 201 589 13 21 00
4 Run the engine at idle and check vacuum pressure after 30 sec. Notice If out of standard, replace the vacuum pump.
5. Remove the vacuum tester.
6. Connect the vacuum line to the ancillaries connection.
7. Install the fuel filter.
Standard > 70 mbar