engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1F2-48 M161 ENGINE CONTROLS
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

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

1F2-54 M161 ENGINE CONTROLS
INJECTOR
Preceding Work : Removal of fuel distributor
1 O-ring .................................Replace, if damaged
2 Injector Bracket
3 Injector4 O-ring .................................Replace, if damaged
5 Fuel Distributor

M161 ENGINE CONTROLS 1F2-55
Removal & Installation Procedure
1. Remove the O-ring.
Check for damage and replace it if necessary.
2. Remove the injector bracket from the injector.
Installation Notice
Exactly seat the anti-twist lock into the square groove in
injector.
3. Separate the injector from the fuel distributor.
Inspection & Maintenance
Inspection of the Injector operation and spray pattern
1. Connect the contact box to the ECU.
2. Connect the shop made test plug to the injector and place
it into the tank.
3. Position the ignition switch to ON.
4. Connect the pin 63(+) and 69(-) of the contact box with a
test cable.
5. Check the injector spray pattern.
Notice
Replace the injector if the injector spray pattern is abnormal
or the fuel doesn't inject.
Injector Resistance Inspection
1. Remove the injector connector.
2. Measure the injector coil resistance using a resistance
tester.
Notice
Replace the injector if the measured values is out of the
specified values. Check the connector and wire connection
between the ECU and the injector if the measured values
are normal.
Specified Value
14 - 17 W

1F2-56 M161 ENGINE CONTROLS
The Injector Spray Pattern Check
1. Connect the test box (129 589 00 21 00) to the ECU.
2. Disconnect the connector from connector.
3. Disconnect the fuel distributor and injector with a unit from
engine without removing the fuel supply and return line.
Notice
Prepare the beaker for taking the poping fuel.
4. Connect either end of shop made cable to the injector.
5. Connect the other end of shop made cable to the (+:63)
and (-:69) terminal of the test box.
6. Turn the ignition switch to "ON" position.
7. Check the injector for normal spray pattern as shown in the
figure. Check injector for leaks or later drops.
Notice
Refer to fuel injector test of engine diagnosis in this section
for detailed information.

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