1998 SSANGYONG MUSSO air condition

1A2-8 GENERAL ENGINE INFORMATION
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating
conditoins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to
the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined n order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange must
be repaired also. Before attempting to repair a leak,
check for the following conditions and correct them as
they may cause a leak.
Gaskets
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe fasteners are tightened improperly or the threads
are dirty or damaged.
lThe flanges or the sealing surface is warped.
lThere are scratches, burrs or other damage to the
sealing surface.
lThe gasket is damaged or worn.
lThere is cracking or porosity of the component.
lAn improper seal was used (where applicable).
Seals
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe seal bore is damaged (scratched, burred or
nicked).
lThe seal is damaged or worn.
lImproper installation is evident.
lThere are cracks in the components.
lThe shaft surface is scratched, nicked or damaged.
lA loose or worn bearing is causing excess seal wear.
DIAGNOSIS

GENERAL ENGINE INFORMATION 1A2-13
Leakage Test
1. Warm the engine up to normal operating temperature.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant surge tank
cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the scale
of tester.
7. Install the connecting hose to spark plug hole.
9. Connect the connecting hose to tester and measure the
leakage volume after blowing up 5bar of compressed air.
Notice
Measure the leakage volume in the completely opening
condition of throttle valve by pulling the acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order : 1 - 3 - 4 - 2
11. Compare the leakage pressure with the specifications.8. Position the piston of No.1 cylinder at TDC by rotating the
crankshaft.

1A3-10 GENERAL ENGINE INFORMATION
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following
procedures may help you in locating and repairing
most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine
oil, automatic transmission fluid, power steering
fluid, etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large
sheet of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be
necessary to clean the suspected area with a
degreaser, steam or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at
normal operating temperature and varying
speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot
powder) to the suspected area.
3. Operate the vehicle under normal operating
conditions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer
to the manufacturer's directions when using the kit.1. Pour the specified amount of dye into the engine
oil fill tube.
2. Operate the vehicle normal operating conditions
as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must
be determined n order for it to be repaired properly. If
a gasket is replaced, but the sealing flange is bent,
the new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
leak, check for the following conditions and correct
them as they may cause a leak.
Gaskets
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe fasteners are tightened improperly or the
threads are dirty or damaged.
lThe flanges or the sealing surface is warped.
lThere are scratches, burrs or other damage to the
sealing surface.
lThe gasket is damaged or worn.
lThere is cracking or porosity of the component.
lAn improper seal was used (where applicable).
Seals
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe seal bore is damaged (scratched, burred or
nicked).
lThe seal is damaged or worn.
lImproper installation is evident.
lThere are cracks in the components.
lThe shaft surface is scratched, nicked or damaged.
lA loose or worn bearing is causing excess seal
wear.
DIAGNOSIS

M162 ENGINE MECHANICAL 1B1-17
Operation at Idling and Mid-Load
lIt show that the throttle valve (19) is closed or very partially
opened and the vacuum pressure in intake manifold is high.
The blowby gas in the crankcase in partial load flows into
the intake manifold through the vent line (20) after passing
the air conditioner bracket (6) and the filter (4). The air
reentered into the intake manifold will be dilluted on the flow
through the restriction hole (11) in the vent line (10).
The circulated engine oil is separated at the air conditioner
bracket (6) and then returns into the oil pan through the
drain pipe (7).
The vacuum pressure generated at the crankcase sucks
fresh air from intake air line(13) through the air admission
and vent connection (17,18).
The fresh air prevents engine oil from being contami-nated
and the air admission and vent connection (17,18) is
designed to control the rapid pressure changes in intake
air line (13).
Operation at Full-Load
lThe throttle valve (19) is fully opened.
All the blowby gases flow into the intake air duct (13) after
passing through the oil separator (15,16) of the cylinder
head cover (14) when fully loaded. This dilluted air will be
supplied to the combustion chamber through the intake
manifold (12).

1B1-50 M162 ENGINE MECHANICAL
Installation Notice
lMake sure the crankshaft bearing cap properly seated
in place in the crankcase side. When perfectly installed,
the projected part (arrow) locates in the left side (intake
manifold side).
lAssemble so that the projected part of the cap and
crankcase face the same direction.
Removal & Installation Procedure
1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice
2. Unscrew the crankshaft bearing cap bolts and separate the
upper and lower bearing shells and thrust washers.
Installation Notice
lRemove the bearing cap from front (pulley side) to rear.
lMake sure that the upper and lower bearing shells do
not change each other and coat with engine oil.
lThe oil grooves (arrows) in the thrust washers must face
outward and insert the thrust bearing into the bearing
cap.
lThere are five kinds of thrust washers by thickness. Select
the proper washer when repaired.
3. Remove the crankshaft.
4. Installation should follow the removal procedure in the
reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
lMake sure that the upper and lower bearing shells do
not change each other.
lCoat the bearing shell with engine oil.
lInstall the bearing cap according to the consecutive
number.
Part No. : 601 030 00 622.15 mm
Part No. : 601 030 01 622.20 mm
Part No. : 601 030 02 622.25 mm
Part No. : 601 030 03 622.30 mm
Part No. : 601 030 04 622.40 mm
Tightening Torque 40 Nm + 90°
Tightening Torque 55 Nm + 90°

M161 ENGINE MECHANICAL 1B2-17
CRANKCASE VENTILATION SYSTEM
Operation at Idling and Mid-Load
1 HFM Sensor
2 Cylinder Head Cover
3 Oil Spearation Chamber (Full-Load or Over
Mid-Load)
4 Intake Air Duct (Cross Pipe)
5 Vent Line (Full-Load or Over Mid-Load)
6 Throttle Valve
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold
9 Vent Line (Mid-Load at Idling)
10 Air Conditioner Bracket11 Oil Separation Chamber (Mid-Load at Idling)
12 Crank Chamber
13 Oil Return Pipe
14 Oil Pan
15 Timing Gear Case Cover
16 Crankcase
17 Chain Housing
A Fresh Air
C Blow-by Gas
D Vent Connection

1B2-18 M161 ENGINE MECHANICAL
Operation at Idling and Mid-Load
lThe throttle valve(6) is closed or very partially opened, and
the vacuum pressure in intake manifold is high.
The blow-by gas and the fresh air that is additionally supplied
through the vent connection(D) in the crankcase in partial
load gets supplied to the combustion chamber from the crank
chamber(12) through the oil separation chamber(11), air-
conditioner bracket(10), vent line(9), and restrictor(7)
mounted to the cylinder head.
The circulated engine oil returns to the oil pan through the
oil return pipe(13) at the bottom of oil separation
chamber(11).
The fresh air gets supplied to the crank chamber(12) through
the HFM sensor(1), intake air duct(4), vent line(5), oil
separation chamber(3), chain housing(17), and the timing
gear case cover(15).
The additional supply of the fresh air is needed to prevent
from forming the residues of the engine oil.

M161 ENGINE MECHANICAL 1B2-19
Operation When Full-Load at Partial Load
1 HFM Sensor
2 Cylinder Head Cover
3 Oil Spearation Chamber (Full-Load or Over
Mid-Load)
4 Intake Air Duct (Cross Pipe)
5 Vent Line (Full-Load or Over Mid-Load)
6 Throttle Valve
7 Restrictor, Diameter 1.1mm (Mid-Load at Idling)
8 Intake Manifold
9 Vent Line (Mid-Load at Idling)
10 Air Conditioner Bracket11 Oil Separation Chamber (Mid-Load at Idling)
12 Crank Chamber
13 Oil Return Pipe
14 Oil Pan
15 Timing Gear Case Cover
16 Crankcase
17 Chain Housing
A Fresh Air
C Blow-by Gas
D Vent Connection