2003 SSANGYONG MUSSO engine

GENERAL ENGINE INFORMATION 1A1-5
PERFORMANCE CURVE
E32 ENGINE

1A1-6 GENERAL ENGINE INFORMATIONSPECIAL TOOLS
SPECIAL TOOLS TABLE
000 589 10 99 01 Torque Wrench
001 589 76 21 00
Compression Pressure Tester 119 589 01 09 00
Spark Plug Wrench 001 589 65 09 00
Socket

GENERAL ENGINE INFORMATION 1A1-7
OIL LEAK DIAGNOSIS Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing thenecessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following proceduresmay 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 forleaks. A mirror is useful for finding leaks in areas thatare hard to reach.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steamor 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 agasket 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 asthey may cause a leak. Gaskets
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The fasteners are tightened improperly or the threads are dirty or damaged.
The flanges or the sealing surface is warped.
There are scratches, burrs or other damage to thesealing surface.
The gasket is damaged or worn.
There is cracking or porosity of the component.
An improper seal was used (where applicable).
Seals
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The seal bore is damaged (scratched, burred or nicked).
The seal is damaged or worn.
Improper installation is evident.
There are cracks in the components.
The shaft surface is scratched, nicked or damaged.
A loose or worn bearing is causing excess seal wear.
DIAGNOSIS

1A1-8 GENERAL ENGINE INFORMATION
ENGINE CRANKING AT THE FRONT OF CRANKSHAFT Preceding Work : Removal of cooling fan
1 Vibration Damper Assembly
2 Crankshaft Pulley
Notice
Remove the negative ground cable before proceeding the work.
Rotate the pulley in normal engine rotating direction when cranking. 3 Bolt
................................................. 8.6 ± 0.9 Nm
Tools Required
000 589 10 99 01 Torque wrench001 589 65 09 00 Socket

GENERAL ENGINE INFORMATION 1A1-9
COMPRESSION PRESSURE TEST
1 Compression Pressure Tester
2 Diagram Sheet3 Adaptor
4 Sealing Cone
Tools Required
001 589 76 21 00 Compression Pressure Tester
119 589 01 09 00 Spark Plug Wrench Standard Service Data
Compression Ratio
Normal Engine TemperatureNormal Compression Pressure Permissible Pressure Difference Between Individual Cylinders
10 : 180°C
Min. 10 bar, Max. 14 bar
Min. 6 bar, Max. 10 bar Max. 1.5 bar
General Fuel Optimization

1A1-10 GENERAL ENGINE INFORMATION Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs.
3. Place the diagram sheet to compression pressuretester.
4. Connect the adaptor to compression pressure tester and install it into the spark plug hole.
5. Crank the engine approx. eight revolutions by using the start motor.
6. Compare the measurements of compression pressure tester with the specifications.
7. Measure the compression pressure of the other cylinders in the same way.
8. If measured value is not within the specifications, perform the cylinder pressure leakage test. Notice
Discharge the combustion residues in the cylinders
before testing the compression pressure.
Apply the parking brake before cranking the
engine.

GENERAL ENGINE INFORMATION 1A1-11
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap
4 Vibration Damper
Permissible Pressure Leakage 6 Cylinder Pressure Leakage T
ester with
Connecting Hose
Universal Tool
At Whole Engine
At Valve and Cylinder Head GasketAt Piston and Piston RingMax. 25 % Max. 10 %Max. 20 %
Cylinder Number By Mark On Vibration Damper At TDC
TDC Mark
Cylinder Numberb (240°)
3, 4a (120°)2, 5
OT (TDC)
1, 6
Cylinder Pressure Leakage Tester Bosch, EFAW 210A
Sun, CLT 228

1A1-12 GENERAL ENGINE INFORMATION
Leakage Test1. 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 - 5 - 3 - 6 - 2 - 4
11. Compare the leakage pressure with the specifications. 8. Position the piston of No.1 cylinder at TDC by rotating the
crankshaft.