engine oil SSANGYONG MUSSO 1998 Workshop User Guide

GENERAL ENGINE INFORMATION 1A1-3
COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor
2 Intake Air Duct
3 Resonance Flap
4 Cylinder Head Cover
5 Exhaust Camshaft
6 Intake Camshaft
7 Cylinder Head
8 Spark Plug Connector
9 Valve Tappet
10 Injector
11 Exhaust Valve12 Intake Manifold
13 Connecting Rod
14 Exhaust Manifold
15 Crankshaft
16 Engine Mounting Bracket
17 Starter
18 Crankcase
19 Oil Pump Sprocket
20 Oil Strainer
21 Oil Pan
22 Drain Plug

1A1-4 GENERAL ENGINE INFORMATION
23 Camshaft Adjuster
24 Cooling Fan and Viscous Clutch
25 Piston
26 Flywheel of Drive Plate27 Oil Pump Drive Chain
28 Oil Return Pipe
29 Timing Chain
30 Oil Pump
SIDE VIEW

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 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 1A1-11
CYLINDER PRESSURE LEAKAGE TEST
3 Engine Oil Filler Cap
4 Vibration Damper
Permissible Pressure Leakage
6 Cylinder Pressure Leakage Tester with
Connecting Hose
Universal Tool
At Whole Engine
At Valve and Cylinder Head Gasket
At 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 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 - 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.

GENERAL ENGINE INFORMATION 1A1-13
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating of
enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop practice
even if not specifically stated.
Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when they were removed.Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.
ON-ENGINE SERVICE
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 otherwise noted.
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against
accidental entrance of foreign material, which could
follow the intake passage into the cylinder and cause
extensive damage when the engine is started.

SECTION 1
ENGINE
SECTION 1A2(M161 ENGINE)
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1A2-1
Engine Specifications . . . . . . . . . . . . . . . . . . 1A2-1
Component Locator . . . . . . . . . . . . . . . . . . 1A2-3
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-3
Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-4
Performance Curve . . . . . . . . . . . . . . . . . . 1A2-5
E23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-5
E20 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1A2-7
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1A2-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A2-8
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . 1A2-8
Engine Cranking At The
Front of Crankshaft . . . . . . . . . . . . . . . . . . 1A2-9
Compression Pressure Test . . . . . . . . . . . . 1A2-10
Cylinder Pressure Leakage Test . . . . . . . . . 1A2-12
General Information . . . . . . . . . . . . . . . . . 1A2-14
Cleanliness and Care . . . . . . . . . . . . . . . . . 1A2-14
On-Engine Service . . . . . . . . . . . . . . . . . . . 1A2-14
E20 Engine
M161.940
1998
89.9 x 78.7
¬
9.6:1
¬
¬
¬
135 / 5500
19.3 / 4000
¬
¬
¬
ATDC 13.15° / ABDC 13.57°
BBDC 16.58° / BTDC 17.05°
¬ Application
Engine Model
Displacement (CC)
Cylinder (Bore x Stroke) (mm)
Fuel Injection / Ignition System
Compression Ratio
Number of Cylinders
Camshaft Valve Arrangement
Camshaft Drive Type
Max. Output (ps/rpm)
Max. Torque (kg•m/rpm)
Firing Order
Ignition Type
Ignition Timing
Valve Timing Intake Open/Close
ExhaustOpen/Close
Valve Clearance Adjustment
SPECIFICATIONS
ENGINE SPECIFICATIONS
E23 Engine
M161.970
2295
90.9 x 88.4
MSE 3.53S
10.4:1
4
DOHC
Chain-Driven
149 / 5500
22.4 / 4000
1-3-4-2
Distributorless
BTDC 6° ± 2°
ATDC 19.25° / ABDC 28.76°
BBDC 20.62° / BTDC 15.08°
Automatic Control

1A2-2 GENERAL ENGINE INFORMATION
E20 Engine
¬
¬
¬
¬
¬
¬ Application
Idle Speed (rpm)
Fuel Injection Pressure (kg/cm²)
Oil Capacity (liter)
Lubrication Type
Oil Filter Type
Fuel
ENGINE SPECIFICATIONS (Cont'd)
E23 Engine
750 ± 50
3.2 - 4.2
7.5
Forced by Gear Pump
Full Flow with Paper Filter
Unleaded Gasoline
MSE 3.62S/3.53S (Motorsteuer Elektronik : German)
MSE : Engine Control Electronic
3.62S : 6 cylinder version
3.53S : 4 cylinder version

GENERAL ENGINE INFORMATION 1A2-3
COMPONENT LOCATOR
FRONT VIEW
1 HFM Sensor
2 Intake Air Duct
3 Cylinder Head Cover
4 Ignition Coil
5 Spark Plug Connector
6 Fuel Distributor
7 Injector
8 Exhaust Camshaft
9 Intake Camshaft
10 Valve Tappet
11 Intake Valve12 Intake Manifold
13 Cylinder Head
14 Exhaust Manifold
15 Dipstick Guide Tube and Gauge
16 Connecting Rod
17 Crankshaft
18 Engine Mounting Bracket
19 Starter
20 Crankcase
21 Oil Pump Sprocket
22 Oil Pan

1A2-4 GENERAL ENGINE INFORMATION
23 Camshaft Adjuster
24 Oil Filler Cap
25 Engine Hanger Bracket
26 Cooling Fan and Viscous Clutch
27 Oil Filter
28 Timing Chain29 Oil Pump Drive Chain
30 Oil Strainer
31 Oil Pump
32 Ring Gear and Flywheel of Drive Plate
33 Piston
SIDE VIEW