2002 Ssangyong Musso

baldur

Fast

506

01-21-2018, 06:41 PM #1

I figured it was time to make a project thread for my daily driver, since it's now making nearly three times as much power as it did in stock form and I never intended to modify it...
It's a 2002 Ssangyong Musso, purchased in 2016 after my 1997 Musso was t-boned by a driver who was hunting for pokemons on her phone instead of minding where the hell she was driving.
The engine is an OM662, which is a 2.9L displacement OM602 variant with prechambers produced by Ssangyong in Korea under license from Mercedes Benz.
I started the engine build for the old car, as the old car had thrown a rod which is very common for a high mileage OM662 to do, but a couple of weeks after fitting the engine the car was totalled and I picked up another car that was without an engine.
I first fitted an OM605 turbo injection pump, EDC pump with 6mm elements, and to enable this swap the DSL1 ECU was initially developed. I have since swapped a number of Ssangyong cars locally to EDC pumps for improved power.

Current specs:
OM662 engine with Ssangyong turbo intake manifold
OM605 EDC injection pump built by Barrote with Dieselmeken 75L3 elements. Capable of 177cc injection quantity with rack at the 18mm travel limit.
DSL1 ECU set up to control engine, turbo boost, cruise control, speedometer calibration, tachometer calibration (originally tacho was taken from alternator and was off by 10%).
Chinese GT2860 turbo, 46mm compressor inducer.
Stock Ssangyong intercooler
Snow Performance water/methanol injection, controlled by DSL1 ECU. Flow tested this at 650cc/min but have not tested it after fitting the 7.5mm pump. With the 6mm pump where the engine was fuel limited, the methanol made a huge difference in power. Boosting total power in the region of 50-60 horsepower when running a mix of 75% methanol, 25% water. I do plan to keep the methanol injection with the 7.5mm pump but I may reduce the methanol quantity.
Other bits:
Borgwarner T5 "world class" transmission, stock to the Musso.
F-Tune performance built clutch using modified Ssangyong single mass flywheel, ZF Performance Engineering pressure plate and 240mm Ssangyong clutch disc.
Stock axles (Dana 44 rear, Dana 30 IFS front) with 4.27:1 final drive ratios.
35x12.5" tyres mounted on 10" wide 15" rims.

I have not dyno tested engine with the 7.5mm pump and I ran out of time when performing the initial test with the 6mm pump so I was unable to test with the water/methanol injection also. I believe with the 7.5mm pump the power output is around 300 horsepower.

Finding TDC to place the timing pointer on the front cover. This is a brand new short block from Korea.
[Image: 2016_05_13_14_51_39.sized.jpg]

Engine built and sporting a chinese GT2860 turbo on a STT cast T25 flange manifold.
[Image: 2016_06_01_16_49_41.sized.jpg]

I decided to run the engine in on my engine dyno.
[Image: 2016_06_21_15_02_46.sized.jpg]

Busted a boost hose on the dyno. Things get really hot when engine dyno testing and you can see how the hoses expand when holding 20+psi pressure.
[Image: 2016_07_11_13_58_47.sized.jpg]

Engine wiring and DSL1 ECU sitting on shelf beside dyno.
[Image: 2016_06_29_18_16_48.sized.jpg]

One of the tests I ran. Not really representative of the final result but it shows where the engine was making max power.
End result was 220bhp and 460Nm of torque on standard OM605 EDC injection pump.
[Image: 2016_07_10_21_43_21.sized.jpg]

https://www.youtube.com/watch?v=Vpdw5KYLnQg

I fabricated a stainless exhaust for it. Pretty happy with how that turned out.
[Image: 2016_11_18_12_11_24.sized.jpg]

Engine sitting in the car, after I fitted the methanol injection.
[Image: 2018_01_14_14_11_56.sized.jpg]

Picked up a cheap OBD2 display gauge and implemented OBD2 support in the DSL1 ECU.
[Image: 2017_12_03_18_29_49.sized.jpg]

New years day was spent replacing the transmission.
[Image: 2018_01_01_15_04_42.sized.jpg]

And rear differential was also broken. Installed an Eaton Truetrac LSD in its place.
[Image: 2018_01_01_15_18_57.sized.jpg]

Latest addition, a superpump. Fingers crossed the engine cares for it in the long run. I'm really happy with how the car performs and drives with it.
[Image: 2018_01_14_14_11_43.sized.jpg]

This post was last modified: 01-21-2018, 06:47 PM by baldur.

Baldur Gislason