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2002 Ssangyong Musso
baldur Offline
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#1
2002 Ssangyong Musso
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]
[Image: 2016_06_21_17_16_32.sized.jpg]
[Image: 2016_06_23_18_17_39.sized.jpg]
[Image: 2016_06_29_18_16_51.sized.jpg]
[Image: 2016_07_11_13_54_30.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]
[Image: 2016_11_18_15_54_50.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]
Baldur Gislason

(This post was last modified: 01-21-2018, 06:47 PM by baldur.)
01-21-2018, 06:41 PM
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jhw. Offline
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#2
RE: 2002 Ssangyong Musso
Very good mate! Shame there's not a lot of interest on here, the forum seems dead these days.
02-02-2018, 08:33 PM
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Mallinman Offline
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#3
RE: 2002 Ssangyong Musso
That’s s nice project. It would be nice to have my own engine dyno. Nice job on the exhaust.
Mitsubishi L200 manual om605  
7.5mm Bosch 044 fed pump 
Borgwarner S200 
02-04-2018, 04:15 AM
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baldur Offline
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#4
RE: 2002 Ssangyong Musso
Latest additions, a sensor that reads the pump angle relative to crank angle, to let me data log what the timing device is doing, and a Walbro GSL392 255lph in line fuel pump to feed the 7.5mm pump the fuel it needs, along with a fuel feed pressure sensor to let me log the feed pressure.
[Image: 2018_02_04_18_36_00.sized.jpg]
[Image: pumpangle.png]
[Image: 2018_01_25_16_35_16.sized.jpg]
[Image: 2018_01_25_13_55_44.sized.jpg]
Baldur Gislason

02-04-2018, 05:23 PM
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Petar Offline
7.5mm M pump
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#5
RE: 2002 Ssangyong Musso
Very interesting results on that pump angle sensor. Seems that it retards the injection at full load. Makes sense since it is sprung loaded.

BTW your project is pretty nice, quite unusual to see a modded Musso. I am surprised you didn't go for a 605 since you were already swapping engines.
02-04-2018, 06:28 PM
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baldur Offline
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#6
RE: 2002 Ssangyong Musso
(02-04-2018, 06:28 PM)Petar Wrote: Very interesting results on that pump angle sensor. Seems that it retards the injection at full load. Makes sense since it is sprung loaded.

BTW your project is pretty nice, quite unusual to see a modded Musso. I am surprised you didn't go for a 605 since you were already swapping engines.

Thank you. Truth is there is not a single 605 turbo engine to be found in my country. The W210 came with that awful little OM602 2.9 DI engine over here until they went common rail. And I didn't swap engines. My old OM662 just threw a rod after 300000km and I fitted a new short block. Still using the same cylinder head, etc.
And yes, I had a hunch that the timing was going to depend on the torque needed to turn the pump, so I decided to go this way rather than getting a timing light and observing the curve with the car in neutral, since the curve in neutral gear is not going to be anything close the the curve at full throttle and thus completely useless information.
Baldur Gislason

02-04-2018, 07:35 PM
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Petar Offline
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#7
RE: 2002 Ssangyong Musso
Is this timing data logged by the DSL1. If so you are not far away from timing control on EDC VE pumps. If your controller could also run VE pumps the market for the DSL1 could be much bigger, TDI guys would love a standalone controller.


What rpm are you running at 100km/h in fifth gear and what's average fuel consumption of the Musso ?
(This post was last modified: 02-05-2018, 05:23 AM by Petar.)
02-05-2018, 05:21 AM
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starynovy Offline
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#8
RE: 2002 Ssangyong Musso
Why is 602 DI awful? Big Grin
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
02-05-2018, 11:51 AM
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baldur Offline
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#9
RE: 2002 Ssangyong Musso
(02-05-2018, 05:21 AM)Petar Wrote: Is this timing data logged by the DSL1. If so you are not far away from timing control on EDC VE pumps. If your controller could also run VE pumps the market for the DSL1 could be much bigger, TDI guys would love a standalone controller.


What rpm are you running at 100km/h in fifth gear and what's average fuel consumption of the Musso ?

around 2200RPM at 100km/h in fifth gear. Fuel consumption when running on the cruise control at that speed is around 9.5l/100km
Fuel consumption in the city has been as high as 14l/100km but usually around 12, depending on my driving.
Yes the DSL1 is logging the timing.
Baldur Gislason

02-05-2018, 12:46 PM
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baldur Offline
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#10
RE: 2002 Ssangyong Musso
(02-05-2018, 11:51 AM)starynovy Wrote: Why is 602 DI awful? Big Grin

Because those cars should all have had an OM606 turbo. 120 horsepower is just pitiful.
Baldur Gislason

02-05-2018, 12:47 PM
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starynovy Offline
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#11
RE: 2002 Ssangyong Musso
Yeah well.. that is Mercedeses fault. The engine could have made 110kW and 350Nm without any stress by looking at Audi AEL (2,5L 105kW 290Nm) which is topologicaly the same engine. So more power than 605 turbo but much nicer consumption. So shame on Stuttgart. Smile
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
02-10-2018, 03:40 AM
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addi.bigg Offline
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#12
RE: 2002 Ssangyong Musso
(02-04-2018, 05:23 PM)baldur Wrote: Latest additions, a sensor that reads the pump angle relative to crank angle, to let me data log what the timing device is doing, and a Walbro GSL392 255lph in line fuel pump to feed the 7.5mm pump the fuel it needs, along with a fuel feed pressure sensor to let me log the feed pressure.
[Image: 2018_02_04_18_36_00.sized.jpg]
[Image: pumpangle.png]
[Image: 2018_01_25_16_35_16.sized.jpg]
[Image: 2018_01_25_13_55_44.sized.jpg]

What is your timing chain condition? That could be also interesting.
02-13-2018, 05:17 AM
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baldur Offline
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#13
RE: 2002 Ssangyong Musso
(02-13-2018, 05:17 AM)addi.bigg Wrote: What is your timing chain condition? That could be also interesting.

Chain has 20.000km on it since brand new.
Baldur Gislason

02-13-2018, 07:51 AM
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Sotvisp Offline
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#14
RE: 2002 Ssangyong Musso
Hello interesting project..
Did you make the dyno yourself is it an Eddycurrent brake ??
Br Per
Diesel Power
02-14-2018, 04:57 AM
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baldur Offline
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#15
RE: 2002 Ssangyong Musso
(02-14-2018, 04:57 AM)Sotvisp Wrote: Hello interesting project..
Did you make the dyno yourself is it an Eddycurrent brake ??
Br Per

Yes I built the dyno myself. The brake is a Superflow 8xx water brake, the most popular engine dyno brake in the world, used on the Superflow 801 and 901.
Baldur Gislason

02-14-2018, 02:40 PM
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Antonytriolo Offline
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#16
RE: 2002 Ssangyong Musso
(02-05-2018, 12:47 PM)baldur Wrote:
(02-05-2018, 11:51 AM)starynovy Wrote: Why is 602 DI awful? Big Grin

Because those cars should all have had an OM606 turbo. 120 horsepower is just pitiful.

So you don't recommend a 1999 Musso for a doner engine for another project then ?
02-18-2018, 03:06 PM
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baldur Offline
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#17
RE: 2002 Ssangyong Musso
(02-18-2018, 03:06 PM)Antonytriolo Wrote:
(02-05-2018, 12:47 PM)baldur Wrote:
(02-05-2018, 11:51 AM)starynovy Wrote: Why is 602 DI awful? Big Grin

Because those cars should all have had an OM606 turbo. 120 horsepower is just pitiful.

So you don't recommend a 1999 Musso for a doner engine for another project then ?

I don't recommend a W210 sold in Iceland for a donor engine. Every W210 sold here had that awful 120hp DI engine.
The Musso on the other hand has the OM662 which is for the most part identical to the OM602.940, an IDI 2.9L 5 cylinder. Same power output though, unless you fit a bigger injection pump. It's not as strong as a 605 though.
Baldur Gislason

02-18-2018, 04:05 PM
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baldur Offline
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#18
RE: 2002 Ssangyong Musso
The engine bent 4 connecting rods and has since been rebuilt with a bigger turbo.
here it is on the dyno on new years day https://youtu.be/4z6qBl7yEVU
Made a smoke free 325 horsepower at 2.1 bar boost.
Baldur Gislason

01-02-2019, 09:41 AM
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Turbo Offline
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#19
RE: 2002 Ssangyong Musso
Nice work
Really like the intake Smile
01-02-2019, 03:32 PM
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atypicalguy Offline
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#20
RE: 2002 Ssangyong Musso
Nice truck. I really like how this company just keeps cranking out mercedes clones.

What is your strategy for avoiding future rod bending? Did you machine the pistons for lower compression, change the timing, or just use bigger rods? What is the stock compression ratio on that motor?

Thanks for posting the failures also. They are the most important aspect for anyone wanting to daily drive a superpump motor.
01-09-2019, 06:27 AM
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baldur Offline
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#21
RE: 2002 Ssangyong Musso
The engine is rebuilt with OM602.982 rods, OM601.970 pistons, ARP2000 head studs, OM605.960 MLS head gasket with the cylinder bores ground out to the correct diameter. Compression ratio remains stock, although it may be a tiny bit lower with the MLS gasket since it does not crush like the composite gasket.
I initially rebuilt with just bigger rods and those pistons were necessary as the wristpin diameter is bigger (28mm). At the time I also O-ringed the engine block with copper O rings to help head gasket seal. I decided to use the intake manifold off the OM602.982 engine as it was a much nicer looking design than the older OM602 manifold.

I then tested the engine on my dyno and on my third dyno session after changing to the GTX2867R turbo I started seeing over 300 horsepower but blew a head gasket.
I then changed from 12.9 bolts to ARP2000 studs and MLS head gasket.
I have a little bit of work left to do before the engine goes back in to the car but as far as power goals, I'm there already. 325 horsepower with no visible smoke whatsoever is the current tune. There's a little more left in it, I have a few more things to try out.
Baldur Gislason

01-09-2019, 08:40 PM
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Buzzliteyear Offline
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#22
RE: 2002 Ssangyong Musso
Hi Baldur, my first post and thanks for sharing this info

I have 100 question but ive restrained myself to 5ish

is there no MSL head gasket for the OM662
why did you use the OM601.970 pistons (was it wrist pin size) 28mm over 24mm for musso ?
did you bend the stock OM662 rods because of your 20psi boost
did you re balance the motor for the heaver rod
would stock rods be fine for 10-15psi boost or do this 662 fail with age
the quote I got from dieslmeken for 7.5mm pump is more than the purchase of both my OM662engines, is there a way to
get power around 200hp (350nw) staying with full manual pump and looking at lpg injecting

cheers
Brett
09-12-2019, 04:05 AM
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baldur Offline
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#23
RE: 2002 Ssangyong Musso
(09-12-2019, 04:05 AM)Buzzliteyear Wrote: Hi Baldur, my first post and thanks for sharing this info

I have 100 question but ive restrained myself to 5ish

is there no MSL head gasket for the OM662
No. And the OM602.980 engine which shares the same block but was direct injection had a composite gasket, which is really silly considering how sturdy the rest of that engine is.

why did you use the OM601.970 pistons (was it wrist pin size) 28mm over 24mm for musso ?
Yes, 28mm over the standard 26mm. Needed because the 602.980 rods have the 28mm pin.

did you bend the stock OM662 rods because of your 20psi boost
No I was running 35psi boost and a 7.5mm pump. Bent 4 rods out of 5.

did you re balance the motor for the heaver rod
No.

would stock rods be fine for 10-15psi boost or do this 662 fail with age
20psi and 6mm elements is what the standard rods can handle. These rods do fail with age also, around 300000km because of fatigue.

the quote I got from dieslmeken for 7.5mm pump is more than the purchase of both my OM662engines, is there a way to
get power around 200hp (350nw) staying with full manual pump and looking at lpg injecting
6mm elements will give you 200hp. Standard rods cannot handle the torque of 7.5mm.
Baldur Gislason

09-12-2019, 07:29 AM
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baldur Offline
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#24
RE: 2002 Ssangyong Musso
Time for an update.
Built a 722.6 with the help of Sound German Automotive
[Image: 2019_07_17_20_55_27.sized.jpg]
[Image: 2019_07_17_21_00_34.sized.jpg]
[Image: 2019_07_28_15_39_00.sized.jpg]

Fitted the engine in the car along with transmission. Used a SsangYong Kyron transfer case. Fitted new intercooler.
[Image: 2019_07_29_21_25_24.sized.jpg]
[Image: 2019_08_02_23_31_23.sized.jpg]
[Image: 2019_08_03_21_25_15.sized.jpg]


GTX2867R only lasted 1 week in the car before destroying its bearings. Purchased a brand new GTX2971R and the car is much faster now.
[Image: 2019_09_05_09_06_54.sized.jpg]
[Image: 2019_09_05_09_09_42.sized.jpg]
[Image: 2019_09_07_15_43_58.sized.jpg]
[Image: 2019_09_08_15_26_09.sized.jpg]
Baldur Gislason

09-12-2019, 09:14 AM
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atypicalguy Offline
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#25
RE: 2002 Ssangyong Musso
(09-12-2019, 09:14 AM)baldur Wrote: Time for an update.
Built a 722.6 with the help of Sound German Automotive
[Image: 2019_07_17_20_55_27.sized.jpg]
[Image: 2019_07_17_21_00_34.sized.jpg]
[Image: 2019_07_28_15_39_00.sized.jpg]

Fitted the engine in the car along with transmission. Used a SsangYong Kyron transfer case. Fitted new intercooler.
[Image: 2019_07_29_21_25_24.sized.jpg]
[Image: 2019_08_02_23_31_23.sized.jpg]
[Image: 2019_08_03_21_25_15.sized.jpg]


GTX2867R only lasted 1 week in the car before destroying its bearings. Purchased a brand new GTX2971R and the car is much faster now.
[Image: 2019_09_05_09_06_54.sized.jpg]
[Image: 2019_09_05_09_09_42.sized.jpg]
[Image: 2019_09_07_15_43_58.sized.jpg]
[Image: 2019_09_08_15_26_09.sized.jpg]


Wow. Serious improvements!
What TCU are you using for the 722.6? The PCS unit? Thanks.
09-12-2019, 07:13 PM
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baldur Offline
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#26
RE: 2002 Ssangyong Musso
Yes I have a PCS controller for the 722.6. Car performs great, I reckon around 400 horsepower now according to logged data. The new turbo flows a lot more air but spools just the same as the 2867. Car still needs some work (is a modified car ever finished?), need to upgrade the cooling system, it's not up to the task of keeping 400 horsepower cool. I also think I should upgrade the exhaust, go from 63mm up to 76mm. 63 is on the small side for a 400 horsepower diesel.
Baldur Gislason

09-13-2019, 04:19 AM
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Buzzliteyear Offline
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#27
RE: 2002 Ssangyong Musso
That is silly about the head gasket.

would I be ok with composite H-gasket with 10-15 psi boost

So the 602.982 rod has the same big end

why did you use the 601.970 piston why not the 602.982 same pin size 28mm?

Is there a stock pump that already has the 6mm elements inside

id like a turbo range from 1200-4000 for towing would stock be ok and to get the 200hp

Love the intercooler pipe work

cheers heaps
09-13-2019, 04:33 AM
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baldur Offline
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#28
RE: 2002 Ssangyong Musso
(09-13-2019, 04:33 AM)Buzzliteyear Wrote: That is silly about the head gasket.

would I be ok with composite H-gasket with 10-15 psi boost

So the 602.982 rod has the same big end

why did you use the 601.970 piston why not the 602.982 same pin size 28mm?

Is there a stock pump that already has the 6mm elements inside

id like a turbo range from 1200-4000 for towing would stock be ok and to get the 200hp

Love the intercooler pipe work

cheers heaps

Composite head gasket is fine for anything a 6mm pump can throw at the engine, up to 25 psi boost or so.
602.982 rod has a 28mm small end. Stock Musso rod has 26mm small end so I had to use the 601.970 piston to be able to use the 602.982 rod. The 602.982 piston is for direct injection and thus not suitable for the normal 602 cylinder head.

OM605 turbo with the electronic injection pump has 6mm elements standard.

Stock turbo is no good past 160 horsepower. I would recommend using a turbo off an OM606, bolts directly to the stock exhaust manifold. I used a GT2860 when I was at the 200hp level but I have a Swedish STT exhaust manifold with a T25 flange as my engine was originally not a turbo engine.

Yes I'm very happy with how the intercooler fit the car as well as the pipe routing, there are no clearance issues anywhere, nothing that rattles.
Baldur Gislason

(This post was last modified: 09-13-2019, 07:35 AM by baldur.)
09-13-2019, 07:34 AM
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baldur Offline
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#29
RE: 2002 Ssangyong Musso
Went sand drag racing and am very pleased with the result. An elapsed time of 5.75 with a highest trap speed of 59mph is phenomenal for a 2.2 ton truck.
https://www.facebook.com/photo.php?fbid=...=3&theater

This was with a lot of wheel spin off the line as I was just using standard all-terrain tyres too. I predict if I were to switch to mud tyres the time would drop by 0.3-0.4 seconds.
Baldur Gislason

09-29-2019, 12:14 PM
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Buzzliteyear Offline
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#30
RE: 2002 Ssangyong Musso
Thats cool......we got more traction with bald tyres in the sand and letting them down heaps,
but did not have 3-400hp trying to pull them of the rims like you.
09-30-2019, 06:11 AM
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