engine SSANGYONG MUSSO 2003 Service Manual

M162 ENGINE COOLING 1D1-7
COOLANT CONNECTION FITTING Preceding Work : Removal of cooling fan shroud
1 Bolt (M8 X 100, 2 pieces) ...............22.5-27.5 Nm
2 Engine Hanger Bracket
3 Coolant Outlet Port
Removal & Installation Procedure
1. Drain coolant from the radiator.
2. Remove the hose mounting clamp (5) and disconnect the coolant hose (6).
3. Remove the two bolts (1), the engine hanger bracket (2) and coolant outlet port (3).Installation Notice 4 O-ring
5 Hose Mounting Clamp
6 Hose
Replace the O-ring with new one.
4. Installation should follow the removal procedure in the reverse order.
5. Fill up the coolant as specified.
6. Check the leaks in the cooling system.
Tightening Torque 22.5 - 27.5 Nm

1D1-8 M162 ENGINE COOLING WATER PUMP Preceding Work : Removal of V-beltRemoval of air admission housing
1 Air Admission Housing
2 Oil Cooler Pipe Line
3 Seal....................................................... Replace
4 Bolt ........................................................ 9-11 Nm
5 Coolant Hose
6 Coolant Hose
7 Outlet Coolant Hose 8 Coolant Hose
9 Inlet Coolant Hose
10 Coolant Pump
11 Bolt ........................................................... 21 Nm
12 Dowel Sleeve
13 Seal ....................................................... Replace

M162 ENGINE COOLING 1D1-9
Removal & Installation Procedure
1. Drain the coolant.
2. Disconnect the coolant pump wire connector.
3. Loosen the hose clip and dsconnect all hoses from thecoolant pump
4. Remove the coolant line bolts (4) and then remove the
coolant line (2).Installation Notice Notice Replace the seal (3).
5. Remove the mounting bolts (11) and carefully pull out coolant pump (10).Installation Notice
Tightening Torque 9 - 11 Nm
Notice Replace the seal (13).
Tightening Torque 21 Nm
6. Installation should follow the removal procedure in the reverse order.
7. Fill up coolant.
8. Do coolaing system leakage test

1D1-10 M162 ENGINE COOLING THERMOSTAT
Removal & Installation Procedure
1. Drain the coolant from the radiator.
2. Loosen the hose mounting clamp (6) and remove the heaterhose (7).
3. Unscrew the three bolts (5) and remove the thermostat cover bracket, thermostat cover and the thermostat in order. Installation Notice
1 Thermostat Cover
2 Thermostat
3 O-ring
4 Thermostat Cover Bracket
5 Bolt (M6 X 25, 3 pieces)
.........................9-11 Nm
6 Hose Mounting Clamp
7 Heater Hose
Do not separate the thermostat cover and thermostat.
4. Replace the O-ring if necessary.
5. Check the leakage in the cooling system.
Tightening Torque 9 - 11 Nm

M162 ENGINE COOLING 1D1-11
OIL COOLER PIPE LINE Preceding Work : Removal of upper intake manifold
Tightening Torque 9 - 11 Nm
1 Upper Intake Manifold
2 Bolt (M6 X 35, 1 piece)
...........................9-11 Nm
3 Bolt (M6 X 16, 2 pieces) .........................9-11 Nm4 Oil Cooler Pipe Line
5 O-ring .................................................... Replace
Removal & Installation Procedure
1. Drain the coolant.
2. Unscrew the bolts (2, 3) and remove the oil cooler pipe line (4). Replace the O-ring with new one. Installation Notice
3. Installation should follow the removal procedure in the reverse order.
4. Fill up the coolant as specified.
5. Check the leaks in the cooling system.

1D1-12 M162 ENGINE COOLING COOLING FAN AND VISCOUS CLUTCH Preceding Work : Removal of cooling fan shroud
1 Cooling Fan Pulley
2 Viscous Clutch
3 Cooling Fan4 Bolt (M6 X 12, 4 pieces)
.........................9-11 Nm
5 Bolt (M10 X 45, 1 piece) .................40.5-49.5 Nm

M162 ENGINE COOLING 1D1-13
Tools Required 603 589 00 40 00 Counter Holder Removal & Installation Procedure
1. Hold the cooling fan pulley using the counter holder (special tool : 603 589 00 40 00) and remove the cooling fan after unscrewing the four bolts (4). Installation Notice
2. Remove the bolt (5) from the viscous clutch and remove the viscous clutch from the cooling fan pulley.Installation Notice
Tightening Torque 9 - 11 Nm
Tightening Torque 40.5 - 49.5 Nm
3. Installation should follow the removal procedure in the reverse order.

1D1-14 M162 ENGINE COOLING COOLING FAN SHROUD
Removal & Installation Procedure1. Pull out the 2 clips (1) from the fan shroud assembly.
2. Remove the lower fan shroud (2). NoticeFor installation, exactly align the lower fan shroud pin into the hole of the fan shroud assembly (4) and insert theclips.
3. Remove the bolts (3) and then remove the cooling fan shroud assembly (4).
1 Clip
2 Lower Fan Shroud
3 Bolt
Installation Notice
4. Installation should follow the removal procedure in the reverse order.
Tightening Torque 7 Nm 4 Fan Shroud Assembly
5 Radiator

M162 ENGINE COOLING 1D1-15
RADIATOR Preceding Work : Removal of cooling fan shroud
1 Radiator Inlet Coolant Hose
2 Radiator Outlet Coolant Hose
3 Make Up Coolant Hose
4 Automatic Transmission Oil Cooling Hose
5 Automatic Transmission Oil Cooling Line 6 Bolt
7 Insulator
8 Stopper
9 Bolt
............................................................. 7 Nm
10 Radiator

1D1-16 M162 ENGINE COOLING Removal & Installation Procedure1. Drain coolant from the radiator.
2. Remove the coolant thermo connector from the radiator.
3. Remove the each coolant hoses.
Tightening Torque 14 Nm
4. Remove the automatic transmission oil cooling hose.
Installation Notice
5. Remove the automatic transmission oil cooling line bolts and then remove the oil cooling line.
6. Remove the radiator upper mounting bolts and then remove the bracket and insulator.
7. Remove the radiator.
8. Check the radiator pin for crack, damage, leakage and bending and replace if necessary.
9. Installation should follow the removal procedure in the reverse order.
10. Do cooling system leakage test.