cooling SSANGYONG MUSSO 2003 Workshop Manual

1D1-2 M162 ENGINE COOLINGFASTENER TIGHTENING SPECIFICATIONS
N

 m
30
22.5 - 27.5
9 - 11
9 - 11
9 - 11
40.5 - 49.5
3 - 73 - 7
Application
Coolant Drain PlugEngine Hanger Bracket and Coolant OutletPort Bolt Thermostat Cover Bracket Bolt Oil Cooler Pipe Line BoltCooling Fan BoltViscous Clutch Bolt
Automatic Transmission Oil Cooling Hose Bolt Cooling Fan Shroud Bolt

M162 ENGINE COOLING 1D1-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
124 589 15 21 00 Tester
603 589 00 40
Counter Holder

1D1-4 M162 ENGINE COOLINGDIAGNOSIS
3. Connect the special tool to the reservoir filler cap and apply 1.4 bar of pressure.
SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester Test Procedure
1. Loosen the cap a little and release pressure and removethe cap. NoticeFor the risk of scalding, cap must not be opened unless the coolant temperature is below 90 °C.
2. Fill coolant up to upper edge (arrow) of reservoir.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check leakage at the all coolant hoses and pipes and each connections. Replace or retighten if necessary.

M162 ENGINE COOLING 1D1-5
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. NoticeFor the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 o
C.
2. Loosen the radiator lower drain cock and drain the coolant.
Notice Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose(dia. 14mm) onto the drain bolt on the side of crankcase (exhaust manifold) and by loosening the plug. Notice
Just loosen the drain plug to drain the coolant and do not remove the plug completely.
Collect coolant by using proper container.
4. After complete draining of the coolant, remove the hose connector to drain plug and reinstall the drain plug. Installation Notice
5. Tighten the radiator lower drain cock.
Tightening Torque 30 Nm

1D1-6 M162 ENGINE COOLING
6. Remove the de-aeration hose clamp in the coolant pumpand remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank. Notice
Match the anti-freeze and the water ratio to 50 : 50.
Supplement the coolant until the coolant overflows to the deaeration hose.
8. Insert the de-aeration hose and completely tighten the clamp.
9. Check the coolant level in the coolant reservoir tank.
10. Warm up(until thermostat is opened) the engine and recheck the coolant level in the reservoir tank and fill upthe coolant if necessary.

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.