engine SSANGYONG KORANDO 1997 Service Repair Manual

M161 ENGINE COOLING 1D2 -- 5
D AEW OO M Y_2000
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 re-
move the cap.
Notice:For the risk of scalding, the cap must not be
opened unless the coolant temperature is below 90°C.
2. Loosen the radiator lower drain cock and drain the
coolant.
Notice:Collect the 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
DJust loosen the drain plug to drain the coolant and do
not remove the plug completely.
DCollect the coolant by using the proper container.

1D2 -- 6 M161 ENGINE COOLING
D AEW OO M Y_2000
4. After complete draining of the coolant, remove the
hose connector to drain plug and reinstall the drain
plug.
Installation Notice
Tightening Torque
30 NSm (22 lb-ft)
5. Tighten the radiator lower drain cock.
6. Remove the de-- aeration hose clamp in the water
pump and remove the de-- aeration hose.
7. Fill up the coolant through the coolant reservoir
tank.
Notice
DMatchtheanti--freezeandthewaterratioto50:50.
DSupplement 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
up the coolant if necessary.

M161 ENGINE COOLING 1D2 -- 7
D AEW OO M Y_2000
COOLING FAN AND VISCOUS CLUTCH
Preceding Work: Removal of cooling fan shroud
1 Bolt (M6 X 14, 3 piece)
9--11 NSm (80-- 97 lb-in) ......................
2 Cooling Fan3 Viscous Clutch
4 Union Nut (Left Threaded Screw)
40.5-- 49.5 NSm (29.8--36.5 lb-ft) ..............

1D2 -- 8 M161 ENGINE COOLING
D AEW OO M Y_2000
Tools Required
111 589 02 01 00 Open End Wrench
111 589 00 40 00 Open End Wrench
Removal & Installation Procedure
1. Install the holder (special tool : 111 589 00 40 00) to
the bolt at the pulley as shown in the right figure to
hold the pulley.
2. Remove the viscous clutch using an open end
wrench(specialtool:111589020100).
Installation Notice
Tightening Torque
40.5 -- 49.5 NSm
(29.8 -- 36.5 lb-ft)
Notice:The union nut is left threaded screw.
3. Remove the 3 bolts (1) from the viscous clutch and
remove the cooling fan and the viscous clutch.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
Notice:You may change the procedure (2) and (3) if ne-
cessary.
4. Installation should follow the removal procedure in
the reverse order.

M161 ENGINE COOLING 1D2 -- 9
D AEW OO M Y_2000
WAT E R P U M P
Preceding Work: Removal of viscous clutch
1 Bolt (M6 X 45, 1 piece)
9--11 NSm (80-- 97 lb-in) .....................
2 Bolt (M6 X 95, 1 piece)
9--11 NSm (80-- 97 lb-in) .....................
3 Bolt (M6 X 25, 4 piece)
9--11 NSm (80-- 97 lb-in) .....................
4 Bolt (M8 X 85, 2 piece)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............5 Water Pump Housing
6 Bolt (M6 X 16, 4 piece)
9--11 NSm (80-- 97 lb-in) .....................
7 Water Pump Pulley
8 Coolant Inlet Hose
9HeaterHose
10 Coolant Bypass Hose
11 Gasket

1D2 -- 10 M161 ENGINE COOLING
D AEW OO M Y_2000
Tools Required
124589152100 Tester
Removal & Installation Procedure
1. Drain the coolant.
2. Disconnect the coolant hoses (8, 9, 10).
3. Take off the drive belt.
4. Unscrew the four bolts (6) from water pump pulley
and remove the pulley (7).
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
Notice:Hold the pulley with fan clutch holder 603 589
00 40 00 while removing the pulley.
5. Unscrew the bolts (1, 2, 3, 4) from water pump hous-
ing (5) and remove the water pump.
Installation Notice
Tightening
(1,2,3)9--11NSm
(80 -- 97 lb-in)
Tightening
Torque(4)22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
6. Clean the sealing surface.
7. Replace the gasket with new one.
Notice:Apply the sealant when the sealing surface of
water pump housing and coolant mounting area is clean.
8. Installation should follow the removal procedure in
the reverse order.
9. Check for leaks by starting the engine.

M161 ENGINE COOLING 1D2 -- 11
D AEW OO M Y_2000
THERMOSTAT
1 Bolt (M6 X 25, 3 pieces)
9--11 NSm (80-- 97 lb-in) .....................
2 Thermostat Cover
3 De-- aeration Hose4 Coolant Outlet Hose
5 Thermostat
6O--ring
Removal & Installation Procedure
1. Drain the coolant from the radiator.
2. Loosen the hose mounting clip and remove the cool-
ant hose (3, 4).
3. Unscrew the three bolts (1) and remove the thermo-
stat cover assembly from thermostat housing.
Installation Notice
Tightening Torque
9--11NSm (80 -- 97 lb-in)
Do not separate the thermostat cover and thermo-
stat.
4. Replace the O -- ring if necessary.
5. Check the leakage in the cooling system.

1D2 -- 12 M161 ENGINE COOLING
D AEW OO M Y_2000
THERMOSTAT HOUSING ASSEMBLY
Preceding Work: Removal of viscous clutch
1a Bolt (M6 X 95, 2 pieces)
9--11 NSm (80-- 97 lb-in) .....................
1b Bolt (M8 X 75, 2 pieces)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............
1c Bolt (M8 X 35, 1 piece)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............
2 Thermostat Housing Assembly3O--ring
4 De-- aeration Hose
5 Coolant Outlet Hose
6 Coolant Bypass Hose
7 Tensioning Device Shock Absorber
8 Engine Hanger Brocket

M161 ENGINE COOLING 1D2 -- 13
D AEW OO M Y_2000
Removal & Installation Procedure
1. Drain the coolant.
2. Remove the de-- aeration hose (4), coolant outlet
hose (5) and coolant bypass hose (6).
3. Disconnect the coolant temperature sensor connec-
tor.
4. Unscrew the bolt (1c) and pry off the tensioning de-
vice shock absorber (7).
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
5. Unscrow the bolts (1a, 1b) and remove the engine
hanger bracket and thermostat housing.
Installation Notice
Tightening
(1a)9--11NSm
(80 -- 97 lb-in)
Tightening
Torque(1b)22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
6. Replace the O -- ring with new one.
7. Installation should follow the removal procedure in
the reverse order.
8. Check for leaks in cooling system.

1D2 -- 14 M161 ENGINE COOLING
D AEW OO M Y_2000
FAN SHROUD
Removal & Installation Procedure
1. Unscrew two bolts from cooling fan shroud and re-
move the shroud.
Installation Notice
Tightening Torque
3--7NSm (27 -- 62 lb-in)
2. Installation should follow the removal procedure in
the reverse order.