engine SSANGYONG MUSSO 1998 Workshop Repair Manual

OM600 ENGINE MECHANICAL 1B3-185
Removal & Installation Procedure
1. Remove the timing case cover.
2. By inserting a round bar (6) approx. 0.7m from the back to
the front side through the oil gallery, knock out the steel
balls (1,3).
Notice
Be careful not to damage the bores of the steel balls.
6 Shop-made tool
3. Thoroughly clean the bores of steel balls.
4. Place the steel ball (3) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 15 00
5. Place the steel ball (1) onto the drift (7) with a little grease
and position to the bore and then tap until the drift stops.
Drift 601 589 08 1500
6. Warm up the engine and check the oil for leaks.

1B3-186 OM600 ENGINE MECHANICAL
Installation of Screw Plug
Notice
If steel ball leaks again, install the screw plug.
1. Remove the steel ball.
2. Tap thread into the bores of the oil gallery.
Notice
Front bore : M18 ´ 1.5, depth 10mm
Rear bore : M16 ´ 1.5, depth 14mm
3. Thoroughly clean the oil gallery.
4. Tighten the front plug (5) with seal (4).
5. Apply Loctite 241 and then tighten the rear plug (2).
Tightening Torque 50 Nm
Tightening Torque 50 Nm

OM600 ENGINE MECHANICAL 1B3-187
Standard size
Wear limit in direction of travel and in transverse direction
Permissible deviation of cylinder shape
Honing angle
CYLINDER BORE MEASUREMENT
a Longitudinal Direction
b Transverse Direction
c, d, e. Measuring Point
1 Crankcase Contacting Surface
2 TDC of 1st Piston Ring
4 BDC of Ring
Service Data
Code letter ‘A’
Code letter ‘X’
Code letter ‘B’
When new
Wear limit89.000 - 89.006mm
89.006 - 89.012mm
89.012 - 89.018mm
Max. 0.20mm
0.01mm
0.05mm
50° ± 10°

SECTION 1D1
M162 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D1-1
General Specifications . . . . . . . . . . . . . . . . . 1D1-1
Fastener Tightening Specifications . . . . . . . . 1D1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D1-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D1-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-4
System Leakage Test . . . . . . . . . . . . . . . . . . 1D1-4
Maintenance and Repair . . . . . . . . . . . . . . 1D1-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1D1-5Coolant Drain and Fill Up . . . . . . . . . . . . . . . 1D1-5
Coolant Connection Fitting . . . . . . . . . . . . . . 1D1-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-10
Oil Cooler Pipe Line . . . . . . . . . . . . . . . . . . 1D1-11
Cooling Fan and Viscous Clutch . . . . . . . . . 1D1-12
Cooling Fan Shroud . . . . . . . . . . . . . . . . . . 1D1-14
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
TABLE OF CONTENTS
Description
Water Cooling Forced Circulation
Double Cross Flow
70,000 kcal/h
580 x 482 x 45 mm

f 460, Six Blades
ALUTEC - P78
50 : 50
11.3 L
3.4 L
1.4 bar Application
Cooling Type
Radiator
Dimension(Width´Height´Thickeness)
Cooling Fan
Anti-Freeze Agent
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water)
Coolant Capacity
Reservoir Capacity
Cap Operating Pressure (Reservoir Tank Pressure Cap)
Circulation Type
Radiation Capability

1D1-2 M162 ENGINE COOLING
FASTENER TIGHTENING SPECIFICATIONS
N
· ·· ·
·m
30
22.5 - 27.5
9 - 11
9 - 11
9 - 11
40.5 - 49.5
3 - 7
3 - 7 Application
Coolant Drain Plug
Engine Hanger Bracket and Coolant Outlet
Port Bolt
Thermostat Cover Bracket Bolt
Oil Cooler Pipe Line Bolt
Cooling Fan Bolt
Viscous 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
Tester603 589 00 40
Counter Holder

1D1-4 M162 ENGINE COOLING
DIAGNOSIS
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 remove
the cap.
Notice
For 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.
Notice
For the risk of scalding, the cap must not be opened unless
the coolant temperature is below 90
oC.
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
lJust loosen the drain plug to drain the coolant and do
not remove the plug completely.
lCollect 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 pump
and remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank.
Notice
lMatch the anti-freeze and the water ratio to 50 : 50.
lSupplement 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.

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 Notice4 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 Torque22.5 - 27.5 Nm