SSANGYONG MUSSO 1998 Workshop Repair Manual

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

1D1-8 M162 ENGINE COOLING
WATER PUMP
Preceding Work : Removal of V-belt
Removal 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 Hose8 Coolant Hose
9 Inlet Coolant Hose
10 Coolant Pump
1 1 Bolt........................................................... 21 Nm
12 Dowel Sleeve
1 3 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 the
coolant 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 heater
hose (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 Bracket5 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.