engine SSANGYONG MUSSO 1998 Workshop Repair Manual

1D2-12 M161 ENGINE COOLING
THERMOSTAT HOUSING ASSEMBLY
Preceding Work : Removal of viscous clutch
1a Bolt (M6 X 95, 2 pieces)......................... 9-11 Nm
1b Bolt (M8 X 75, 2 pieces).................22.5-27.5 Nm
1c Bolt (M8 X 35, 1 piece)...................22.5-27.5 Nm
2 Thermostat Housing Assembly
3 O-ring4 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
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 connector.
4. Unscrew the bolt (1c) and pry off the tensioning device shock
absorber (7).
Installation Notice
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. 5. Unscrow the bolts (1a, 1b) and remove the engine
hanger bracket and thermostat housing.
Installation Notice
Tightening Torque9 - 11 Nm
22.5 - 27.5 Nm
(1a)
(1b)
Tightening Torque 22.5 - 27.5 Nm

1D2-14 M161 ENGINE COOLING
REMOVAL AND INSTALLATION OF COOLING FAN SHROUD
Removal & Installation Procedure
1. Unscrew two bolts from cooling fan shroud and remove
the shrud.
Installation Notice 1 Fan Suroud Assembly
Tightening Torque 3 - 7 Nm
2 Bolt (M6 X 16, 2 pieces)...........................3-7 Nm
2. Installation should follow the removal procedure in the
reverse order.

M161 ENGINE COOLING 1D2-15
REMOVAL AND INSTALLATION OF RADIATOR
Preceding Work : Removal of cooling fan shroud
1 Inlet Hose
2 Hose (to Engine)
3 Hose (to 3-way Connector)
4 Make-up Hose (to Coolant Reservoir)
5 3-way Connector
6 Automatic Transmission Oil Cooling Hose (A/T
Equippend Vehicle)7 Bolt (M6 X 20, 4 pieces)...........................3-7 Nm
8 Insulator
9 Radiator Bracket
10 Radiator

1D2-16 M161 ENGINE COOLING
Removal & Installation Procedure
1. 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. Unscrew the bolts from radiator bracket and remove the
bracket and insulator.
Installation Notice
Tightening Torque 3 - 7 Nm
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. Berform the cooling system leakage test.

SECTION 1D3
OM600 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D3-1
General Specifications . . . . . . . . . . . . . . . . . 1D3-1
Fastener Tightening Specifications . . . . . . . . 1D3-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-2
Cooling Circulation . . . . . . . . . . . . . . . . . . . . 1D3-2
Thermostat Operation . . . . . . . . . . . . . . . . . 1D3-3
Cooling System Leakage Test . . . . . . . . . . . 1D3-4
Maintenance and Repair . . . . . . . . . . . . . . 1D3-5On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1D3-5
Drain and Filling of Coolant . . . . . . . . . . . . . 1D3-5
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D3-6
Coolant Pump Housing . . . . . . . . . . . . . . . . . 1D3-8
Cooling Fan Clutch . . . . . . . . . . . . . . . . . . . 1D3-10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-12
Cooling Sub-System . . . . . . . . . . . . . . . . . . 1D3-14
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-16
TABLE OF CONTENTS
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.
Application
Coolant
Mixing Ratio (Water : anticorrosion)
CapacityDescription
ALUTEC P- 78
50 : 50
10.5L - 11L
9.5L - 10L
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Coolant Pump Bolt
Belt Pulley Bolt
Coolant Pump Housing Return Pipe Bolt
Thermostat Bolt
Cooling Fan Clutch Socket Bolt (Center)
Cooling Fan Clutch Socket Bolt (Side)
Radiator Bolt
Coolant Sub-tank BoltN
· ·· ·
·m
10
10
10
10
45
10
3 - 7
3 - 7
FASTENER TIGHTENING SPECIFICATIONS
662LA
661LA

1D3-2 OM600 ENGINE COOLING
COOLING CIRCULATION
A Thermostat
B Radiator
D From Heater
E HoseG Deaeration Line
H Reservoir
DIAGNOSIS

OM600 ENGINE COOLING 1D3-3
THERMOSTAT OPERATION
Operation
1. At warming up
Valve closes until temperature of coolant reaches to 85°C.
B. From Radiator
C. From Crankcase
D. To Crankcase
2. At partial opening.
Valve opens partially as temperature of coolant is maintained
between 85-100°C.
3. At full opening.
Valve opens full as temperature of coolant is more then
100°C.

1D3-4 OM600 ENGINE COOLING
COOLING SYSTEM LEAKAGE TEST
Tools Required
124 589 15 21 00 Tester
Test
1. Loosen the pressure cap by 1 notch and remove the cap
after.
Notice
Do not remove radiator cap when coolant is above 90°C.
2. Add the coolant to the arrow mark of coolant reservoir.
3. Connect the special tool to the injector of reservoir and apply
1.4bar pressure.
Tester 124 589 15 21 00
4. If the pressure on the tester drops, check the hose, pipe
and leakage and, replace or retighten.

OM600 ENGINE COOLING 1D3-5
DRAIN AND FILLING OF COOLANT
Preceding Work : Removal of skid plate
Drain / Filling
1. Loosen the pressure cap of reservoir by 1 notch and remove
pressure and then loosen the cap.
Notice
Do not remove radiator cap when coolant is above 90°C.
2. Open the drain plug and drain the coolant.
Notice
Collect the coolant by using the proper bottle.
3. Remove the drain plug(1) and seal(2) of cylinder block and
drain the coolant.
4. Replace the seal to new one and tighten the drain plug
Installation Notice
Tightening Torque 30 Nm
5. Tighten the drain plug of the lower radiator.
6. Fill the coolant through coolant reservoir-tank.
Notice
lA proportion of 50% by volume of water / anticorrosion
must be ensured
7. After engine is running at idle speed, check the level of
coolant. If necessary, add enough specified coolant.
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE