engine coolant SSANGYONG MUSSO 1998 Workshop Workshop Manual

1D2-4 M161 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.

M161 ENGINE COOLING 1D2-5
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 90oC.
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.

1D2-6 M161 ENGINE COOLING
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.
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.
Tightening Torque 30 Nm
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 1D2-9
COOLANT PUMP
Preceding Work : Removal of viscous clutch
1 Bolt (M6 X 45, 1 piece)........................... 9-11 Nm
2 Bolt (M6 X 95, 1 piece)........................... 9-11 Nm
3 Bolt (M6 X 25, 4 piece)........................... 9-11 Nm
4 Bolt (M8 X 85, 2 piece)...................20.5-20.5 Nm
5 Coolant Pump Housing
6 Bolt (M6 X 16, 4 piece)........................... 9-11 Nm7 Coolant Pump Pulley
8 Coolant Inlet Hose
9 Heater Hose
10 Coolant Bypass Hose
11 Gasket

1D2-10 M161 ENGINE COOLING
Tools Required
124 589 15 21 00 Tester
Removal & Installation Procedure
1. Drain the coolant.
2. Disconnect the coolant hoses (8, 9, 10).
3. Tak off the drive belt.
4. Unscrew the four bolts (6) from coolant pump pulley and
remove the pulley (7).
Installation Notice
Tightening Torque 9 - 11 Nm
22.5 - 27.5 Nm
(1, 2, 3)
(4) Notice
Hold the pulley with special tool (603 589 00 40 00) while
removing the pulley.
Tightening Torque 9 - 11 Nm
5. Unscrew the bolts (1, 2, 3, 4) from coolant pump housing
(5) and remove the coolant pump.
Installation Notice
6. Clean the sealing surface.
7. Replace the gasket with new one.
Notice
Apply the sealant when the sealing surface of coolant 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
THERMOSTAT
Removal & Installation Procedure
1. Drain the coolant from the radiator.
2. Loosen the hose mounting clip and remove the coolant hose
(3, 4).
3. Unscrew the three bolts (1) and remove the thermostat cover
assembly from thermostat housing.
Installation Notice
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 1 Bolt (M6 X 25, 3 pieces)........................ 9 -11 Nm
2 Thermostat Cover
3 De-aeration Hose4 Coolant Outlet Hose
5 Thermostat
6 O-ring

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

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.