torque SSANGYONG MUSSO 2003 Service Manual

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 thecoolant 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 heaterhose (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 Bracket
5 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.

M162 ENGINE COOLING 1D1-13
Tools Required 603 589 00 40 00 Counter Holder Removal & Installation Procedure
1. Hold the cooling fan pulley using the counter holder (special tool : 603 589 00 40 00) and remove the cooling fan after unscrewing the four bolts (4). Installation Notice
2. Remove the bolt (5) from the viscous clutch and remove the viscous clutch from the cooling fan pulley.Installation Notice
Tightening Torque 9 - 11 Nm
Tightening Torque 40.5 - 49.5 Nm
3. Installation should follow the removal procedure in the reverse order.

1D1-14 M162 ENGINE COOLING COOLING FAN SHROUD
Removal & Installation Procedure1. Pull out the 2 clips (1) from the fan shroud assembly.
2. Remove the lower fan shroud (2). NoticeFor installation, exactly align the lower fan shroud pin into the hole of the fan shroud assembly (4) and insert theclips.
3. Remove the bolts (3) and then remove the cooling fan shroud assembly (4).
1 Clip
2 Lower Fan Shroud
3 Bolt
Installation Notice
4. Installation should follow the removal procedure in the reverse order.
Tightening Torque 7 Nm 4 Fan Shroud Assembly
5 Radiator

1D1-16 M162 ENGINE COOLING Removal & Installation Procedure1. 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. Remove the automatic transmission oil cooling line bolts and then remove the oil cooling line.
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. Do cooling system leakage test.

1D2-6 M161 ENGINE COOLING
4. After complete draining of the coolant, remove the hoseconnector 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 pumpand remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank. Notice
Match the anti-freeze and the water ratio to 50 : 50.
Supplement 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.

1D2-8 M161 ENGINE COOLING
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 boltat the pulley as shown in the right figure to hold the pulley.
2. Remove the viscous clutch using an open end wrench (special tool : 111 589 02 01 00). Installation Notice
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 40.5 - 49.5 Nm
Tightening Torque 9 - 11 Nm
Notice
You may change the procedure (2) and (3) if necessary.
4. Installation should follow the removal procedure in the reverse order.

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 andremove 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. NoticeApply 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 Hose 4 Coolant Outlet Hose
5 Thermostat
6 O-ring