coolant reservoir SSANGYONG MUSSO 2003 User Guide

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

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 capafter. 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 removepressure 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
A 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

MUSSO-SPORTS 1A-29
SUPPLEMENT
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Engine Engine - MainMain - Floor Floor - FRAME FRAME - DECKMain Engine EngineMain Main Floor
C101 (21Pin, Colorless) C103 (2Pin, White) C108 (16Pin, Black)C206 (Colorless) C904 (10Pin, Black) C905 (12Pin, Black)S101 (Black) G101 G102G201 G204 G301
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Inside Co-Driver Side Cowl PanelBehind The Left FRAME Behind The Left FRAME Inside The Engine Room Fuse BlockBehind The Left Lamp Behind The Right Head Lamp Right The I/P Fuse BlockUpper The ECM Center The Left 'B' Pillar
123 456
HEAD LAMP
MULTI-FUNCTION SWITCH
C1C2
C3 C4
B1 B2 B3 B4
B5 B6 B7 B8 B9
B10
A1 A2 A3 A4 A5 A6
A7 A8 A9
A10 A11 A12 A13 A14
123456789101112
29 30 31 32 33 34 35 36 37 38
28 13 2714261525162417231822
19 2021
39 43 40
44 45 46 4147
48
42
CLUSTER C108
W/H ENGINE
1234 5678
9 101112
13 14 15 16
C103
W/H MAIN
12
5678910 34
HAZARD
SWITCH
2
1
TAIL
LAMP
123 456
1234 5678
9 101112
C905
W/H DECK
5432
109871 6
C904
W/H FLOOR

POSITION OF CONNECTORS AND GROUNDS 2-3
C361 C371C381C401C402C403 22
88626 White
ColorlessColorlessColorlessColorlessColorless Main - Co-Driver DoorFloor - Rear Left DoorFloor - Rear Right DoorFloor - Tail GateFloor - Tail GateFloor - Tail Gate
Inside Co-Driver Side Cowl PanelCenter 'B' PillarCenter Left 'B' PillarBehind The Left LampBehind The Left LampBehind The Left Lamp
2. CONNECTOR, GROUND AND SPLICE PACK INFORMATION
1) CONNECTOR
Connector
Number Connecting Wiring HarnessConnector PositionColorPin
Number
C101 C102C103C104C105C106C107 C108 C109C110C111C112C201C203C204C205 C206
C206B C207 C208C208
C208B C209C210C211C212 C213 C251C301C302C303 C304 C305 C351212 2
15 143 2
16 6
40 6 84
10 33
4 [6]
1616121584
1417 6 3
20 1614 12 6
22 Colorless Colorless
WhiteBlackBlackBlackBlack Black BlackBlackBlack Gray
White
Colorless WhiteBlackBlack Black BlackBlackBlackBlackBlackBlackBlack
White
Colorless Black
White WhiteWhite
Colorless White
Blue Main - Engine Main - EngineMain - EngineEngine - MainEngine - EngineGenerator - EngineGenerator - Engine Genertor - Engine Engine - MainMain - Engine MainEngine Main - ECM MainEngine Main - ECM MainMain - RoofMain Air BagMain - Driver SeatMain - T/MMain - Fuel Tank Main - Fuel Tank Main - T/MMain - T/MMain - T/MMain - T/MMain - T/MMain - T/MDLC Connector - MainMain - Air ConMain - ECM Main Driver Seat - Driver Seat, AUX Main - FloorMain - Floor Main - Floor Main - FloorMain - Floor Main - Driver DoorInside The Engine Room Fuse Block Inside The Engine Room Fuse BlockInside The Engine Room Fuse BlockUnder The Engine Room Fuse BlockBeside Pre-Heating Unit (DSL)Under The Air Cleaner Housing (DSL, Turbo)Under The Air Cleaner Housing (DSL, N/Turbo) Under The Air Cleaner Housing (GSL) Under The Coolant Reservoir TankBehind The ABS Module (HFM)Center The Engine Room Dash PanelCenter The Engine Room Dash PanelUpper The I/P Fuse BlockLeft The AudioUnder The Driver SeatUpper The T/C MotorUpper The T/C (DSL) Upper The T/C (GSL) Upper The T/CUpper The T/C (GSL)Upper The T/C (DSL)Upper The T/C (GSL)Upper The T/C (DSL)Upper The T/C (GSL)Beside The Steering ColumnBehind The Glove BoxBeside The ECM (MSE) Under The Driver Seat Beside The I/P Relay BlockBeside The I/P Relay BlockBeside The I/P Relay Block Inside Co-Driver Side Cowl Panel Beside Center ConsoleUpper The I/P Fuse Block
Connector
Number Connecting Wiring HarnessConnector PositionColorPin
Number
2) GROUND
G101 G102 G103G201 G202 G203G204G205 G206 G207G208 G209 G301G302G303 Ground Position
Wiring Harness
Ground
Number
Behind The Left LampBeside The Start Motor Behind The Right Head Lamp Right The I/P Fuse BlockBeside The STICSUpper The ECM Behind The Ashtray Beside The TCCUBeside The ABS Module Beside THe ECM Under THe CO-Driver SeatBeside The EBCMCenter The Left 'B' Pillar Beside The Left Rear Speaker Beside The Right Rear Speaker
Engine Engine Engine
Main MainMain Main MainMain Main MainMain
Floor Floor Floor
* [ ] : EURO III

5-12 ELECTRICAL WIRING DIAGRAMS
3) DSL NA BTRE A/T, M/TMain - Engine Main - Engine Genertor - Engine Engine - MainMain - T/M Main
C101 (21Pin, Colorless) C102 (2Pin, Colorless) C107 (3Pin, Black) C109 (16Pin, Black) C207 (16Pin, Black) G201
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C107
W/H GENERA- TOR C207
W/H T/M
C101
W/H MAIN C102
W/H MAIN C109
W/H ENGINE
IGNITION SWITCH
CLUSTER
CONNECTOR(NUMBER)CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Under The Air Cleaner Housing (DSL, N/Turbo)Under The Coolant Reservoir Tank Upper The T/C Right The I/P Fuse Block
12345 678910
11 12 13 14 15 16 17 18 19 20 2112123
1234 5678
9 101112
13 14 15 16
1234 5678
9 101112
13 14 15 16
123 456
11 2
29 38
28
13 2021
39 434842PNP SWITCH
12
34
CLUTCH
SWITCH
12
M
30 (BAT +) 15 (IGN 1)15A (IGN 2)
15C (ACC)
31 GND
Cluster (Charging
WarningLamp)
G201
G201
G105 B BST3
4
OFF
ACC
ONST BL
R M/T
A/T 162
F22
10A
F24
15A
RG RG
W
+-
LB 18 5 YW YW
C107
Generator
I.C Regulator L
B+ P 2
C109
10
C107
F(I)
1
C101
15
Ef7
40A
F110A
E
f2 80A
BW L LW
Ignition Switch
C102
1
C207
Battery
PNP Switch(BTRE A/T)
BG BL BY
BY
BY BY
B
B
Starter Motor
"29"
Cluster
(RPM)
BG BG
1 3
1 2
4
C101
A/T
M/T 20C101
13
C207
3 87
Clutch
Switch 85
Starter Motor
Relay
30 86
C107
RL RL
3
C109
9
G104

5-14 ELECTRICAL WIRING DIAGRAMS
4) DSL LA BTRE A/T, M/TMain - Engine Main - Engine Genertor - Engine Engine - MainMain - T/M Main
C101 (21Pin, Colorless) C102 (2Pin, Colorless) C106 (4Pin, Black) C109 (16Pin, Black) C207 (16Pin, Black) G201
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C106
W/H GENERA- TOR C207
W/H T/M
C101
W/H MAIN C102
W/H MAIN C109
W/H ENGINE
IGNITION SWITCH
CLUSTER
CONNECTOR(NUMBER)CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Under The Air Cleaner Housing (DSL, Turbo)Under The Coolant Reservoir Tank Upper The T/C Right The I/P Fuse Block
12345 678910
11 12 13 14 15 16 17 18 19 20 211212 34
1234 5678
9 101112
13 14 15 16
1234 5678
9 101112
13 14 15 16
123 456
11 2
29 38
28
13 2021
39 434842PNP SWITCH
12
34
CLUTCH SWITCH
12
M
30 (BAT +) 15 (IGN 1)15A (IGN 2)
15C (ACC)
31 GND
Cluster (Charging
WarningLamp)
G201
G201
G105 B BST3
4
OFF
ACC
ONST BL
R M/T
A/T 162
F22
10A
F24
15A
RG RG
W
+-
LB 18 5 YW YW
C106
Generator
L
B+ P 2
C109
10
C106
F(I)
I.C Regulator 3
C101
15
Ef7
40A
F110A
E
f2 80A
BW L LW
Ignition Switch
C102
1
C207
Battery
PNP Switch(BTRE A/T)
BG BL BY
BY
BY
BY BY
YB
Starter Motor "2"
Preheat'g Unit
"29"
Cluster
(RPM)
BG BG
1 3
1 2
4
C101
A/T
M/T 20C101
13
C207
3 87
Clutch
Switch 85
Starter Motor
Relay
30 86
C106
RL RL
1
C109
9
G104

5-24 ELECTRICAL WIRING DIAGRAMS
2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, MAP, CKP), CAM SHAFTACTUATOR CIRCUIT (1) W/O EURO III
Main - Engine Engine - Main Engine Main - ECM Main Engine Main - ECM MainMain - ECM Main
C101 (21Pin, Colorless)C109 (16Pin, Black) C111 (40Pin, Black) C112 (6Pin, Gray) C213 (6Pin, Colorless)
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C101
W/H MAIN C109
W/H ENGINE
CAM SHAFT ACTUATOR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Center The Engine Room Dash PanelCenter The Engine Room Dash Panel Beside The ECM (MSE)
CMP
SENSOR HFM SENSOR
C213
W/H ECM MAIN C112
W/H ENG. MAIN
CKP SENSOR OVPR C111
W/H ECM MAIN
1212312 345
122167
5348
12345 678910
11 12 13 14 15 16 17 18 19 20 21
10 1
20 11
30 21
40 31
321
654
321
654

5-26 ELECTRICAL WIRING DIAGRAMS(2) W/ EURO III
Main - Engine Engine - Main Engine Main - ECM Main Engine Main - ECM MainMain - ECM Main
C101 (21Pin, Colorless)C109 (16Pin, Black) C111 (40Pin, Black) C112 (6Pin, Gray) C213 (6Pin, Colorless)
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C101
W/H MAIN C109
W/H ENGINE
CAM SHAFT ACTUATOR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Center The Engine Room Dash PanelCenter The Engine Room Dash Panel Beside The ECM (MSE)
CMP
SENSOR MAP SENSOR
123
C213
W/H ECM MAIN C112
W/H ENG. MAIN
CKP SENSOR
12
OVPR
2167
5348
C111
W/H ECM MAIN
KNOCK SENSOR (KS)
12
12345 678910
11 12 13 14 15 16 17 18 19 20 21
10 1
20 11
30 21
40 31
321
654
12123321
654

5-40 ELECTRICAL WIRING DIAGRAMS
2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, CKP), CAM SHAFTACTUATOR, RESONANCE FLAP CIRCUIT
Main - Engine Engine - Main Engine Main - ECM Main Engine Main - ECM MainMain - ECM Main
C101 (21Pin, Colorless)C109 (16Pin, Black) C111 (40Pin, Black) C112 (6Pin, Gray) C213 (6Pin, Colorless)
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C101
W/H MAIN C109
W/H ENGINE
CAM SHAFTACTUATOR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Center The Engine Room Dash PanelCenter The Engine Room Dash Panel Beside Yhe ECM (MSE)
12345 678910
11 12 13 14 15 16 17 18 19 20 21
12
CMP
SENSOR
123
HFM SENSOR
12 345
C213
W/H ECM MAIN C112
W/H ENG. MAIN
321
654
321
654
CKP SENSOR
12
OVPR
2167
5348
C111
W/H ECM MAIN
10 1
20 11
30 21
40 31
RESONANCE
FLAP
12
ECMSIG
SIG
SIG
SIG
SIG 5V
#5
#2
#1
12 #4
#3
#2
12
71
73 97 104 106 80 105 108 81 100 99 72 70 27#6
A/C
Relay "85"
35
Cooling Fan
Motor Relay "86"
44
Thermo
Amp"1"
45
EBCM
(ABD) "32"
"F1"2
Cluster
(ABD
Warning Lamp) "4"
#1
#3
12
OVPR
"8"
C112 3
12
C101
8
C213
BW PR
PR BG B BG BW
BW
BW
BY
LB BYLW
BY
BG BY
BB WBYI
gnition
Coil
1
C112 6
C109
16
C112 4
C213 YG
RG BrGr BrG GBr RL YW Br RL BrY YG G GW GGW
YW Br BrY YG
RG GV
RG BrG GBr
GV
YG RL 1
2
3
OVPR "2" Cam Shaft
Actuator CMP Sensor HFMS CKPAIR
TEMP SIG
( - ) SIG
( + )
B+ Ref
13
21
-+2
2
1
132 5 4
Resonance Flap C111
27 25
24 29 15 28 30 16 26
11