coolant SSANGYONG MUSSO 2003 Owner's Guide

1B3-60 OM600 ENGINE MECHANICAL
35. Connect the wires to the coolant temperature sensor andthe glow plug sensor.
36. Replace the intake manifold gasket.
37. Install the intake manifold.
Tightening Torque 25 Nm
33. Replace the gasket and install the cylinder head cover.
Tightening Torque 10 Nm
34. Install the blow-by hose.

OM600 ENGINE MECHANICAL 1B3-177
CYLINDER HEAD PRESSURE LEAKAGE TEST Preceding Work : Removal of the cylinder head Removal of the exhaust manifold Removal of the valve
1 Feed Pipe
2 Bolt
3 Return Connection
4 Gasket ................................................................ Replace
5 Coolant Gallery ................................................... Sealing
6 Pressure Measuring Plate ..................................Completely tight to the cylinder head
7 Cylinder Head .....................................................
Immerse with pressure measuring plate into warm water of approx. 60 °C and pressurize with compressed
airof 2 bar.
Notice If air bubbles are seen, replace the cylinderhead.
Tools Required
115 589 34 63 00 Pressure Measuring Plate 601 589 00 25 00 Suspension Device
UNIT REPAIR

OM600 ENGINE MECHANICAL 1B3-181
Tools Required 102 589 00 15 00 Drift 102 589 12 15 00 Drift Replacement Procedure
1. Completely drain the coolant.
2. Remove any parts which impede access.(Example : transmission, injection pump)
3. Place the screwdriver to the deepdrawn edge of the core plug and pull forward and then rotate 90 °.
4. Pull out the core plug with pliers.
5. Thoroughly clean the sealing surface and apply Loctite 241.
6. Install the new core plug by using a drift. Drift 102 589 00 15 00 (F34) Drift 102 589 12 15 00 (F17)
7. Install the removed parts and fill the coolant. Notice The adhesive must be allowed to harden for about 45 minutes before filling of coolant.
8. Warm up the engine and check the coolant for leaks.

OM600 ENGINE MECHANICAL 1B3-183
OIL GALLERY STEEL BALL Preceding Work : Removal of cooling fan Removal of the coolant pump housing Removal of the flywheel and driven plate
1 Steel Ball.................................................15mm 2 Screw Plug ............................... Loctite 241,50Nm
Notice The screw plug (2) has to be installed as a repair solution if the steel ball (1) is leaking.

SECTION 1D1
M162 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D1-1General Specifications . . . . . . . . . . . . . . . . . 1D1-1
Fastener Tightening Specifications . . . . . . . . 1D1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1D1-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1D1-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-4 System Leakage Test . . . . . . . . . . . . . . . . . . 1D1-4
Maintenance and Repair . . . . . . . . . . . . . . 1D1-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1D1-5Coolant Drain and Fill Up . . . . . . . . . . . . . . .
1D1-5
Coolant Connection Fitting . . . . . . . . . . . . . . 1D1-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-8
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-10
Oil Cooler Pipe Line . . . . . . . . . . . . . . . . . . 1D1-11
Cooling Fan and Viscous Clutch . . . . . . . . . 1D1-12
Cooling Fan Shroud . . . . . . . . . . . . . . . . . . 1D1-14
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS
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 otherwisenoted.
TABLE OF CONTENTS
Description
Water Cooling Forced Circulation Double Cross Flow
70,000 kcal/h
580 x 482 x 45 mm
460, Six Blades
ALUTEC - P78
50 : 50
11.3 L 3.4 L
1.4 bar
Application
Cooling Type Radiator Dimension(Width ×Height ×Thickeness)
Cooling Fan Anti-Freeze Agent
Mixing Ratio of Anti-Freeze Agen with Water (Anti-Freeze Agent : Water)Coolant CapacityReservoir Capacity
Cap Operating Pressure (Reservoir Tank Pressure Cap)
Circulation Type Radiation Capability

1D1-2 M162 ENGINE COOLINGFASTENER TIGHTENING SPECIFICATIONS
N

 m
30
22.5 - 27.5
9 - 11
9 - 11
9 - 11
40.5 - 49.5
3 - 73 - 7
Application
Coolant Drain PlugEngine Hanger Bracket and Coolant OutletPort Bolt Thermostat Cover Bracket Bolt Oil Cooler Pipe Line BoltCooling Fan BoltViscous Clutch Bolt
Automatic Transmission Oil Cooling Hose Bolt Cooling Fan Shroud Bolt

1D1-4 M162 ENGINE COOLINGDIAGNOSIS
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 removethe cap. NoticeFor 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. NoticeFor the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 o
C.
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
Just loosen the drain plug to drain the coolant and do not remove the plug completely.
Collect 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 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.
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 upthe 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 Notice 4 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 Torque 22.5 - 27.5 Nm