SSANGYONG MUSSO 2003 Service Manual

1D2-4 M161 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 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. NoticeFor 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
Just loosen the drain plug to drain the coolant and do
not remove the plug completely.
Collect coolant by using proper container.

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.

M161 ENGINE COOLING 1D2-7
COOLING FAN AND VISCOUS CLUTCH
1 Bolt (M6 X 14, 3 piece) ........................... 9-11 Nm
2 Cooling Fan 3 Viscous Clutch
4 Union Nut (Left Threaded Screw) ... 40.5-49.5 Nm

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.

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 Nm 7 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 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

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
1 c Bolt (M8 X 35, 1 piece) ...................22.5-27.5 Nm
2 Thermostat Housing Assembly
3 O-ring 4 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 Torque 9 - 11 Nm
22.5 - 27.5 Nm
(1a) (1b)
Tightening Torque 22.5 - 27.5 Nm