engine SSANGYONG MUSSO 2003 Service Manual

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

1D2-14 M161 ENGINE COOLING
REMOVAL AND INSTALLATION OF COOLING FAN SHROUD
Removal & Installation Procedure1. Unscrew two bolts from cooling fan shroud and remove the shrud. Installation Notice
1 Fan Suroud Assembly
Tightening Torque 3 - 7 Nm
2 Bolt (M6 X 16, 2 pieces)
...........................3-7 Nm
2. Installation should follow the removal procedure in the reverse order.

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 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. 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.

SECTION 1D3
OM600 ENGINE COOLING
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1D3-1General Specifications . . . . . . . . . . . . . . . . . 1D3-1
Fastener Tightening Specifications . . . . . . . . 1D3-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-2 Cooling Circulation . . . . . . . . . . . . . . . . . . . . 1D3-2
Thermostat Operation . . . . . . . . . . . . . . . . . 1D3-3
Cooling System Leakage Test . . . . . . . . . . . 1D3-4
Maintenance and Repair . . . . . . . . . . . . . . 1D3-5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . .
1D3-5
Drain and Filling of Coolant . . . . . . . . . . . . . 1D3-5
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . 1D3-6
Coolant Pump Housing . . . . . . . . . . . . . . . . . 1D3-8
Cooling Fan Clutch . . . . . . . . . . . . . . . . . . . 1D3-10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-12
Cooling Sub-System . . . . . . . . . . . . . . . . . . 1D3-14
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 1D3-16
TABLE OF CONTENTS
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.
Application
Coolant
Mixing Ratio (Water : anticorrosion) Capacity
Description
ALUTEC P- 78 50 : 50
10.5L - 11L 9.5L - 10L
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Coolant Pump Bolt Belt Pulley BoltCoolant Pump Housing Return Pipe BoltThermostat Bolt Cooling Fan Clutch Socket Bolt (Center) Cooling Fan Clutch Socket Bolt (Side)Radiator BoltCoolant Sub-tank BoltN 

 m
10 101010 45 10
3 - 73 - 7
FASTENER TIGHTENING SPECIFICATIONS
662LA 661LA

1D3-2 OM600 ENGINE COOLING
COOLING CIRCULATIONA Thermostat
B Radiator
D From Heater
E Hose
G Deaeration Line
H Reservoir
DIAGNOSIS

OM600 ENGINE COOLING 1D3-3
THERMOSTAT OPERATION Operation
1. At warming upValve closes until temperature of coolant reaches to 85 °C.
B. From Radiator
C. From Crankcase
D. To Crankcase
2. At partial opening. Valve opens partially as temperature of coolant is maintained between 85-100 °C.
3. At full opening. Valve opens full as temperature of coolant is more then 100 °C.

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.