2003 SSANGYONG MUSSO torque

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

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.

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.

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

OM600 ENGINE COOLING 1D3-7
Removal & Installation Procedure
1. Loose the bolts(5) and remove the pulley (4).Installation Notice
Tightening Torque 10 Nm
2. Loose the bolts (3). Installation Notice
Tightening Torque 10 Nm
3. Pull the tensioning lever(1) to the arrow direction.
4. Remove the coolant pump(6). NoticeClean gasket residues on the sealing surface of coolant pump and replace the gasket.
5. Installation should follow the removal procedure in the reverse order.

OM600 ENGINE COOLING 1D3-9
Removal & Installation Procedure
1. Disconnect the connector(3).
2. Separate the coolant hose (5) and return pipe(6).
3. Remove the bolts(4) evenly.Installation Notice
Tightening Torque 10 Nm
Notice Clean gasket residues on the sealing surface of coolant pump and replace the gasket.
4. Remove the coolant pump housing(2).
5. Installation should follow the removal procedure in the reverse order.