engine SSANGYONG MUSSO 2003 Service Manual

M162 ENGINE INTAKE & EXHAUST 1G1-7
RESONANCE FLAP1 Soft Cap (2)
2 Bolt (M6 x 25, 4 pieces) ......................... 9-11 Nm
3 O-ring
Removal & Installation Procedure
1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after removing
4 bolts (2). Notice Connect carefully the vacuum hose (4) for installation.
3. Check the O-ring (3) and replace it if necessary.
4. Remove the lower resonance flap (5).
5. Replace the gasket (6).
6. Installation should follow the removal procedure in the reverse order. 4 Vacuum Hose
5 Resonance Flap
6 Gasket ................................................... Replace

1G1-8 M162 ENGINE INTAKE & EXHAUST
Function Description A pneumatically actuated resonance flap (5) is located on the intake manifold, and will be opened and closed by load, whichoperates resonance flap according to engine and controlled by ECU and rpm.
1. Resonance flap closed (at idle/partial load : less than3,800/rpm) The switch valve (7) will be adjusted by ECU and resonance falp will be colosed. By increasing air flow passage throughdividing intaking air flow toward both air collection housing(8). This leads to a signficant increase in the torque in thelower speed range.
2. Resonance flap open (at full load : over 3,800/rpm) The switch valve (7) will not be adjusted by ECU andresonance falp (5) will be open. The colllected air in the aircollection housing (8) will not be divided and intaking airpassage will be shorten.

M162 ENGINE INTAKE & EXHAUST 1G1-9
EXHAUST MANIFOLD Preceding Work : Removal of air cleaner
1 Nut .......................................................36-44 Nm
2 Gasket ................................................... Replace3 Exhaust Manifold

1G1-10 M162 ENGINE INTAKE & EXHAUST
Tools Required 103 589 01 39 00 Caulking Bolt Removal & Installation Procedure
1. Remove the flange bolt from the exhaust manifold, anddisconnect the front exhaust pipe. Installation Notice Notice
Check for nut damages and replace the nut if necessary.
2. Remove the 23 nuts (1) from the stud bolt, and remove the exhaust manifold. Installation Notice
3. Replace the gasket (2).
4. Installation is reverse order of the removal. Replacement of Rivet Nut
1. Pull out the rivet nut from the connecting point of the exhaust manifold and the exhaust pipe using a proper bolt (arrow).
2. Insert a new rivet nut into the exhaust manifold hole, and tighten with a special tool (Caulking Bolt). Installation Notice
Caulking Bolt 103 589 01 39 00
Tightening Torque 30 Nm
Tightening Torque 26 - 34 Nm
Tightening Torque 30 Nm

M162 ENGINE INTAKE & EXHAUST 1G1-11
Removal and Installation of Exhaust Line
1 Exhaust Manifold
2 Rivet Nut
3 Bolt........................................................... 30 Nm
4 Front Pipe
5 Oxygen Sensor
6 Bolt ...................................................... 28-47 Nm
7 Rubber Pad
8 Catalytic Converter
9 Gasket ................................................... Replace10 Nut 11 Gasket ................................................... Replace
12 Rubber Pad
13 Nut ....................................................... 28-47 Nm
14 Center Muffler
15 Rubber Pad
16 Tail Muffler
17 Gasket ................................................... Replace
18 Nut ....................................................... 28-47 Nm

SECTION 1G2
M161 ENGINE INTAKE & EXHAUST
TABLE OF CONTENTSSPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N m
9 - 11
22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 28 28 - 47
Application
Air Cleaner Housing Cover NutIntake Manifold Bolt (M8 x 20) Intake Manifold Bolt (M8)Exhaust Mainfold Stud BoltExhaust Pipe Nut (Engine) Exhaust Pipe Bolt
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G2-1 Fastener Tightening Specifications . . . . . . . . 1G2-1
Maintenance and Repair . . . . . . . . . . . . . . 1G2-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 1G2-2
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 1G2-2Air Intake Shield . . . . . . . . . . . . . . . . . . . . . .
1G2-4
Intake Air Duct . . . . . . . . . . . . . . . . . . . . . . . 1G2-5
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 1G2-7
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 1G2-9

1G2-2 M161 ENGINE INTAKE & EXHAUSTMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AIR CLEANER
1 Air Cleaner Assembly
2 Element Assembly
3 Insulator
4 Air Duct Hose5 Air Inlet Duct
6 Bolt (M8 × 30 ) ................................... 22.5-27.5 Nm
7 Bolt (M6 × 35 ) ........................................... 9-11 Nm

M161 ENGINE INTAKE & EXHAUST 1G2-3
Removal & Installation Procedure1. Release the clamp securing HFM sensor and air cleaner.
2. Disengage the air cleaner assembly and HFM sensor assembly.
3. Unserew the mounting bolt(6) from the bracket.
Installation Notice
Tightening Torque 22.5 - 27.5 Nm
4. Release the clamp from air cleaner assembly housing and remove the cover.
5. Remove the air cleaner assembly.
6. Remove the air cleaner housing from insulator.
Notice
Make sure the air cleaner to be seated in insulator.
7. Disengage the air duct hose and air cleaner housing and remove the housing.
8. Remove the air duct hose.
9. Unscrew the two bolts(7) from air inlet duct. Installation Notice
10. Remove the air inlet duct.
11. Installation should follow the removal procedure in the reverse order.
Tightening Torque 8 - 9 Nm

1G2-4 M161 ENGINE INTAKE & EXHAUST
AIR INTAKE SHIELD Preceding Work : Removal of air cleaner
Removal & Installation Procedure
1. Remove the upper cover (3) from the air intake shield (5)upper mounting pin.
2. Remove the bolts (4 and 6).
3. Remove the air intake shield (5).
4. Installation should follow the removal procedure in the reverse order.
1 Air Cleaner
2 Gasket
3 Air Intake Shield Upper Cover
4 Bolt
5 Air Intake Shield
6 Bolt
7 Bracket

M161 ENGINE INTAKE & EXHAUST 1G2-5
INTAKE AIR DUCT
1 Clamp
2 Sleeve
3 HFM Sensor
4 Intake Air Duct
5 Blow-by Hose
7 Clamp(2 pieces)
8 Intake Air Duct MountingBracket
Removal & Installation Procedure
1. Release the clamp (1) and intake air duct.
2. Remove the Blow-by hose (5) (arrow).