SSANGYONG MUSSO 2003 Service Manual

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).

1G2-6 M161 ENGINE INTAKE & EXHAUST
3. Release the clamp (7) and remove the intake air duct.Notice Completely fit the intake air duct with the mounting bracket (8).

M161 ENGINE INTAKE & EXHAUST 1G2-7
INTAKE MANIFOLD Preceding Work : Removal of intake air duceRemoval of fuel distributor and injector
1 Bolt (M6 X 40, 6 pieces) .................22.5-27.5 Nm
2 Intake Manifold
3 Gasket (2 pieces) .................................. Replace
4 Bolt (M8 X 40, 3 pieces) .................22.5-27.5 Nm 5 Idle Regulator
6 Intermediate Flange
7 Bolt (M6 X 35, 4 pieces)
......................... 9-11 Nm
8 Connection Piece With Seal Ring ........ 36-44 Nm

1G2-8 M161 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
1. Disconnect the battery ground cable.
2. Remove idle speed control plug connector (arrow).
3. Disconnect the brake booster vacuum line and othervacuum lines.
4. Disconnector the rod from bearing bracket assembly and remove the connection piece (8). Installation Notice
Tightening Torque 36 - 44 Nm
5. Unscrew the three bolts (4) and remove the idle regulatorand intermediate flange (6). Installation Notice
Tightening Torque 22.5 - 27.5 Nm
6. Unscrew the two bolts (M8 X 16) and remove the support assembly (arrow). Installation Notice
7. Unscrew the intake manifold assembly mounting bolts (1) and remove the intake manifold and gasket.Installation Notice Notice Replace the gasket with new one.
8. Installation should follow the removal procedure in the reverse order.
9. Start the engine and check for leaks in each connection.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 22.5 - 27.5 Nm