SSANGYONG KORANDO 1997 Service Repair Manual

M162 ENGINE INTAKE & EXHAUST 1G1 -- 3
D AEW OO M Y_2000
MAINTENANCE AND REPAIR
ON -- VEHICLE SERVICE
AIR CLEANER
1 Element Assembly
2 Cleaner Assembly -- Air
3 Shield Cover -- Air Intake4 Shield Assembly -- Air Intake
5 Braket Assembly -- Air Cleaner Mounting
6 Braket Assembly -- Shield Surport

1G1 -- 4 M162 ENGINE INTAKE & EXHAUST
D AEW OO M Y_2000
Removal and Installation Procedure
1. Disconnect the HFM sensor and the air cleaner by
prying up the clamp.
2. Remove the air cleaner mounting bolt.
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
3. Remove air intake shield upper cover, and then re-
move the air cleaner from rubber bearing on bracket.
Notice:For installation, exactly seat the air cleaner into
the rubber bearing.
4. Installation should follow the removal procedure in
the reverse order.

M162 ENGINE INTAKE & EXHAUST 1G1 -- 5
D AEW OO M Y_2000
INTAKE AIR DUCT
1 Clamp
2 Sleeve
3Nut4 Clamp
5 Intake Air Duct

1G1 -- 6 M162 ENGINE INTAKE & EXHAUST
D AEW OO M Y_2000
Removal & Installation Procedure
1. Remove the clamp (1) and disconnect the HFM sen-
sor.
2. Remove the nut (3) (arrow).
3. Remove the clamp (4).
4. Remove the intake air duct (5) carefully.
Installation Notice
Exactly seat the pin of intake air duct onto the crank-
case ventilation rubber mount.
5. Installation should follow the removal procedure in
the reverse order.

M162 ENGINE INTAKE & EXHAUST 1G1 -- 7
D AEW OO M Y_2000
INTAKE MANIFOLD
Preceding Work: Removal of fuel rail
Removal of battery
Removal of canister
1 Bolt (M6 X 40, 4 pieces)
9--11 NSm (80-- 97 lb-in) .....................
2 Softcap
3 Resonance Flap
4 Gasket Replace...........................
5 Upper Intake Manifold
6 Bolt (M8 x 50, 9 pieces)
22.5-- 27.5 NSm (16.6-- 20.3 lb-ft) .............
7 Gasket Replace...........................
8Blow--byHose
9Blow--byHose
10 Clamp
11 Blow-- by Nipple
12 Inlet Air Housing13 Bolt (M6 x 40, 4 pieces)
9--11 NSm (80-- 97 lb-in) .....................
14 Throttle Body -- Electric
15 Gasket Replace...........................
16 Lower Intake Manifold
17 Bolt (M8 x 40, 4 pieces)
22.5-- 27.5 NSm (16.6--20.3 lb-ft) .............
18 Nipple Replace............................
19 Seal Ring
20 Connection House
21 Clamp
22 Noise Damper Assembly
23 Tapping Screw

1G1 -- 8 M162 ENGINE INTAKE & EXHAUST
D AEW OO M Y_2000
Removal & Installation Procedure
DUpper Intake Manifold
1. Disconnect the vacuum hose (8,9).
2. Loosen the clip (22).
3. Disconnect the resonance flap connector.
4. Remove the upper intake manifold (5) after unscrew-
ing the bolt (6).
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
Notice:Check the gasket and replace it if necessary.
5. Installation should follow the removal procedure in
the reverse order.
DLower Intake Manifold
Preceding work : removal of upper intake manifold
1. Remove the hose of brake booster vacuum line and
idle speed connector.
2. Disconnect the hot water inlet pipe from the bottom of
lower intake manifold.
3. Unscrew the bolt (17) and remove the lower intake
manifold (16).
Installation Notice
Tightening Torque
22.5 -- 27.5 NSm
(16.6 -- 20.3 lb-ft)
4. Start the engine and check for leaks at each connec-
tion part.

M162 ENGINE INTAKE & EXHAUST 1G1 -- 9
D AEW OO M Y_2000
RESONANCE FLAP
1 Soft Cap (2)
2 Bolt (M6 x 25, 4 pieces)
9--11 NSm (80-- 97 lb-in) .....................
3O--ring4 Vacuum Hose
5 Resonance Flap
6 Gasket Replace...........................
Removal & Installation Procedure
1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after re-
moving 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.

1G1 -- 10 M162 ENGINE INTAKE & EXHAUST
D AEW OO M Y_2000
Function Description
A pneumatically actuated resonance flap (5) is located
on the intake manifold, and will be opened and closed by
load, which operates resonance flap according to engine
and controlled by ECU and rpm.
1. Resonance flap closed (at idle/partial load : less
than 3,800/rpm)
The switch valve (7) will be adjusted by ECU and res-
onance flapwill be closed. By increasing air flow pas-
sage through dividing intaking air flow toward both air
collection housing (8). This leads to a signficant in-
crease in the torque in the lower speed range.
2. Resonance flap open (at full load:over 3,800/rpm)
The switch valve (7) will not be adjusted by ECU and
resonance flap (5) will beopen. The colllected air in
the air collection housing (8)will not be divided and
intaking air passage will be shorten.

M162 ENGINE INTAKE & EXHAUST 1G1 -- 11
D AEW OO M Y_2000
EXHAUST MANIFOLD
Preceding Work: Removal of air cleaner
1 Nut 36-- 44 NSm (27-- 33 lb-ft) .................
2 Gasket Replace...........................3 Exhaust Manifold

1G1 -- 12 M162 ENGINE INTAKE & EXHAUST
D AEW OO M Y_2000
Removal & Installation Procedure
1. Remove the flange bolt from the exhaust manifold,
and disconnect the front exhaust pipe.
Installation Notice
Tightening Torque
30 NSm (22 lb-ft)
Notice:Check for nut damages and replace the nut if
necessary.
2. Remove the 23 nuts (1) from the stud bolt, and re-
move the exhaust manifold.
Installation Notice
Tightening Torque
36 -- 44 NSm (27 -- 33 lb-ft)
3. Replace the gasket (2).
4. Installation is reverse order of the removal.