SSANGYONG MUSSO 1998 Workshop Repair Manual

1G2-10 M161 ENGINE INTAKE & EXHAUST
4. Unscrew the eleven nuts (4) and remove the exhaust
manifold (5) and gasket (7).
Installation Notice
Tightening Torque 31.5 - 38.5 Nm
5. Replace the gasket (7) with new one.
6. Installation should follow the removal procedure in the
reverse order.

M161 ENGINE INTAKE & EXHAUST 1G2-11
Removal and Installation of Exhaust Line
1 Heat Protector-Floor
2 Pipe Assembly-Front Exhaust
3 Gasket
4 Heat Protector-Rear Exhaust5 Road Assembly-Muffler Mounting Rear
6 Heat Pro-Tector Dash
7 Heat Pro-Tector Floor
8 Heat Pro-Tector Rear Exhaust

SECTION 1G3
OM600 ENGINE INTAKE & EXHAUST
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G3-1
Fastener Tightening Specifications . . . . . . . . 1G3-1
Schematic and Routing Diagrams . . . . . . . 1G3-2
EGR Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-2
Maintenance and Repair . . . . . . . . . . . . . . 1G3-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1G3-3
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 otherwise
noted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Air Cleaner Housing Cover Nut
Intake Manifold Bolt (M8 x 20)
Intake Manifold Bolt (M8)
Exhaust Mainfold Stud Bolt
Exhaust Pipe Nut (Engine)
Exhaust Pipe BoltN
· ·· ·
·m
9 - 11
22.5 - 27.5
22.5 - 27.5
9.5 - 12.5
15 - 28
28 - 47
Air Cleaner and Inlet Duct & Hose . . . . . . . . 1G3-3
Intake and Exhaust Manifold . . . . . . . . . . . . . 1G3-5
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 1G3-8
Charge Air System Diagram . . . . . . . . . . . . . 1G3-8
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-9
Turbocharger Assembly . . . . . . . . . . . . . . . 1G3-11

1G3-2 OM600 ENGINE INTAKE & EXHAUST
SCHEMATIC AND ROUTING DIAGRAMS
EGR CIRCUIT

OM600 ENGINE INTAKE & EXHAUST 1G3-3
AIR CLEANER AND INLET DUCT & HOSE
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
1 Air Intake Shield Assembly
2 Air Cleaner Assembly
3 Mounting Bracket
4 Air Cleaner Element...........Clean : 20,000km
Replace : 60,000km5 Bolt......................................................... 9-11Nm
6 House
7 Clamp
8 Engine Cover Assembly (Turbo)
9 Mounting Bracket

1G3-4 OM600 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
1. Loosen the air duct hose clamp and then remove the air
cleaner and air duct hose.
2. Disconnect the air cleaner housing cover clamp and remove
the cover and element.
Tightening Torque 9 - 11 Nm 3. Loosen the nut (4EA) and remove the air cleaner housing
from the intake manifold.
Notice
Do not fold the rubber.
Operating IntervalClean
Replaceevery 20,000km
every 60,000km
4. Loosen the clamp and remove the air duct hose.
5. Loosen the mounting nut and bolt.
6. Remove the air inlet duct and hose.
7. Installation should follow the removal procedure in the
reverse order.

OM600 ENGINE INTAKE & EXHAUST 1G3-5
INTAKE AND EXHAUST MANIFOLD
1 Nut .................................................22.5-27.5 Nm
2 Washer
3 Support Assembly Bar
4 Nut .................................................22.5-27.5 Nm
5 Exhaust Manifold Assembly
6 Exhaust Gasket7 Stud Bolt..........................................9.9-12.1 Nm
8 Bolt (M8)........................................22.5-27.5 Nm
9 Intake Duct
10 Intake Duct Gasket
11 Intake Manifold
12 Intake Gasket

1G3-6 OM600 ENGINE INTAKE & EXHAUST
Exhaust Line
1 Heat Protector Assembly
2 Heat Protector Floor
3 Exhaust Front Pipe Assembly
4 Ring
5 Exhaust Rear Pipe Assembly6 Muffler
7 Mounting
8 Heat Protector Front Floor
9 Tail Exhaust Pipe Assembly

OM600 ENGINE INTAKE & EXHAUST 1G3-7
Removal & Installation Procedure
1. Remove the bolt from the exhaust manifold and then remove
the front exhaust pipe.
Installation Notice
Tightening Torque 15 - 18 Nm
Notice
When tightening the nut(3), maintain the clearance between
exhaust manifold(1) and front exhaust pipe.
2. Remove the nut from the front of center muffler and then
remove the front exhaust pipe.
Installation Notice
3. Remove the nut from the rear of center muffler and then
remove the tail muffler.
Installation Notice
4. Remove the muffler mounting hanger from the rubber pad
and remove the center muffler and tail muffler.
Notice
Check the gasket, if necessary, replace the new one.
5. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 28 - 47 Nm
Tightening Torque 28 - 47 Nm

1G3-8 OM600 ENGINE INTAKE & EXHAUST
1 Turbocharger Oil Inlet
2 Turbine Wheel
3 Waste Gate
4 Oil Outlet
5 Compressor Wheel6 Air Inlet
7 Exhaust Gas Outlet
8 Compressed Air Flow
9 Intercooler
10 Cylinder
TURBOCHARGER
CHARGE AIR SYSTEM DIAGRAM