torque SSANGYONG MUSSO 2003 Service Manual

1G1-6 M162 ENGINE INTAKE & EXHAUST Removal & Installation Procedure
Upper Intake Manifold
1. Disconnect the vacuum hose (8,9).
2. Loosen the clip (22).
3. Remove the upper intake manifold (5) after unscrewing the bolt (6). Installation Notice Notice
Check the gasket and replace it if necessary.
4. Installation should follow the removal procedure in the reverse order.
Lower Intake ManifoldPreceding 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
4. Start the engine and check for leaks at each connection part.
Tightening Torque 22.5 - 27.5 Nm
Tightening Torque 22.5 - 27.5 Nm

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.

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

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

1G2-8 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

M161 ENGINE INTAKE & EXHAUST 1G2-9
EXHAUST MANIFOLD
1 Oxygen Sensor.............................. 49.5-60.5 Nm
2 Bolt (4 pieces) ........................................ 9-11 Nm
3 Upper Cover
4 Nut (11 pieces) ............................... 31.5-38.5 Nm 5 Exhaust Manifold
6 Flange Bolt & Exhaust Pipe
Mounting Nut ............................................ 30 Nm
7 Gasket ................................................... Replace
Removal & Installation Procedure
1. Remove the oxygen sensor if necessary. Installation Notice
Tightening Torque 49.5 - 60.5 Nm
2. Unscrew the bolt (2) and remove the exhaust manifold upper cover (3).
3. Unscrew the flange bolt (6) of front exhaust pipe and separate the front exhaust pipe. Installation Notice
Tightening Torque 30 Nm
Notice Check the exhaust pipe mounting nut, and replace it with
new one if necessary.

1G2-10 M161 ENGINE INTAKE & EXHAUST
4. Unscrew the eleven nuts (4) and remove the exhaustmanifold (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.

1G3-4 OM600 ENGINE INTAKE & EXHAUST
Removal & Installation Procedure
1. Loosen the air duct hose clamp and then remove the aircleaner 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
Replace every 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 1G3-7
Removal & Installation Procedure
1. Remove the bolt from the exhaust manifold and then removethe 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

2C-2 FRONT SUSPENSIONApplication
Torque Arm Bolt N
m
40 - 60 60 - 80
FASTENER TIGHTENING SPECIFICATIONS
Stabilizer Bar
Application
Stabilizer Bar Retaining Nut Stabilizer Bar Link NutLower Arm Nut N
m
30 - 45 60 - 80 16 - 22
Torsion Bar
Lower and Upper Arm
Application
Upper Arm Nut Upper Arm End Castle NutLower Arm Nut Lower Arm End Castle Nut N
m
120 - 140 80 - 150
150 - 180 120 - 180
Steering Knuckle and Drive Shaft
Application
Brake Caliper Hose Bolt Brake Caliper Mounting Bolt
Tie Rod Retaining Nut Upper Arm Retaining NutLower Arm Retaining Nut N
m
25 - 35
85 - 105 35 - 45
80 - 150
120 - 180
M10 M12