SSANGYONG MUSSO 2003 Service Manual

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.

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 . . . . . . . . . . . . . . . . . . . . . . . 1G3-1Fastener 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 otherwisenoted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Air Cleaner Housing Cover Nut Intake Manifold Bolt (M8 x 20)Intake Manifold Bolt (M8)Exhaust Mainfold Stud BoltExhaust Pipe Nut (Engine) Exhaust Pipe Bolt
N 

 m
9 - 11
22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 2828 - 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 & EXHAUSTSCHEMATIC AND ROUTING DIAGRAMS
EGR CIRCUIT

OM600 ENGINE INTAKE & EXHAUST 1G3-3
AIR CLEANER AND INLET DUCT & HOSEMAINTENANCE 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 : 60,000km 5 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 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 1G3-5
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 Gasket 7 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

1F3-42 OM600 ENGINE CONTROLS
After Testing Preceding Work : Start of delivery test Position Sensor (RIV method)
1 Adjusting Screw
2 Bolt ............................................................ 23Nm
3 Fuel Injection Pump 4 Bolt
............................................................ 23Nm
5 Scale .......... Rl start of delivery = 14 ° - 16 ° ATDC