2003 SSANGYONG MUSSO engine

M162 ENGINE INTAKE & EXHAUST 1G1-3
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

1G1-4 M162 ENGINE INTAKE & EXHAUST
INTAKE AIR DUCT
1 Clamp
2 Sleeve
3 Nut
4 Clamp
5 Intake Air Duct
3. Remove the clamp (4).
4. Remove the intake air duct (5) carefully. Installation NoticeExactly seat the pin of intake air duct onto the crankcase ventilation rubber mount.
5. Installation should follow the removal procedure in the reverse order.
Removal & Installation Procedure
1. Remove the clamp (1) and disconnect the HFM sensor.
2. Remove the nut (3) (arrow).

M162 ENGINE INTAKE & EXHAUST 1G1-5
INTAKE MANIFOLD Preceding Work : Removal of fuel distributor and injection valve
1 Bolt (M6 X 40, 4 pieces)......................... 9-11 Nm
2 Softcap
3 Resonance Flap
4 Gasket ................................................... Replace
5 Upper Intake Manifold
6 Bolt (M8 x 50, 9 pieces) .................22.5-27.5 Nm
7 Gasket ................................................... Replace
8 Blow-by Hose
9 Blow-by Hose
1 0 Clamp
11 Blow-by Nipple
12 Inlet Air Housing 13 Bolt (M6 x 40, 4 pieces)
......................... 9-11 Nm
14 Throttle Body - Electric
15 Gasket ................................................... Replace
16 Lower Intake Manifold .........................................
17 Bolt (M8 x 40, 4 pieces) .................22.5-27.5 Nm
1 8 Nipple .................................................... Replace
19 Seal Ring
20 Connection House
2 1 Clamp
22 Noise Damper Assembly
23 Tapping Screw

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

M162 ENGINE INTAKE & EXHAUST 1G1-7
RESONANCE FLAP1 Soft Cap (2)
2 Bolt (M6 x 25, 4 pieces) ......................... 9-11 Nm
3 O-ring
Removal & Installation Procedure
1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after removing
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. 4 Vacuum Hose
5 Resonance Flap
6 Gasket ................................................... Replace

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.

M162 ENGINE INTAKE & EXHAUST 1G1-9
EXHAUST MANIFOLD Preceding Work : Removal of air cleaner
1 Nut .......................................................36-44 Nm
2 Gasket ................................................... Replace3 Exhaust Manifold

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