SSANGYONG KORANDO 2012 Service Manual

01-70000-00
3) General Instructions
Before lifting up the vehicle with a lift, correctly support the lifting points.
When using a jack, park the vehicle on a level ground and place the wheel chocks under the tires.
Position the jack under the frame and lift up the vehicle and then support with chassis stand before
service work.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle them
during service work.
To improve the efficiency of service work, use only recommended and specified tools.
Use only Ssangyong genuine spare parts.
Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them
with new ones. If reused, normal functions cannot be maintained.
Store the disassembled parts as a set based on disassembly order and unit.
Pay particular attention not to miss or mix the fasteners.
If necessary, especially for inspection, clean the removed parts completely.
Apply the oil or grease on the running and sliding surfeces before installation. Use the specified
sealant and gasket to prevent leakage if necessary.
Tighten the fasteners to the specified tightening torque.
As a final stage of service work, check if the serviced system is working properly and the problem
has been eliminated clearly. (1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14) Remove the engine and transaxle as a set.
Manual transaxle: Transaxle can be separated after removing the front module (sub frame, engine
and transaxle).
Automatic transaxle: Transaxle can be separated after removing the sub frame. -
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2) Equipment
Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are
integrated into a module. Therefore, 2-post lift and general equipment are necessary when working
on the engine and transmission.
Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission jack,
Engine hanger -
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01-8
4) Basic Inspection
(1) Horn operation
Listen for the horn sound when pressing the horn pad on the steering wheel. -
(2) Brake operation
Check if there is any abnormal noise, unusually long braking distance, or uneven braking force. If the
brake warning lamp does not go out even after starting the engien or are flashing during driving,
have the brake system checked immediately.
Check the brake pipes and hoses for connection, oil leak, crack or interference after changing the
position of tires. When replacing the tires, check the brake disc for surface condition and wear.
Check the parking brake cable and brake operation. Shorten the checking interval if the parking
brake is used frequently. -
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(3) Exhaust system
Be aware to any changes in sound or smell from the exhaust system. These may be caused by leak or
overheat. Have the exhaust system checked and repaired immediately.
Inspect the exhaust system including catalytic converter. Inspect all the components and body frame
near the exhaust system. -
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(4) Tires
Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads
may indicates the uneven tire inflation pressure or poor wheel balance. -
(5) Steering and suspension system
Inspect the front and rear suspension and the steering system for damage, looseness or missing
parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for
connection, leak, crack and chafing. Inspect the drive axle boot and seals for damage, tear or leak.
Replace or repair the system if necessary. -
(6) Engine oil
Check the oil level when the engine is still warm and add the specified engine oil if necessary. -
(7) Coolant
Check the coolant level in the coolant reservoir, coolant conditions (contamination, foreign material),
and hoses for damage and leak. Replace or add the Ssangyong genuine coolant, if needed. -
(8) Engine drive belt
Check all drive belts on the engine for wear, crack and looseness. Retighten or replace the belt, if
needed. -

01-90000-00
5) Guidelines on Engine Service
(1) Cautions before service works
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
Make sure to clean the working area and to prepare the necessary tools before service works.
Always place the ignition switch to OFF position if not required. Otherwise, there could be unexpected
damage to electric devices or personal injuries due to short-circuit.
To prevent the foreign material from entering into the fuel injection system, completely seal the inlets o
f
HP pump, fuel hoses and high pressure pipes.
To remoev the engine, use the dedicated equipments such as engine jack, transmission jack, engine
stand and engine crane. -
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(2) Engine and accessories
When disassembling the engine, related parts (bolts, gaskets, etc.) should be stored as a set.
Clean the components completely with engine oil before assembling if needed.
Fully drain the engine oil, coolant and fuel from the vehicle and seal the inlets with the plugs before
removing the engine.
All the interference should be eliminated before removing the engine. -
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- To prevent the personal injuries and vehicle damages that can be caused by mistakes during service
and to provide the optimized performance and safety after service works, the service technicials must
keep the basic cautions and service guidelines below. These could be easily forgotten during service
works.
Engine has a lot of precise components. The specified tightening torque and correct procedures should
be kept during service works. And, the working area is always clean and well prepared.
To prevent any damage to electric systems, make sure to disconnect the negative (-) cable from the
battery and place the ignition switch to OFF position before servicing.
Use only the specified parts with same ratings when replacing the electric devices. Check the
grounds and connections for looseness. -
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(3) Electric devices
Extraordinary care should be taken when servicing the electric systems. Currently, the engine uses a lot
of electric devices. Short circuit and poor contact may cause the low engine performance, incomplete
combustion and other abnormalities.
When working with the fuel or oil systems in enclosed area, always keep the working area well-
ventilated and never allow anybody to smoke.
Gaskets and seals on the fuel and oil systems should be replaced with new ones. All bolts and nuts
should be tightened as specified.
Make sure to check the connections for leak after installation. -
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(4) Fuel and lubrication system

01-10
Jack-up points and setup
(rear side)
Jack-up points and setup
(front side)
2. JACK-UP POINTS
Stand jack-up points and installation status (front side) ▶
Jack-up points
for 2-post liftJack-up points
for 2-post liftSupporting
Supporting

01-110000-00
3. STANDARD BOLTS SPECIFICATIONS
Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as
4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.
Observe standard tightening torque during bolt tightening works and can adjust torque to be proper
within 15 % if necessary. Try not to over max. allowable tightening torque if not required to do so.
Determine extra proper tightening torque if tightens with washer or packing.
If tightens bolts on the below materials, be sure to determine the proper torque. 1)
2)
3)
4)
Aluminum alloy: Tighten to 80 % of above torque table.
Plastics: Tighten to 20 % of above torque table. -
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01-12
4. CODING AND SETUP
1) Engine Variant Coding
Description Coding
Vehicle speed input to ECUCAN
with ABS or ESP: CAN
WIRE
Fan3 Relays
3 Relays
PWM fan
Auto cruiseNO
with Auto cruise system: YES
YES
Engine level controlNO
without Engine level control system: NO
(Korando)
YES
G-sensorNO
with 2WD ABS and non-ABS: NO
with 4WD ABS and ESP: YES
YES
Smart keyNO
with Smart key: YES
YES

01-130000-00
1. ENGINE COMPARTMENT
Coolant reservoir
OCV
Ignition coil
Rear oxygen sensor connector
Front oxygen sensor connector
Coolant temperature sensor
Purge control solenoid valve
Engine ECU
Battery
Fuse box 1.
2.
3.
4.
5.
6.
7.
8
9.
10.HECU assembly
Alternator
Fuel rail assembly
Injector
Intake manifold
Oil dipstick gauge
VIS solenoid valve
T-MAP sensor
Electronic throttle body
Air cleaner assembly 11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

01-14
Engine ECU
2. FUEL SYSTEM
Engine compartment
Purge control solenoid
valveFuel railInjector

01-150000-00
Fuel tank assembly
CanisterFuel filter
Fuel pump & fuel sender assembly

01-16
3. IGNITION SYSTEM
Ignition coilIgnition plugEngine ECU
Knock sensorCamshaft position
sensorCrankshaft position
sensor