battery 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 with 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)
(15) Remove the engine and transaxle as a set.
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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01-90000-00
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
of 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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(3) Electric devices
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. -
- 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.
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.

02-14
4. GUIDELINES ON ENGINE SERVICE
To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and
unit inspection/repair and to secure optimum engine performance and safety after service works, basic
cautions and service work guidelines that can be easily forgotten during engine service works are
described in.
Cautions before service works
For safe and correct works, you must observe the working procedures and instructions in this
manual. And, use the designated tools as follow:
Engine stand / Heavy duty engine jack
To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while
servicing in engine compartment.
Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)
terminal.
Before service works, be sure to prepare the works by cleaning and aligning work areas.
Do not allow the foreign material get into the fuel injection system.
When removing the engine, use only the safety hook on engine and engine hanger. Do not support
the bottom of oil pan with a jack.
Engine and accessories ▶
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Completely drain the engine oil, coolant and fuel from engine before removal.
Before disassembling/assembling the engine components, carefully read the working procedures in
this manual.
Make sure to keep the specified tightening torques during installation.
Clean and properly lubricate the parts before reassembly.
Carefully check that there are not any interference while servicing. -
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- Engine has a lot of precise portions so tightening torque should be correct during disassembly/assembly
and removal/installation and service work should be done in clean ways during disassembly/assembly.
Maintaining working area clean and cautious service administration is essential element of service works
while working on the engine and each section of the vehicle. So the mechanics should well aware of it.

02-150000-00
Electrical equipment ▶
Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. there could be poor engine performance, incomplete
combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)
terminal.
When replacing the electric device, use only genuine part and check the conditions of connections
and grounds. Loosened connection or ground make cause a fire and personal injury. -
-Fuel and lubrication system ▶
Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking
should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and nuts
should be tightened as specified.
After removal/installation works, be sure to check whether there is leak on the connecting section. -
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages in HP
pump and injectors. Thus, be sure to plug the inlets of removed fuel line components with cap and
protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual while working
on DI engine fuel system)

03-6
Check the installed components again and connect the negative battery cable. Start the engine and
check the operating status.
With Scan Tool, check if there are current faults and erase the history faults. 8.
9.

09-30000-00
1. SPECIFICATION
Specification HPS EPS
Alternator Crankshaft pulley : Alternator Pulley 1 : 2.94
Normal output (idling/2200 rpm) 70/120 A 70/140A
Regulator voltage 14.6 V←
Brush Length 12.5 mm←
Wear limit 7 mm←
Battery Type MF←
Capacity 90AH←

09-4
2. INSPECTION
1) Alternator Output Test
Item How to check DTC set value / Action
Output
current
B terminal
current
Rotor
coil
resistance
L terminal
voltage
Disconnect the cable connected to the B
terminal on the alternator. Connect one end
of the ammeter to the B terminal and the
other end to the cable connected to the B
terminal.
Measure the maximum output value.
(Maintain the engine speed between 2,500
and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.) 1.
2.Pass: If the measured current is 45 A
or higher.
Fail: If the measured current is less
than 45 A.
Check the current of the B terminal. -
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Move the gear selector lever to the
neutral position.
Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.) 1.
2.Open circuit: If the measured
current is 5 A or higher. -
Disconnect the negative cable from the
battery.
Remove the B terminal and turn off the
ignition switch.
Measure the resistance between the L and F
terminals with an ohmmeter. 1.
2.
3.Pass: If the measured resistance is
between 3 and 6 Ω.
Faulty rotor coil or slip ring: If the
measured resistance is less than
3 Ω or greater than 6 Ω. -
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Connect the B terminal wiring.
Measure the voltage with the engine running. 1.
2.Specification: 12.5 V to 14.5 V
Faulty IC regulator or field coil: If
the measured voltage is 14.5 V or
higher. -
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Disconnect the negative battery cable.
Connect the negative cable again after connecting the ammeter. -
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09-50000-00
2) Troubleshooting for Alternator
Item Cause Action
Overcharged battery Defective alternator voltage regulator Replace
defective alternator detection wiring Repair or replace
Discharged battery Loose alternator drive belt Adjust the belt tension or replace
Poor connection of related circuit or
open circuitRetighten the loose connection or
repair open circuit
Defective alternator voltage regulator Replace
Terminated battery Replace
Defective ground Repair
Charge warning lamp
does not come on when
turning on ignition switch
with engine stoppedDefective alternator voltage regulator Replace
Open circuit in charge warning lamp,
fuse or wiringReplace or repair the charge
warning lamp or fuse
Defective ignition switch Replace
Defective ground of alternator circuit Repair
Charge warning lamp
does not go off after
starting engineDefective alternator voltage regulator Replace
Corroded or worn battery cable Repair or replace
Loose alternator drive belt
Adjust the belt tension or replace the
belt
Defective wiring harness Repair or replace

09-6
3) Checking Battery

09-70000-00
(1) Checking
Using battery tester ▶
PASS (11.0 V or more): Explain to the customer that the battery is reusable.
Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the
customer.
Need to be replaced (9.0 V or more): The battery should be replaced due to overdischarging. -
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(2) How to use battery tester
How it works and How to use it ▶
Determine battery capacity by fixing current
(load capacity) and time and varying voltage.
Determine battery capacity based on the
amount of voltage drop when discharging a
fixed load capacity (120 A) for 5 seconds.
Connect the tester to the battery and read the
display while applying a load for 5 seconds. -
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How to read display ▶
Red area (①): overdischarge or faulty
battery
Yellow area (②): Need to be charged
(using a vehicle alternator and a battery
charger)
Green area (③): Normal
Red area on the left-hand side of OK
(④): Impossible to charge with an
alternator
Green area with OK (⑤): Normally
charged
Red area on the right-hand side of OK (
⑥
Overcharged by an alternator -
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