fuel system SSANGYONG KORANDO 2012 Service Manual

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. -
-
-
-
-
(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. -
-
-
-
(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.

01-10
(4) Fuel and lubrication system
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. -
-
-
If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
between HP pump and injectors. So, be sure to cover removed fuel system 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)
When working on the fuel line between priming pump and injector (including return line), always
plug the openings with caps to prevent foreign materials or dust from entering to the openings and
connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector) should be
replaced with new ones when removed. 1.
2.
3.

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 ▶
-
-
-
-
-
-
▶
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. -
-
-
-
- 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. -
-
-
-
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)

02-290000-00
10. FLYWHEEL AND DRIVE PLATE
1) DMF (Dual Mass Flywheel)
The dual mass flywheel, or DMF, eliminates excessive transmission gear rattle, reduces gear
change/shift effort, and increases fuel economy. There is a friction ring located between the inner and
outer flywheel that allows the inner and outer flywheel to slip. This feature is designed to alleviate any
damage to the transmission when torque loads exceed the vehicle rating of the transmission. The friction
ring is the weak spot in the system and can wear out if excessive engine torque loads are applied
through it. The system also has a center support bearing that carries the load between the inner and
outer flywheel, and is fitted with damper springs to absorb shocks.
2) Drive Plate
Drive plate receives the power from the start motor when starting the engine. With this, the drive plate
initially drives the power train system. And, it is connected to the torque converter to transfer the engine
torque to the power train system.Components ▶
Dual mass flywheel
Trigger ring
Drive plate
Components ▶

03-30000-00
1. SPECIFICATION
Description Specification
Fuel Diesel
Fuel filterTypeFuel heater + priming pump + water separator
integrated type
Filter type Changeable filter element type
every 40,000 km
every 45,000 km
Water accumulating capacity 200 cc
Heater capacity 250W 13.5V
Injector System pressure 1800 bar
High pressure fuel
pumpType Eccentric cam/Plunger type
Operating type Gear driven type
Normal operating temperature-40 ~ 125℃
Operating pressure 1800 bar
Operating temperature-30℃ ~ 120℃
Low pressure fuel
pumpType Vane type
Gear ratio (pump/engine) 0.5 : 1
Pressure 6 bar
Fuel tankCapacity 60 L
Material Plastic
Fuel sender Dual sender type
Change intervalEU
GEN

03-4
2. MAINTENANCE AND INSPECTION
1) Maintenance Procedures for DI Engine Fuel System
Always keep the workshop and lift clean (especially, from dust).
Always keep the tools clean (from oil or foreign materials).
Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
Wash your hands and do not wear working gloves. 1.
2.
3.
Follow the below procedures before starting service works for fuel system.
If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing
caps to perform the diagnosis for DI engine fuel system in this manual. At this point, thoroughly clean
the related area in engine compartment. 4.
Clean the engine compartment before starting service works.
Tool kit for high pressure lineTook kit for low pressure line

03-70000-00
2) Diagnostic Test for Engine Fuel System
(1) Overview
If a DTC is displayed on the diagnostic device, check the low pressure- and high pressure fuel systems
before removing the components.
To run the system properly, the electric system must be intact but for the DI engine, the fuel pressure
should be measured also when there is a malfunction even after the diagnostic test with a diagnostic
device.
(2) Hydraulic system

03-10
3) Pressure Test for Fuel System in DI Engine
(1) Test device (Tool kit)
Tool kit for high pressure line
Tool kit for low pressure line
(2) Pre-inspection
Connections in fuel supply line
Fuel level in fuel tank
Air in fuel supply line (air bubbles in fuel supply line or fuel)
Fuel leaks from fuel supply line (low/high pressure line)
Used the specified
Fuel filter contamination -
-
-
-
-
-

03-110000-00
(3) DTC Check
If several DTCs are output simultaneously, check the electric wiring for open or short circuit.
Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities. Carry
out the high pressure fuel system check.