torque 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.

01-12
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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02-4
2. TIGHTENING TORQUE
Component Size
QuantityTightening torque
(Nm)Remark
(Total torque)
Main bearing capM12×821055 ± 5Nm,
180˚Not re-usable
Connecting rod capM9×52840 ± 5Nm,
90˚ ± 10˚50~80Nm
Crankshaft rear cover
M6×20610 ± 1Nm-
Oil pumpM8×35325 ± 2.5Nm-
FlywheelM10×22845 ± 5Nm,
90˚ ± 10˚Not re-usable
Isolation damper center
boltM18×501200 ± 20Nm,
180˚ ± 20˚660~720Nm
Not re-usable
Oil panM6×201810 ± 1Nm-
M6×35210 ± 1Nm-
M6×85210 ± 1Nm-
M6×120210 ± 1Nm-
M8×40225 ± 2.5Nm-
HP pump main nutM14×1.5-8-11650 ± 5Nm-
HP pump mounting bolt
M8×553
25 ± 2.5Nm-
Cylinder headM13×1501285Nm
270° ± 10°-
Camshaft capM6×301610 ± 1Nm-
M8×60425 ± 2.5Nm-
Exhaust stud bolt 1015 ± 1.5Nm-
Exhaust sprocket boltM11×40130 ± 3Nm-
Chain tensioner screw
plugM38×1.5125 ± 2.5Nm
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Coolant temperature
sensor120 ± 2.0Nm-
Belt auto tensionerM8×30(LOW)125 ± 2.5Nm-
M10×75(Upper)155 ± 5.5Nm-
Coolant pumpM6×50710 ± 1.0Nm-

02-50000-00
품명 규격 볼트
수량규정토오크(Nm) 비고
(총 토오크)
Knock sensorM8×28220 ± 5Nm-
Cam position sensorM8×141 10 ~ 14Nm -
T-MAP pressure sensor
M6×201
10 ± 1Nm-
Exhaust manifold M8 1040 ± 4Nm-
Turbocharger M8 325 ± 2.5Nm-
T/C support bracket bolt
125 ± 2.5Nm-
T/C support bracket bolt
M8 125 ± 2.5Nm-
T/C oil supply pipeM6(block side) 110 ± 1.0Nm-
M6(turbo side) 117 ± 2.0Nm-
T/C oil return pipeM6×16
(turbo side)210 ± 1Nm-
M6×16
(block side)210 ± 1Nm-
EGR valveM8×22325 ± 2.5Nm-
EGR pipe bolt (Intake
side)M6×25210 ± 1Nm-
EGR pipe bolt (EGR
cooler side)M8×16225 ± 2.5Nm-
Component Size
QuantityTightening torque
(Nm)Remark
(Total torque)
Hot water inlet pipeM6×12210 ± 1Nm-
AlternatorM10×90125 ± 2.5NmLower
M10×116146 ± 4.6NmUpper
A/C compressorM8×85425 ± 2.5Nm-
A/C bracketM6×25410 ± 1Nm-
Intake manifoldM8×35225 ± 2.5Nm-
M8×110625 ± 2.5Nm-
Oil filter moduleM8×40625 ± 2.5Nm-
M8×20125 ± 2.5Nm-
M8×140225 ± 2.5Nm-

02-6
품명 규격 볼트
수량규정토오크(Nm) 비고
(총 토오크)
Oil gauge tubeM6×16110 ± 1Nm-
Oil filter cap 125 ± 2.5Nm-
Fuel railM8×35225 ± 2.5Nm-
Injector clamp boltM6×6029 ± 1.0Nm
130˚ + 10˚-
High pressure pipe
(between HP pump and
fuel rail)M17 130 ± 3Nm
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High pressure pipe
(between fuel rail and
injector)M17 430 ± 3Nm
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Crank position sensor
M5×1418 ± 0.4Nm
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Main wiringM6×16510 ± 1Nm-
Intake duct M8x25 325 ± 2.5Nm-
Power steering pumpM8×100325 ± 2.5Nm-
Mass balance shaft
(MBU)M8×45630 ± 3Nm-
Cylinder head front cove
rM6×10510 ± 1Nm-
품명 규격볼트
수량규정토오크(Nm)비고
(총 토오크)
Timing gear case coverM6×40710 ± 1Nm-
M6×45110 ± 1Nm-
M6×50310 ± 1Nm-
Cylinder head coverM6×352110 ± 1Nm-
Component Size
QuantityTightening torque
(Nm)Remark
(Total torque)
Idle pulley/Tensioner
pulley145 ± 4.5Nm
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Glow plug M5 420 ± 2Nm-
Vacuum pumpM8×25310 ± 1Nm-

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.

02-18
Right mounting assembly
Location: Engine block side and body side
member
Location Front mountingFront mounting assembly
Location: Front side of transfer axle housing and
front side of sub frame
Location Front mounting
Left mounting assembly
Location: Upper side of transfer axle housing and
body side member
Location Front mountingRear mounting assembly
Location: Rear side of transfer axle housing and
front side of sub frame
Location Front mounting
3. ENGINE MOUNTINGS
D20DTF engine mounting is 4-point mounting type and supports the engine and transaxle.
Front and rear mountings are rubber type and support the torque reaction. Left and right mountings
support the power train rods and torque reaction. Additionally, left mounting is hydraulic type and supports
the engine vibration.
Components ▶

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 ▶

03-50000-00
Fuel filter assembly
Follow the job procedures. If you find a defective component, replace it with new one. 5.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each
injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques
during installation. Over or under torques out of specified range may cause damages and leaks at
connections. Once installed, the pipes have been deformed according to the force during installation,
therefore they are not reusable. The copper washer on injector should be replaced with new one. The
injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point
may be deviated from correct position, and it may cause engine disorder.
Plug the removed components with clean and undamaged sealing caps and store it into the box to
keep the conditions when it was installed. 6.
To supply the fuel to transfer line of HP pump
press the priming pump until it becomes
hard. 7.
Priming pump
Priming pump cap