SSANGYONG KORANDO 2013 Service Manual

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Knock sensor2-
Cam position sensor
1 10~14Nm -
T-MAP pressure sensor
1-
Exhaust manifold M8 10
-
Turbocharger M8 3
-
T/C support bracket bolt
1
-
T/C support bracket bolt
M8 1
-
T/C oil supply pipeM6(block side) 1
-
M6(turbo side) 1
-
T/C oil return pipe
(turbo side)2-
(block side)2-
EGR valve
3-
EGR pipe bolt
(Intake side)
2-
EGR pipe bolt
(EGR cooler side)
2-
Oil pressure sensor M24 1 Max. 50Nm -
Component Size
QuantityTightening torque
(Nm)Remark
(Total torque)
Hot water inlet pipe
2-
Alternator
1Lower
1Upper
A/C compressor
4-
A/C bracket
4-
Intake manifold
2-
6-
Oil filter module
6-
1-
2-

Oil gauge tube1-
Oil filter cap 1
-
Fuel rail
2-
Injector clamp bolt
2-
High pressure pipe
(between HP pump and
fuel rail)M17 1
-
High pressure pipe
(between fuel rail and
injector)M17 4
-
Crank position sensor
1-
Main wiring
5-
Intake duct M8x25 3
-
Power steering pump
3-
Mass balance shaft
(MBU)
6-
Cylinder head front cove
r5-
Timing gear case cover
7-
1-
3-
Cylinder head cover
21-
Component Size
QuantityTightening torque
(Nm)Remark
(Total torque)
Idle pulley/Tensioner
pulley1
-
Glow plug M5 4
-
Vacuum pump
3-

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4. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value
Compression ratio
16.5 : 1
Test condition
Compression pressureStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston ring,
intake and exhaust vale, cylinder head gasket). This test provides current engine operating status.
Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from
moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
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(2) Cylinder pressure leakage test
If the measured value of the compression pressure test is not within the specifications, perform the
cylinder pressure leakage test.Specified value
Perform this test in the sequence of firing order.
Do not test the cylinder pressure leakage with wet type test procedure. (do not
inject the engine oil into the combustion chamber) -
-
Test condition: normal engine operating Specified value
Whole engine below 25%
at valve and cylinder head gasket below 10%
at piston ring below 20%

Measure how the piston is protruded from the
upper side of the cylinder block.
(3) Piston protrusion check
Specified value 0.475 to 0.745mm
Measure it at both end positions in the axial
direction of the crankshaft. -

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2) Cylinder Head
(1) Cylinder head mating surface check
Specified value
Total height "A"131.9 to 132.1 mm
Minimum height after machining131.9mm
FlatnessLongitudinal direction0.1 / 150
Transverse direction0.15
Parallel deviation of cylinder headbelow 0.1 mm
Peak-to valley of surfaceRmax7
Rz6.3
valve recess "a"Intake valve
0.6 to 1.0 mm
Exhaust valve
Measure the cylinder head height "A". 1.
If the height is less than the limit, the cylinder
head must be replaced. -
Insert the valves into the valve guides and
measure the recesses. 2.
If the measured value is out of the specified
range, machine the valve seat as much as
necessary until the specified value is
achieved. -
0.6 to 1.0 mm
(2) Cylinder head pressure Leak test
with compressed air to 2 bar.

5. 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. -
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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.