SSANGYONG KORANDO 2013 Service Manual

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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)

with EPS (electric power steering)with HPS (hydraulic power steering)
1. BELT SYSTEM
The belt system is a single belt drive system which uses single belt and has components on the oil filter
housing as FEAD (Front End Accessories Drive) type.
Components
HPS EPS
1 Crankshaft pulley (DDU)
2 Auto tensioner
3 Tensioner pulley
4 Vacuum pulley
5 A/C compressor pulley
6 Alternator pulley
7 Water pump pulley
8 NO. 1 idler pulley
9 NO. 2 idler pulley
10 Power steering pump -

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EGR cooler bypass valve
Exhaust gas goes to combustion
chamber without through EGR
cooler in engine cooled, and the
valve is closed by vacuum
pressure.
2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This
pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole
in hollow shaft.
Components
Vacuum pump
Pump capacity: 210 cc/rev
Speed: 375 to 3,000 rpm
Lubrication temperature:
Oil: 5W30
Drive type: Driven by exhaust
Camshaft solt
Brake booster

Front mounting assembly
Location: Front side of transfer axle housing and front side of
sub frame
Right mounting assembly
Location: Engine block side and body side member
Rear mounting assembly
Location: Rear side of transfer axle housing and
front side of sub frame
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, right mounting is hydraulic type and
supports the engine vibration.
Components
Left mounting assembly
Location: Upper side of transfer axle housing and
body side member
LocationFront mounting
Location
BRKT-Right
MTG-4WD
LocationFront mounting
BRKT-Right
MTG-2WD
Front MTG MTFront MTG AT
LocationRight MTG-4WDRight MTG-2WD

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Intake manifold
4. INTAKE/EXHAUST SYSTEM
1) Intake Manifold
Intake manifold is installed on the cylinder head with 8 bolts. The variable swirl valve is introduced to
improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas.
2) Exhaust Manifold
Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts. EGR port is integrated in
cylinder head.Components
Exhaust manifold
Components

5. CYLINDER HEAD COVER AND OIL SEPARATOR
The cylinder head cover is made by high strength plastic to reduce the weight. The multi twist type oil
separator improves the oil consumption.
Components
Oil separator
PCV valve

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6. CYLINDER HEAD
Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve
assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are
install in vertical direction. This enables the compact layout in cylinder head assembly.

Vacuum pump drive
Intake/exhaust CamshaftsCamshaft sprocketFinger follower & HLA
Components
Cylinder head
Camshaft position sensorHP pump drive gear
Cylinder head gasket

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Chain upper bush
Chain type: single bush
Chains: 112 EA
Hydraulic tensioner
Contains tensioner housing
plug, spring and check valve,
and operated by hydraulic
pressure
Exhaust Camshaft sprocket
Teeth: 42 EA
Clamping rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
7. CHAIN AND GEAR DRIVE SYSTEM
D20DTF engine uses single stage chain drive system. Timing chain drives the exhaust side and gear drive
the intake side. Timing chain is single bush type. Upper chain drives HP pump connected to intake
Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil pump to lubricate the engine.
And, MBU (Mass Balance shaft Unit) drive gear drives MBU.
Components
Chain lower bush
Chain type: single bush
Chains: 60 EA
Mechanical type tensioner
Operated by internal spring
The timing links (gold color) on the timing chain are aligned with the timing marks on the
crankshaft sprocket and the camshaft sprocket whenever the crankshaft rotates 8 turns.
Oil pump sprocket
Teeth: 30 EA
Tensioner rail
Installed between exhaust
Camshaft sprocket and
crankshaft sprocket
Crankshaft sprocket
Teeth: 21 EA

Intake/exhaust Camshaft assembly
Components
Intake Camshaft
HP pump drive gearExhaust
Camshaft
Connected to
vacuum pump