brake SSANGYONG KORANDO 2013 Service Manual

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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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4) Basic Inspection
(1) Horn operation
Listen for the horn sound when pressing the horn pad on the steering wheel. -
(2) Brake operation
Check if there is any abnormal noise, unusually long braking distance, or uneven braking force. If the
brake warning lamp does not go out even after starting the engien or are flashing during driving,
have the brake system checked immediately.
Check the brake pipes and hoses for connection, oil leak, crack or interference after changing the
position of tires. When replacing the tires, check the brake disc for surface condition and wear.
Check the parking brake cable and brake operation. Shorten the checking interval if the parking
brake is used frequently. -
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(3) Exhaust system
Be aware to any changes in sound or smell from the exhaust system. These may be caused by leak or
overheat. Have the exhaust system checked and repaired immediately.
Inspect the exhaust system including catalytic converter. Inspect all the components and body frame
near the exhaust system. -
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(4) Tires
Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads
may indicates the uneven tire inflation pressure or poor wheel balance. -
(5) Steering and suspension system
Inspect the front and rear suspension and the steering system for damage, looseness or missing
parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for
connection, leak, crack and chafing. Inspect the drive axle boot and seals for damage, tear or leak.
Replace or repair the system if necessary. -
(6) Engine oil
Check the oil level when the engine is still warm and add the specified engine oil if necessary. -
(7) Coolant
Check the coolant level in the coolant reservoir, coolant conditions (contamination, foreign material),
and hoses for damage and leak. Replace or add the Ssangyong genuine coolant, if needed. -
(8) Engine drive belt
Check all drive belts on the engine for wear, crack and looseness. Retighten or replace the belt, if
needed. -

2) Chassis Variant Coding
Description Selection Coding
Domestic/Export EU export Select the appropriate system
General export
EPB application NO Select the appropriate system
YES
Shift lever type Not defined A/T : DURA lever
M/T : M/T
DC lever
DURA lever
M/T
Electric power
steering(EPS)YES Select the appropriate system
NO
Transfer case 2WD Select the appropriate system
AWD(E-coupling)
Not defined
Sedan/Limousine Sedan(RV) Select : Sadan(RV)
Limousine
Vehicle code
(Engine)D32DT Select : D20DTF
D27DT
D27DTP
D20DTF
EAS NO Select : NO
ECS
2 corner EAS
4 corner EAS
Telematics NO Select : NO
YES
Brake NO Select the appropriate system
ABS
TCS
ESP

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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%

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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

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3. MAINTENANCE
1) Level Check
Park the vehicle on a level ground and apply the parking brake. Stop the engine and wait more than 5
minutes.
Pull out the dipstick and wipe it with a clean cloth. Reinsert it all the way.
Pull out it again and check the oil level.
The oil level should be between the maximum (Max) mark and minimum (Min) mark on the oil dipstick.
Oil should be replenished before the level goes below the minimum mark. -
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Operating vehicle with insufficient amount of oil can damage the engine. Make sure the
engine oil level is correct and add oil if necessary.
2) Replenishment
If the level gets to the lower point, open the filler cap on top of the cylinder block and add the genuine oil
without exceeding the level of the upper mark.
Recheck the oil level after 5 minutes.
Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary.
Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
The oil should not go above the upper mark on the dipstick.
The engine oil may be consumed more if the engine is new. -
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- Engine oil filler
Engine oil dipstick

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1) Coolant Level Check
Park the vehicle on level ground and apply the parking brake. Stop the engine and wait until it is
cooled down.
The coolant level should be between the MAX and MIN mark on the coolant reservoir.1.
2.
Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.
Avoid any direct contact of the coolant to the painted body of the vehicle. -
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MAX
MIN

(3) Starting with jumper cable
If the battery is weak or terminated, the battery from another vehicle can be used with jumper cables to
start the engine.
Connecting order
The positive (+) terminal of the discharged battery
The positive (+) terminal of the booster battery
The negative (-) terminal of the booster battery
Connect one end of the other jumper cable to the body of the discharged vehicle, such as the
engine block or a front towing hook. 1.
2.
3.
4.
Starting
Prepare a set of jumper cables.
Place another vehicle that has the same 12 V of power near to the discharged vehicle.
Switch off all electrical accessories for the discharged vehicle.
Apply the parking brake and shift the transaxle to the P position (automatic transaxle) or neutral (N)
position (manual transaxle).
Connect the jumper cables.
Try to start the discharged vehicle while accelerating the engine rpm in the booster vehicle.
Attempt to start the engine with the discharged battery.
After starting the engine, carefully disconnect the jumper cables in the reverse sequence of
connection. 1.
2.
3.
4.
5.
6.
7.
8.

2. OPERATING PROCESS
1) System Layout
(1) Engine start
SKM performs the authentication process for the SMART key and sends the engine start request to
EMS if there is a normally coded SMART key when pressing the Engine Start/Stop button with the
SKM sends the start request signal to PCAN network and the cranking request to BCAN network by
button.
SKM turns off the IGN2/ACC relay during cranking to shut down the electric loads.
SKM receives the starting status signal from EMS throug PCAN.
EMS starts to crank the engine after checking the pre-heating condition if it receives the engine
cranking request 1 when pressing the Engine Start/Stop button. EMS starts to crank the engine
immediately if it receives the engine cranking request 2 when pressing the Engine Start/Stop button. 1.
2.
3.
4.
5.
6.
Engine cranking request 1: when pressing the Engine Start/Stop button shortly in normal
conditions
Engine cranking request 2: when pressing the Engine Start/Stop button again after first press or
when pressing the Engine Start/Stp button for more than 3 seconds -
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Engine start during driving 7.
When pressing the Engine Start/Stop button with IGN ON, the engine start is requested if the
the brake switch is ON (no need authentication for 30 seconds).
When pressing the Engine Start/Stop button with IGN ON, the engine start is requested
position (no need authentication for 30 seconds).
Except input of brake switch signal
In vehicle equipped with A/T, when pressing the Engine Start/Stop button for more than 10
seconds with ACC ON, the engine start is requested regardless of brake signal if the gear shift
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*
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3) Decelerating with the Cruise Control System
(1) While the cruise control system is running
Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached
without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at
less than 38 km/h.
When the desired speed is reached, release the lever. 1.
2.
(2) When the cruise control system is not running
Push down the DECEL switch of the cruise control lever and hold it.
And then release the accelerator pedal slowly.
When the desired speed is reached, release the lever. But the cruise control system cannot maintain
the cruise function at less than 38 km/h.1.
2.
3.
4.
(3) Tap-down while the cruise control system is running
Push down the DECEL switch of the cruise control lever less than 0.5 second per one switching while
the cruise control system is running. This is a tap-down switching.
When you operate a tap-down switching, the vehicle is decelerated by 1 km/h below the previous set
speed.
If you want to decelerate to 10 km/h, operate the tap-down switching ten times without the brake
pedal intervention. 1.
2.
3.