lamp SSANGYONG KORANDO 2013 Service Manual

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. -
-
-
(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. -
-
(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. -

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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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

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4. CAUTIONS FOR DI ENGINE
1) Cautions for DI Engine
This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation
from engine, warning lights, symptoms when engine malfunctioning, causes and actions.
DI Engine 1.
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically,
delivers high power and reduces less emission.
System Safety Mode 2.
When a severe failure has been occurred in a vehicle, the system safety mode is activated to protect the
system. It reduces the driving force, restricts the engine speed (rpm) and stops engine operation. Refer
to "Diagnosis" section in this manual.
Engine CHECK Warning Lamp 3.
The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or
major electronic systems of the engine are not working properly. As a result, the
Water Separator Warning Lamp 4.
When the water level inside water separator in fuel filter exceeds a certain level (approx.
45 cc), this warning light comes on and buzzer sounds.
Also, the driving force of the vehicle decreases (torque reduction). If these conditions
occur, immediately drain the water from fuel filter.

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(2) Di engine and its expected problems and remedies can be caused by
water in fuel
System supplement against paraffin separation
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then
can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply
summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and
season. However, above phenomenon can be happened if stations have poor facilities or sell improper
fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal
preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging
due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by
injector returns through fuel filter to have an effect of built-in heater (see fuel system).
System supplement and remedy against water in fuel
As mentioned above, some gas stations supply fuel with excessive than specified water. In the
conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine
hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can
cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high
speed pumping and bacterization (under long period parking). To prevent problems can be caused by
excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water
that has relatively bigger specific gravity is accumulated on the bottom of the filter.
Water drain from water separator
If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel,
so the engine ECU turns on warning lamp on the meter cluster and buzzer if water level is higher than a
certain level.
Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer
checks in to change engine oil, be sure to perform water drain from fuel filter.
Water separator

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3) Troubleshooting Sequence
The basic checks for intake system are as follows:
Basic Checks for Intake System
Make sure to replace or clean the air cleaner
element periodically. Otherwise, engine will be
derated or work abnormally because of low
intake air volume.
Unlike the fuel system, which is a closed
circuit, the intake system is an open circuit
system. Therefore any malfunction may occur
due to dust and dirt.
Most of the connections consist of hoses so
the system cannot withstand high temperature
and pressure. Also it can be deformed or
loosened easily because it is a clamp
mounting system. Thus, when checking the
engine, basic inspections, such as tightened
status check and visual inspection for hose,
etc., should be carried out in advance.
Other Checks for Intake System
If the intake system is free of any faults, check
for EGR and PCV oil separator.

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2) Inspection of Turbocharger
On-board Inspection 1.
Check the bolts and nuts foe looseness or missing
Check the intake and exhaust manifold for looseness or damage
Check the oil supply pipe and drain pipe for damages
Check the housing for crack and deterioration -
-
-
-
Inspection of turbine 2.
Remove the exhaust pipe at the opening of the turbine and check, with a lamp, the existence of
interference of housing and wheel, oil leakage and contamination (at blade edge) of foreign
materials.
Interference: In case where the oil leak sign exists, even the small traces of interferences on the
turbine wheel mean, most of times, that abrasion has occurred on the journal bearing. Must
inspect after overhauling the turbocharger.
Oil Leakage: Followings are the reasons for oil leakage condition -
-
Problems in engine: In case where the oil is smeared on inner wall section of the exhaust gas
opening.
Problems in turbocharger: In case where the oil is smeared on only at the exhaust gas
outlet section. *
* When problem occurs with the turbocharger, it could cause engine power decline,
excessive discharge of exhaust gas, outbreak of abnormal noise and excessive
consumption of oil.
Idling for long period of time can cause oil leakage to the turbine side due to low pressure of
exhaust gas and the rotation speed of turbine wheel. Please note this is not a turbocharger
problem.
Oil Drain Pipe Defect
In case where oil flow from the turbocharger sensor housing to the crank case is not smooth would
become the reason for leakage as oil builds up within the center housing. Also, oil thickens (sludge)
at high temperature and becomes the indirect reason of wheel hub section. In such case, clogging
and damage of the oil drain pipe and the pressure of blow-by gas within the crank case must be
inspected.
Damages due to Foreign Materials
When the foreign materials get into the system, it could induce inner damage as rotating balance of
the turbocharger gets out of alignment. -
-

2. INSPECTION
Possible Cause Action
Coolant level
is too low- Leak from the radiator
- Leak from the auxiliary reservoir
- Leak from the heater core- Replace the radiator
- Replace the auxiliary reservoir
- Replace the heater
- Leak from the coolant hose connections
- Damaged coolant hose- Reconnect the hose or replace
the clamp
- Replace the hose
- Leak from the water pump gasket
- Leak from the water pump internal seal- Replace the gasket
- Replace the water pump
- Leak from the water inlet cap
- Leak from the thermostat housing- Replace the water inlet cap
gasket
- Replace the thermostat sealing
- Incorrect tightening torque of the
cylinder head bolts
- Damaged cylinder head gasket- Tighten the bolts to the specified
torque
- Replace the cylinder head
gasket
Coolant
temperature is
too high- Coolant leakage (Coolant level is low)
- Improper coolant mixture ratio
- Kinked coolant hose- Add coolant
- Check the coolant concentration
(Anti-freeze)
- Repair or replace the hose
- Defective thermostat
- Defective water pump
- Defective radiator
- Defective auxiliary reservoir or tank cap- Replace the thermostat
- Replace the water pump
- Replace the radiator
- Replace the auxiliary reservoir
or tank cap
- Cracks on the cylinder block or cylinder
head
- Clogged coolant passages in the
cylinder block or cylinder head- Replace cylinder block or
cylinder head
- Clean the coolant passage
- Clogged radiator core - Clean the radiator core
- Improper operation of cooling fan - Replace the cooling fan or repair
the related circuit
- Defective temperature sensor or faulty
wiring- Replace the sensor or repair the
related wiring
Coolant
temperature is
too low- Thermostat is stuck open - Replace the thermostat
- Improper operation of cooling fan - Replace the cooling fan or repair
the related circuit
- Defective temperature sensor or faulty
wiring- Replace the sensor or repair the
related wiring

2. INSPECTION
1) Alternator Output Test
Item How to check DTC set value / Action
Output
current
B terminal
current
Rotor
coil
resistance
L terminal
voltage
Disconnect the cable connected to the B
terminal on the alternator. Connect one end
of the ammeter to the B terminal and the
other end to the cable connected to the B
terminal.
Measure the maximum output value.
(Maintain the engine speed between 2,500
and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.) 1.
2.Pass: If the measured current is 45 A
or higher.
Fail: If the measured current is less
than 45 A.
Check the current of the B terminal. -
-
-
Move the gear selector lever to the
neutral position.
Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.) 1.
2.Open circuit: If the measured
current is 5 A or higher. -
Disconnect the negative cable from the
battery.
Remove the B terminal and turn off the
ignition switch.
Measure the resistance between the L and F
terminals with an ohmmeter. 1.
2.
3.Pass: If the measured resistance is
Faulty rotor coil or slip ring: If the
measured resistance is less than 3
-
-
Connect the B terminal wiring.
Measure the voltage with the engine running. 1.
2.Specification: 12.5 V to 14.5 V
Faulty IC regulator or field coil: If
the measured voltage is 14.5 V or
higher. -
-
Disconnect the negative battery cable.
Connect the negative cable again after connecting the ammeter. -
-

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2) Troubleshooting for Alternator
Item Cause Action
Overcharged battery Defective alternator voltage regulator Replace
defective alternator detection wiring Repair or replace
Discharged battery Loose alternator drive belt Adjust the belt tension or replace
Poor connection of related circuit or
open circuitRetighten the loose connection or
repair open circuit
Defective alternator voltage regulator Replace
Terminated battery Replace
Defective ground Repair
Charge warning lamp
does not come on when
turning on ignition switch
with engine stoppedDefective alternator voltage regulator Replace
Open circuit in charge warning lamp,
fuse or wiringReplace or repair the charge
warning lamp or fuse
Defective ignition switch Replace
Defective ground of alternator circuit Repair
Charge warning lamp
does not go off after
starting engineDefective alternator voltage regulator Replace
Corroded or worn battery cable Repair or replace
Loose alternator drive belt
Adjust the belt tension or replace the
belt
Defective wiring harness Repair or replace