GENERAL INFORMATION
1. LAYOUT................................................. 3
2. MAJOR COMPONENTS......................... 4
GENERAL INSTRUCTIONS
1. GUIDELINES FOR SERVICE WORKS.... 6
2. JACK-UP POINTS.................................. 10
3. STANDARD BOLTS SPECIFICATIONS.. 11
4. CODING AND SETUP............................. 12
OVERVIEW
1. ENGINE COMPARTMENT..................... 13
2. FUEL SYSTEM...................................... 14
3. IGNITION SYSTEM................................ 16
4. INTAKE SYSTEM.................................. 17
5. EXHAUST SYSTEM...............................
18
6. LUBRICATION SYSTEM........................
20
7. COOLING SYSTEM...............................
22
8. ELECTRIC SYSTEM..............................
24
0000-00 01-3
1. LAYOUT
Front view Rear view
Right side view Left side view
01-4
2. MAJOR COMPONENTS
▶ Front View
Cylinder head cover
Cylinder head front cover
Engine mounting bracket
Timing gear case cover
EPS idler pulley
Alternator
Water pump pulley
Hydraulic tensioner assembly
A/C compressor
Crankshaft pulley
Oil pan assembly
▶ Rear View
Camshaft position sensor
Breather nipple
Coolant temperature sensor
Purge control solenoid valve
Electronic throttle body
T-MAP sensor
MCC complete
Dual mass flywheel
Crankshaft position sensor
VIS solenoid valve
0000-00 01-5
▶ Right side view
Rear oxygen sensor connector
Front oxygen sensor connector
Heat protector
Exhaust manifold
Front oxygen sensor
WCC complete
Crankshaft pulley
Rear oxygen sensor
Coolant outlet port
Oil pan drain plug
▶ Left side view
Injector assembly
Fuel rail
Purge control solenoid valve
T-MAP sensor
Electronic throttle body
VIS solenoid valve
Oil dipstick gauge
Thermostat assembly
Oil pressure sensor
Oil filter assembly
01-6
1. GUIDELINES FOR SERVICE WORKS
1) For Safety
To perform the service works easily ans safely, the service technicians must keep the proper
working procedures and rules.
This manual provides the useful instructions to the service technicians so that they can perform
the servive works with standard working process, skills, tips in time.
Please read this manual and follow the instructions carefully.
Signal words such as “WARNING”, “CAUTION” and “NOTE” have special meanings.
indicates information to assist maintenance and instructions.
indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property damage.
indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
However, above references and cautions cannot be inclusive measures, so should have habits of
paying attentions and cautions based on common senses.
0000-00 01-7
2) Equipment
- 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
Remove the engine and transaxle as a set.
- Manual transaxle: Transaxle can be separated after removing the front module (sub frame,
engine and transaxle).
- Automatic transaxle: Transaxle can be separated after removing the sub frame.
3) General Instructions
(1) Before lifting up the vehicle with a lift, correctly support the lifting points.
(2) 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.
(3) Make sure to disconnect the negative (-) cable from the battery to prevent any damage to
electric systems.
(4) If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
(5) Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle
them during service work.
(6) To improve the efficiency of service work, use only recommended and specified tools.
(7) Use only Ssangyong genuine spare parts.
(8) 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.
(9) Store the disassembled parts as a set based on disassembly order and unit.
(10) Pay particular attention not to miss or mix the fasteners.
(11) If necessary, especially for inspection, clean the removed parts completely.
(12) Apply the oil or grease on the running and sliding surfeces before installation. Use the
specified sealant and gasket to prevent leakage if necessary.
(13) Tighten the fasteners to the specified tightening torque.
(14) As a final stage of service work, check if the serviced system is working properly and the
problem has been eliminated clearly.
01-8
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.
0000-00 01-9
5) Guidelines on Engine Service
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.
(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.
(2) Engine and accessories
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.
- 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.
(3) Electric devices
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.
- 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.
(4) Fuel and lubrication system
- When working with the fuel or oil systems in enclosed area, always keep the working area well-
ventilated and never allow anybody to smoke.
- Gaskets and seals on the fuel and oil systems should be replaced with new ones. All bolts and
nuts should be tightened as specified.
- Make sure to check the connections for leak after installation.
01-10
2. JACK-UP POINTS
▶ Stand jack-up points and installation status (front side)
Jack-up points and setup
(front side)
Supporting
Jack-up points Jack-up points
for 2-post lift for 2-post lift
Jack-up points and setup
(rear side)
Supporting
0000-00 01-11
3. STANDARD BOLTS SPECIFICATIONS
1) 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.
2) 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.
3) Determine extra proper tightening torque if tightens with washer or packing.
4) If tightens bolts on the below materials, be sure to determine the proper torque.
- Aluminum alloy: Tighten to 80 % of above torque table.
- Plastics: Tighten to 20 % of above torque table.
01-12
4. CODING AND SETUP
1) Engine Variant Coding
Description Coding
CAN
Vehicle speed input to ECU with ABS or ESP: CAN
WIRE
3 Relays
Fan 3 Relays
PWM fan
NO
Auto cruise with Auto cruise system: YES
YES
NO without Engine level control system: NO
Engine level control
YES (Korando)
NO with 2WD ABS and non-ABS: NO
G-sensor
YES with 4WD ABS and ESP: YES
NO
Smart key with Smart key: YES
YES
0000-00 01-13
1. ENGINE COMPARTMENT
1. Coolant reservoir [Link] assembly
2. OCV [Link]
3. Ignition coil [Link] rail assembly
4. Rear oxygen sensor connector [Link]
5. Front oxygen sensor connector [Link] manifold
6. Coolant temperature sensor [Link] dipstick gauge
7. Purge control solenoid valve [Link] solenoid valve
8 Engine ECU 18.T-MAP sensor
9. Battery [Link] throttle body
[Link] box [Link] cleaner assembly
01-14
2. FUEL SYSTEM
Engine ECU
Engine compartment
Injector Purge control solenoid
Fuel rail
valve
0000-00 01-15
Fuel filter Canister
Fuel pump & fuel sender assembly
Fuel tank assembly
01-16
3. IGNITION SYSTEM
Ignition coil Ignition plug Engine ECU
Knock sensor Camshaft position Crankshaft position
sensor sensor
0000-00 01-17
4. INTAKE SYSTEM
Air cleaner element
Intake manifold assembly Electronic throttle body
VIS solenoid valve T-MAP sensor VIS valve
01-18
5. EXHAUST SYSTEM
WCC Engine ECU Engine CHECK
warning lamp
Green
Exhaust manifold PCV valve Blow-by hose
0000-00 01-19
Exhaust pipe No.1 Exhaust pipe No.2 Exhaust pipe No.3
(muffler)
Front oxygen sensor Rear oxygen sensor UCC
01-20
6. LUBRICATION SYSTEM
Oil pressure switch Oil jet Engine oil gauge
Oil pan Oil pump Oil filter module
01-22
7. COOLING SYSTEM
Coolant reservoir
Water pump assembly
The water pump is driven by the engine drive belt and
supplies the coolant to each area of the engine.
Thermostat assembly
When the engine coolant
reaches 90˚C, the thermostat
starts to open (fully open at
100˚C) and lets the coolant
flow to the radiator to
maintain the engine
temperature.
0000-00 01-23
Coolant outlet port
Coolant temperature sensor
Measures the coolant temperature
and sends the result to the engine
ECU.
Radiator assembly FAN
Releases heat through fins and cools down Circulates the fresh air forcibly to
the hot coolant as the coolant passes through exchange heat with the radiator core
the tube of the radiator core. fin.
01-24
8. ELECTRIC SYSTEM
Start motor assembly Battery
Converts the chemical energy to the
electrical energy and supplies power to
the corresponding electric units when
starting the engine.
Alternator B+ wiring
Charges the battery and supplies power
to each electric unit by converting the
mechanical energy to the electrical
energy.