GENERAL INFORMATION

1. LAYOUT................................................. 3

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2. MAJOR COMPONENTS......................... 4

GENERAL INSTRUCTIONS

1. GUIDELINES FOR SERVICE WORKS.... 6

2. JACK-UP POINTS.................................. 11
3. STANDARD BOLTS SPECIFICATIONS.. 12
4. CODING AND SETUP............................. 13

SPECIAL SERVICE TOOLS

1. SPECIAL SERVICE TOOLS................... 14

2. NORMAL EQUIPMENTS........................ 23
0000-00 SET UP THE ENGINE SUPPORT
HANGER...................................... 26
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1. LAYOUT
Front view Rear view

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Right side view Left side view
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2. MAJOR COMPONENTS
▶ Front View

Vacuum pump

Oil filter assembly

Camshaft position sensor

Power steering pump pulley

Water pump pulley

Alternator pulley

Idler pulley No. 1

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A/C compressor pulley

Auto tensioner

Idler pulley No. 2

Isolation damper

▶ Rear View

E-EGR valve

Fuel temperature sensor

Fuel HP pump assembly

Coolant temperature sensor

Crankshaft position sensor

IMV valve

Magnetic triggering

Crankshaft position sensor

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▶ Right side View

Wide band oxygen sensor

Pre-CDPF pressure port

Front exhaust gas temperature

sensor

Rear exhaust gas temperature

sensor

CDPF assembly

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Post-CDPF pressure port

Oil drain plug

E-VGT turbocharger

▶ Left side View

Thermostat assembly

Knock sensor 1 connector

Oil cooler assembly

Variable swirl valve assembly

E-EGR valve

Knock sensor 2 connector

E-EGR solenoid valve

EGR cooler

Electronic throttle body

T-MAP sensor

Oil level switch

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 “CAUTION” and “NOTE” have special meanings.

indicates information to assist maintenance and instructions.

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indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property damage.

However, above references and cautions cannot be inclusive measures, so should have habits of
paying attentions and cautions based on common senses.

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

Engine crane

Transmission
Engine stand jack
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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

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.

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(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.
Use only Ssangyong genuine spare parts.
(7) Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut.
(8) 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
(13) specified sealant and gasket to prevent leakage if necessary.
(14) Tighten the fasteners with the specified tightening torque.
(15) 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

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- 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.
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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,

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- 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.
01-10

(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.

1. If fine dust or foreign material enters into DI engine's fuel system, there can be serious
damages between HP pump and injectors. So, be sure to cover removed fuel system
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)
2. When working on the fuel line between priming pump and injector (including return line),
always plug the openings with caps to prevent foreign materials or dust from entering to the
openings and connections.

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3. The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector) should
be replaced with new ones when removed.
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2. JACK-UP POINTS
▶ Stand jack-up points and installation status (front side)

Jack-up points and setup

(front side)

Supporting

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Jack-up points Jack-up points
for 2-post lift for 2-post lift

Jack-up points and setup

(rear side)

Supporting
01-12

3. STANDARD BOLTS SPECIFICATIONS

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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.
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4. CODING AND SETUP

1) Engine Variant Coding

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01-14

1. SPECIAL SERVICE TOOLS

Name & Part number Tool How to use (on vehicle)
Part number: T99410010A
Name: Belt tension adjuster

Use to release tension

without removing belt when
replacing pulley or pump.

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How to use (on engine)

Part number:T9911 0010A

Name: Flywheel fixing device

Use to fix flywheel or drive

shaft to prevent engine from
rotating when removing
crankshaft pulley
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Name and Part Number Special tool Use

Part number: T99180010A
Name: EURO-V injector
remover

▶ Components of Injector Remover

No Name Quantity Component

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1 Injector remover set 1

2 Main bar 1

3 Cross bar 2

4 Main bolt holder 1

5 Ball bearing 1
01-16

No Name Quantity Component

6 Main nut - A 1

7 Main bolt - A 1

8 Injector holder - A 1

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9 Injector holder - B 1

10 Injector holder cover 1

11 Bar holder assembly 2

12 Support mounting bolt 4

13 Main support 4
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▶ How to assemble the injector remover (bar holder assembly) for Euro-V

1. Temporarily assemble the main bars (A)

and cross bar (B) with the bar holder
assembly (C).
2. Assemble the main supports (D) and cross
bar (B) and temporarily tighten the bolts (E)
Install the sub supports (F) at the main
3. supports.

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01-18

▶ How to set up the injector remover (injector holder and main bolt) to the vehicle

1. Set up the injector holder assembly on the

injector to be removed.

A. Install the injector holder A.

B. Tighten the main bolt.
C. Install the injector holder B.

Pay particular attention not to damage the

injector return nozzle and thread of injector
during setting up the injector holder.

A B C

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2. Secure the injector holder by inserting the
injector holder cover on the main bolt.
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▶ How to remove the injector for Euro-V

1. Set up the injector remover assembly on

four cylinder head bolts.

- Pay attention not to damage the other

components when installing the main bar
assembly.
- Before setting up the injector remover,
check if the cylinder head bolts have
been tightened with the specified
tightening torque.

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The sub supports should be positioned on
the cylinder head cover bolts.

2. Tighten the support mounting bolts (A) and

the bar holder bolts (B) completely.

3. Install the main bolt holder.

Align the slot on main bolt with the main

bolt holder tab.
01-20

4. Install the ball bearing on the main bolt.

5. Tighten the main nut.

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6. Slowly release the injector by turning it
counterclockwise with a torque wrench and
socket (32 mm).

To avoid any damage to cylinder head

and head cover, keep the specified
tightening torque.

To avoid the damage to injector and

engine, the lifting should be below 15 mm.
Maximum lifting: 15 mm

7. Release the other injector on same clamp

with same manner, and remove two
injectors with the clamp.
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Name & Part number Tool How to use

Part number: Y9922 018
Name: Remover

Use to remove the valve

stem seal.

Part number: Y9922 008

Name: Installer

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Use to install the valve stem
seal.

Part number: Y9922 082B,

W9911 0230A, Y9922 018
Name: Valve spring complete

Use: Used to compress the

valve spring.

Y9922 082B W99110230A

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Name & Part number Tool How to use

Part number: Y9922 012
Name: Dial gauge

Use: Used to measure the

protrusion of piston.

Part number: Y9922 0172B

Name: Piston install guide

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Use: Used to slide the piston
into cylinder.

Part number: W9911 0120A

Name: Inserting guide

Use: Used to install the rear

crankshaft oil seal.
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2. NORMAL EQUIPMENTS
Name and Part Number Tool Use
Name:
Engine and transmission jack

Use:
High load jack dedicated for
Chairman W, but can be used
for Korando C to support
module when lowering engine
and transmission mounted to
sub frame at the same time
(replacing manual
transmission).

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Name:
Engine stand
(1 tone or more)

Use:
Used to fix the removed
engine or engine and
transmission (transaxle) and
can support at least 1 tone.

Name:
Engine crane
(1 tone or more)

Use:
Used to move engine module
(including transaxle) to
working space or engine
stand, and can support at
least 1 tonne.
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Name and Part Number Tool Use

Name:
Engine holder for C200

Use:
Used to hold engine to
prevent it from dropping
when removing engine
mounting (RH) insulator or
sub frame.
Name:
Oil pan gasket remover

Use:

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Used to separate oil pan and
minimize damage when
removing oil pan.

Name:
Torque angle gauge

Use:
Used to angle-tighten
correctly after torque-
tightening

Name:
Fuel sender cover
remover/installer
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Name & Part number Tool How to use

Name: High pressure pump
gear & nut remover

Use to remove & install the

high pressure pump sprocket.

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Name: Adapter & gauge

Use to measure the

compression pressure by
inserting it into glow plug
hole.
01-26

- Disconnect the negatice cable from the battery.

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1. Unscrew three screw rivets on each fender
cover and remove both fender covers.

* Disconnect the negative cable from the battery.

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2. Place the engine support hanger on the fender.

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3. Secure the hanger legs by turning the lever
to arrow direction.
01-28

4. Release the nut (A, B) on the legs and level

the hanger.

5. Chain up the rear engine hanger bracket.

Rear hanger bracket

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6. Align the hook of support hanger with the
hanger bracket by adjusting the top of the
Front hanger bracket engine hanger support.

7. Engage the hook of the engine support

hangers with the engine hanger brackets.
- Engage it with the front hanger bracket
directly. However, to avoid the
interference between hanger hook and
cowl, engage the hook with the chain on
rear hanger bracket.

Make sure that the hanger hook is out of

contact with the rear cowl cover.
Short hanger hook

Chain

Long hanger hook

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8. Make the chain tight by turning the hook

level adjusting lever to arrow direction.

9. Remove the engine support hanger in the

reverse order of installation.

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