2012 SSANGYONG KORANDO service

01-230000-00
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 to 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) 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. -
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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 -
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Engine stand
Engine crane

02-153680-01
This information is used by the TCU to decide which shift pattern to select and for shift energy
management. Electro-hydraulic solenoid valves and variable bleed solenoids control the transaxle gear
changes.
Six variable bleed solenoids and four on/off solenoids are used to direct transaxle fluid flow to control the
fluid pressure within the three clutches and two bands. Separate pressure regulators are used
exclusively for torque converter clutch control and main transaxle line pressure.
The TCU monitors all TCU inputs and outputs to confirm correct system operation. If a fault occurs the
TCU is able to perform default action and inform the driver of the problem through the instrument cluster
warning lights. Detailed information is available via trouble codes which can be read with the service tool.

03-10
6. SPECIAL SERVICE TOLLS
Part number Name Tool How to use
00104-001(UD) Remover &
Installer - U/D
brake return sprin
00104-002(OD) Remover&
Installer - O/D
clutch return
spring
00104-003(LR)
(use with 00104-001)Remover&
Installer - L/R
brake return
spring
* Special service tool Supplier: Tool & Tech

03-173660-01
5. TRANSAXLE ELECTRONIC CONTROL SYSTEM
1) General Information
The transmission control unit (TCU) and its input/output network control the following transmission
operations:
Shift timing
Line pressure
Clutch pressure (shift feel)
Torque converter clutch -
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also uses these signals when determining transaxle operating strategy. Using all of these input signals,
the TCU can determine when the time and conditions are right for a shift, or when to apply or release the
torque converter clutch. It will also determine the pressure needed to optimise shift feel.
2) TCU (Transmission Control Unit)
The transaxle control unit (TCU) is mounted
under the driver's seat and controls the operation
of the transaxle.
Internal sensors and signals received across the
CAN bus in analogue and digital forms such as:
Transaxle input speed
Transaxle output speed
Accelerator pedal position
Gear selector position
Engine torque
Engine speed
Transaxle fluid temperature
Brake pedal status
Engine oil temperature
Engine coolant temperature
Ambient air temperature
Barometric pressure -
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The TCU monitors all TCU inputs and outputs to confirm correct system operation. If a fault occurs the
TCU is able to perform default action and inform the driver of the problem through the instrument cluster
warning lights. Detailed information is available via trouble codes which can be read with the service tool.

09-6
2. SPECIFICATION (DSL ONLY)
Unit Description Specification
Front brake Type Ventilated disc
Outer diameter of discØ298 mm
Inner diameter of caliper cylinderØ43.0 x 2 mm
Thickness of disc 26 mm (wear limit: 24 mm)
Thickness of brake pad 10.5 mm (wear limit: 2 mm)
Pad wear indicator Mechanical type
Rear brake Type Solid disc
Outer diameter of disc2WD: Ø262 mm, 4WD: Ø284 mm
Thickness of disc 10 mm (wear limit: 8.4 mm)
Thickness of brake pad 10 mm (wear limit: 2 mm)
Pad wear indicator Mechanical type
Brake booster Type Vacuum assist type
Size8” + 9” (Tandem)
Master cylinder Type Tandem (level sensor installed)
Inner diameter of cylinderØ25.4 mm
Brake pedal Maximum operating stroke140 ± 3 mm
Pedal ratio 3.8 : 1
Free play 3 to 10 mm
Parking brake Type Mechanically expanded rear lining
Operating type Hand operated type
Inner diameter of drum2WD: Ø168 mm, 4WD: Ø190 mm
Brake oil Specification DOT 4
Capacity 0.7 to 0.8 liters
Service interval for brake fluid: Change every other year.

02-6
Seldom oeprate ▶The air bag deploys when: ▶
The air bag can deploy when: ▶a severe oblique collision occurs with a specific severity, angle, speed, and position. -
A collision with oblique impact to the front seat direction or a front collision to the diagonal
direction occurs.
a frontal or rear collision occurs.
The vehicle rolls over or tips over sideward with minor impact.
The air bag warning lamp is on. -
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-the vehicle rolls over or tips over sideward with a severe impact.
The vehicle is stationary or a front collision occurs with low speed.
A rear collision occurs.
The impact of the collision is low enough for the seat belt to protect the occupant properly. -
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Seldom oeprate ▶The air bag deploys when: ▶
The air bag can deploy when: ▶
The air bag does not deploy when: ▶
The vehicle is stationary or a front collision occurs with low speed.
A rear collision occurs.
The impact of the collision is low enough for the seat belt to protect the occupant properly. -
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C. General Warnings for Air Bag
Do not check the circuits with a circuit tester. Do not attempt to modify any air bag component
including the steering wheel, air bag mountings and related wirings.
Do not subject any air bag component, such as the steering wheel, air bag mountings, wirings, to
impacts. You might get severely injured by sudden deployment of the air bag.
As the air bag/seat belt pretensioner parts are very hot after being deployed. Allow them to cool
down sufficiently before touching them.
The deployed air bag/seat belt pretensioner cannot deploy again. It will work when an additional
impact is applied. The components of the deployed air bag/seat belt pretensioner are non-reusable
parts. Therefore, remove or replace them as a unit.
The air bag and seat belt pretensioner systems contain explosive charges, so handle carefully when
disposing or replacing them.
Incorrect inspection can result in serious injuries or malfunctions in the air bag and seat belt
pretensioner system.
The air bag warning lamp is illuminated for 3 to 7 sec. after the engine is started to check the system.
Drive the vehicle after this warning lamp is turned off. If this warning lamp stays ON, the system may
be defective. Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong
Authorized Service Center. -
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