2012 SSANGYONG KORANDO fuel

01-4
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
A/C compressor pulley
Auto tensioner
Idler pulley No. 2
Isolation damper
Rear View ▶
E-EGR valve
Fuel temperature sensor
Fuel HP pump assemblyE-VGT actuator
Coolant temperature sensor
IMV valve
Magnetic triggering
Crankshaft position sensor

01-90000-00
5) Guidelines on Engine Service
(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. -
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(2) Engine and accessories
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. -
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(3) Electric devices
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. -
- 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.
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.
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.

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. -
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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)
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.
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. 1.
2.
3.

02-6
품명 규격 볼트
수량규정토오크(Nm) 비고
(총 토오크)
Oil gauge tubeM6×16110 ± 1Nm-
Oil filter cap 125 ± 2.5Nm-
Fuel railM8×35225 ± 2.5Nm-
Injector clamp boltM6×6029 ± 1.0Nm
130˚ + 10˚-
High pressure pipe
(between HP pump and
fuel rail)M17 130 ± 3Nm
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High pressure pipe
(between fuel rail and
injector)M17 430 ± 3Nm
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Crank position sensor
M5×1418 ± 0.4Nm
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Main wiringM6×16510 ± 1Nm-
Intake duct M8x25 325 ± 2.5Nm-
Power steering pumpM8×100325 ± 2.5Nm-
Mass balance shaft
(MBU)M8×45630 ± 3Nm-
Cylinder head front cove
rM6×10510 ± 1Nm-
품명 규격볼트
수량규정토오크(Nm)비고
(총 토오크)
Timing gear case coverM6×40710 ± 1Nm-
M6×45110 ± 1Nm-
M6×50310 ± 1Nm-
Cylinder head coverM6×352110 ± 1Nm-
Component Size
QuantityTightening torque
(Nm)Remark
(Total torque)
Idle pulley/Tensioner
pulley145 ± 4.5Nm
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Glow plug M5 420 ± 2Nm-
Vacuum pumpM8×25310 ± 1Nm-

02-14
4. GUIDELINES ON ENGINE SERVICE
To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and
unit inspection/repair and to secure optimum engine performance and safety after service works, basic
cautions and service work guidelines that can be easily forgotten during engine service works are
described in.
Cautions before service works
For safe and correct works, you must observe the working procedures and instructions in this
manual. And, use the designated tools as follow:
Engine stand / Heavy duty engine jack
To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while
servicing in engine compartment.
Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)
terminal.
Before service works, be sure to prepare the works by cleaning and aligning work areas.
Do not allow the foreign material get into the fuel injection system.
When removing the engine, use only the safety hook on engine and engine hanger. Do not support
the bottom of oil pan with a jack.
Engine and accessories ▶
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Completely drain the engine oil, coolant and fuel from engine before removal.
Before disassembling/assembling the engine components, carefully read the working procedures in
this manual.
Make sure to keep the specified tightening torques during installation.
Clean and properly lubricate the parts before reassembly.
Carefully check that there are not any interference while servicing. -
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- Engine has a lot of precise portions so tightening torque should be correct during disassembly/assembly
and removal/installation and service work should be done in clean ways during disassembly/assembly.
Maintaining working area clean and cautious service administration is essential element of service works
while working on the engine and each section of the vehicle. So the mechanics should well aware of it.

02-150000-00
Electrical equipment ▶
Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. there could be poor engine performance, incomplete
combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and each electrical equipment, be sure to disconnect battery negative (-)
terminal.
When replacing the electric device, use only genuine part and check the conditions of connections
and grounds. Loosened connection or ground make cause a fire and personal injury. -
-Fuel and lubrication system ▶
Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking
should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and nuts
should be tightened as specified.
After removal/installation works, be sure to check whether there is leak on the connecting section. -
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages in HP
pump and injectors. Thus, be sure to plug the inlets of removed fuel line 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)

02-26
Mass Balance Unit (MBU)
Fuel HP pump
HP pump gear
Crankshaft MBU
drive gear
MBU
HP pump
drive gear

02-290000-00
10. FLYWHEEL AND DRIVE PLATE
1) DMF (Dual Mass Flywheel)
The dual mass flywheel, or DMF, eliminates excessive transmission gear rattle, reduces gear
change/shift effort, and increases fuel economy. There is a friction ring located between the inner and
outer flywheel that allows the inner and outer flywheel to slip. This feature is designed to alleviate any
damage to the transmission when torque loads exceed the vehicle rating of the transmission. The friction
ring is the weak spot in the system and can wear out if excessive engine torque loads are applied
through it. The system also has a center support bearing that carries the load between the inner and
outer flywheel, and is fitted with damper springs to absorb shocks.
2) Drive Plate
Drive plate receives the power from the start motor when starting the engine. With this, the drive plate
initially drives the power train system. And, it is connected to the torque converter to transfer the engine
torque to the power train system.Components ▶
Dual mass flywheel
Trigger ring
Drive plate
Components ▶