SsangYong Korando III (2010 year). Manual - part 83

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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.

However, above references and cautions cannot be inclusive measures, so should have habits of 

paying attentions and cautions based on common senses.

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.

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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.

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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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4) Basic Inspection

(1) Horn operation

Listen for the horn sound when pressing the horn pad on the steering wheel.

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(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.

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(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.

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(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. 

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(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.

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(6) Engine oil    

Check the oil level when the engine is still warm and add the specified engine oil if necessary.

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(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.

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(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

(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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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.

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.

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(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.

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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(4) Fuel and lubrication system