Content .. 86 87 88 89 ..

SsangYong Korando III (2010 year). Manual - part 88

02-4

2. TIGHTENING TORQUE

Name

Size

Quantity

Tightening torque

Heater core screw bolt

70 ± 7 Nm

Ladder frame bolt

M8 X 1.25 X 20

25 ± 2.5 Nm

TGCC

M6 X 1.0 X 25

10 ± 1.0 Nm

Oil drain plug

30 ± 3.0 Nm

Oil pan bolt

M6 X 1.0 X 20

10 ± 1.0 Nm

Oil pan bolt

M6 X 1.0 X 35

10 ± 1.0 Nm

Oil pan bolt

M6 X 1.0 X 85

10 ± 1.0 Nm

Oil dipstick gauge bolt

M6 X 1.0 X 16

10 ± 1.0 Nm

Camshaft cap

M6 X 1.0 X 30

10 ± 1.0 Nm

Main gallery screw bolt

55 ± 5.5 Nm

Main bearing cap bolt

55 Nm + 90°

Cylinder head bolt

M12X1.75X102

55 Nm + 180°

Cylinder head TGCC side bolt

M8 X 1.25 X 30

25 ± 2.5 Nm

Cylinder head front cover bolt

M6 X 1.0 X 25

10 ± 1.0 Nm

Cylinder head cover bolt

M6 X 1.0 X 30

10 ± 1.0 Nm

Crankshaft center bolt

M18 X 1.5 X 50

200 ± 20 Nm

90 ° + 10 °

Flywheel bolt

M10 X 1.0 X 22

45 ± 5 Nm

90 ° + 10 °

Connecting rod bolt

M9 X 1.0 X 52

40 + 5 Nm

90 ° + 10 °

Cam Cap bolt (#1)

M6 X 1.0 X 35

10 ± 1.0 Nm

Cam Cap bolt (#2~5)

M6 X 1.0 X 30

10 ± 1.0 Nm

Solenoid valve bolt

M5 X 0.8 X 22

8 ± 1 Nm

Intake manifold bolt

M8 X 1.25 X 32

25 ± 2.5 Nm

02-5

1116-01

Name

Size

Quantity

Tightening torque

Intake manifold lower bracket bolt

M8 X 1.25 X 16

25 ± 2.5 Nm

Exhaust manifold nut

40 ± 5 Nm

Heat protector bolt

M6 X 1.0 X 25

10 ± 1 Nm

Oil jet bolt

10 ± 1 Nm

Oil pump bolt

M8 X 1.25 X35

25 ± 2.5 Nm

Oil filter assembly assembly bolt

M8 X 1.25 X30

25 ± 2.5 Nm

Oil filter assembly assembly bolt

M8 X 1.25 X65

25 ± 2.5 Nm

Water pump bolt

M6 X 1.0 X22

10 ± 1 Nm

Belt tensioner upper bolt

M8 X 1.25 X30

25 ± 2.5 Nm

Belt tensioner lower bolt

M10 X 1.5 X55

82 ± 5 Nm

Water pump pulley bolt

M6 X 1.0 X12

10 ± 1 Nm

Thermostat bolt

M6 X 1.0 X22

10 ± 1 Nm

Coolant outlet port bolt

M6 X 1.0 X22

10 ± 1 Nm

Coolant pipe mounting bolt

M6 X 1.0 X14

10 ± 1 Nm

Bypass hose clamp

M24

3 ± 0.5 Nm

EPS idler pulley

25 ± 2.5 Nm

Engine mountinf stud bolt

50 ± 5.0 Nm

Engine front mounting bolt

M10 X 45

60 ± 6.0 Nm

Engine front mounting bolt

M10 X 77

60 ± 6.0 Nm

Engine front hanger bracket

M8 X 1.25 X 20

25 ± 2.5 Nm

Engine rear hanger bracket

M8 X 1.25 X 20

25 ± 2.5 Nm

A/C compressor bolt

25 ± 2.5 Nm

Alternator bolt

M10

45 ± 4.5 Nm

Start motor bolt

M10

Max. 48Nm

02-6

3. GUIDELINES ON ENGINE SERVICE

G20DF engine is for FF (Front Engine Front Drive) type vehicle. Therefore, there are some deferent

maintenance and repair works compared to the engine for FR (Front Engine Rear Drive) type vehicle.

For safe and correct works, you must observe the working procedures and instructions in this manual.

And, use the designated tools as follow:

: Power train mounting stand / Engine hanger / Engine stand / Heavy duty engine jack.

Cautions before service works

▶

G20DF engine is FF (Front Engine Front Drive) type engine, and the engine and transmission are

integrated in a same module. Remember that there are many differences compared to

conventional engine in FR (Front Engine Rear Drive) type SUV vehicle.

To remove the engine, use the dedicated equipments such as engine jack, transmission jack,

engine stand and engine crane (1 ton).

To prevent the engine from abruptly starting during service in engine compartment, never allow

anybody to stay in the vehicle.

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.

Do not remove the engine while supporting the oil pan with a jack.

Lifting up the vehicle

▶

Before lifting up the vehicle with a lift, correctly support the lifting points.

To prevent the vehicle from rolling down, put the chocks under the tires (when using a 4-post lift).

Make sure to support the correct lifting points (when using a 2-post lift).

02-7

1116-01

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.

Carefully read the disassembly and reassembly procedures in this manual before starting the

works.

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.

Tightening the fastener

▶

When reassembling the parts to G20DF, use the angle tightening as a final step.

1. Clean the mating surfaces before tightening.

2. Place the marks with paint to tighten by angle if the angle wrench is not available.

Exhaust system

▶

Wear the protective gloves before removing the exhaust pipe.

The exhaust pipe is very hot immediately after stopping th engine. Check if the exhaust pipe is fully

cooled down before servicing the exhaust system.

Cooling system

▶

Scalding hot coolant and steam could be blown out under pressure, which could cause serious

injury. Never remove the coolant reservoir cap when the engine and the radiator are hot.

The position and direction of the componets is based on the rear view.

Do not tighten the fasteners with excessive force. Especially, the threads of cylinder block could be

damaged.

The self screw bolt makes the thread itself when tightening it. Do not apply excessive force.

Do not reuse the bolt that has been tightened with angle tightening method.

Content .. 86 87 88 89 ..