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ENGINE ASSEMBLY

1336-04 / 1336-25 / 1130-12 / 1610-01 / 1330-01 / 1990-02 / 1990-03 / 1990-11 / 1225-01 / 1214-01 / 1315-01 / 1533-08 / 1533-08 / 1330-40 / 1330-13
ENGINE ASSEMBLY
GENERAL INFORMATION
1. SPECIFICATION..................................... 2. TIGHTENING TORQUE......................... 3. CHECK AND INSPECTION.................... 4. GUIDELINES ON ENGINE SERVICE..... 3 4 7 12

CONFIGURATION
1. BELT SYSTEM..................................... 2. VACUUM PUMP.................................... 3. ENGINE MOUNTINGS.......................... 4. INTAKE/EXHAUST MANIFOLD............. 5. OIL SEPARATOR.................................. 6. CYLINDER HEAD ASSEMBLY.............. 7. CHAIN DRIVE SYSTEM........................ 8. OIL PAN................................................ 9. MASS BALANCE UNIT (MBU)............... 10.DUAL MASS FLYWHEEL (DMF) AND DRIVE PLATE....................................... 11.PISTON/CONNECTING ROD/ CRANKSHAFT/CYLINDER BLOCK........ 29 33 34 36 39 41 46 52 53 54 57

OVERVIEW AND OPERATING PROCESS


1. BELT SYSTEM..................................... 2. VACUUM PUMP.................................... 3. ENGINE MOUNTING............................. 4. INTAKE/EXHAUST SYSTEM................ 5. CYLINDER HEAD COVER AND OIL SEPARATOR......................................... 6. CYLINDER HEAD.................................. 7. CHAIN AND GEAR DRIVE SYSTEM...... 8. OIL PAN................................................ 9. MASS BALANCE UNIT (MBU)............... 10.FLYWHEEL AND DRIVE PLATE............ 11.PISTON/CRANKSHAFT/CYLINDER BLOCK.................................................. 14 15 16 17 18 19 21 25 26 27 28

REMOVAL AND INSTALLATION


1336-00 TIMING CASE (D20DTF)........... 1336-04 BELT TENSIONER ASSEMBLY... 1336-25 IDLER PULLEY ASSEMBLY NO.1 (NO.2) .......................................... 1130-00 CRANKSHAFT.............................. 1130-12 ISOLATION DAMPER ASSEMBLY.................................. 1610-00 VACUUM PUMP........................... 1610-01 VACUUM PUMP ASSEMBLY....... 65 66 70 72 73 77 78

ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
1990-00 ENGINE MOUNTING.................... 1330-01 ENGINE MOUNTING INSULATOR (LH-MTG) ................ 1990-02 ENGINE MOUNTING INSULATOR (RH-MTG) ............... 1990-03 ENGINE MOUNTING INSULATOR (FRT-MTG) ............. 1990-11 ENGINE MOUNTING INSULATOR (RR-MTG) ............... 1225-00 CYLINDER HEAD COVER AND CAMSHAFT (D20DTF).................. 1225-01 CYLINDER HEAD COVER............ 1214-00 CYLINDER HEAD ASSEMBLY AND CYLINDER HEAD GASKET.. 1214-01 CYLINDER HEAD ASSEMBLY..... 0000-00 ENGINE ASSEMBLY (D20DTF).... 1315-00 CHAIN DRIVE............................... 1315-01 TIMING CHAIN ASSEMBLY (UPPER CHAIN-BUSH)................. 1533-08 OIL PAN ASSEMBLY................... 1533-08 OIL PAN ASSEMBLY................... 1130-00 CRANKSHAFT AND FLYWHEEL.. 1130-40 MASS BALANCE SHAFT UNIT (MBU)........................................... 1130-13 DUAL MASS FLYWHEEL (DMF) ASSEMBLY.................................. 1120-00 ENGINE OVERHOLE.................... 81 82 85 87 89 91 92 96 97 112 127 128 137 138 141 142 144 146

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02-3

D20DTF ENGINE
1. SPECIFICATION
Unit Cylinder head Description Height Flatness Valve protrusion Intake valve Exhaust valve Flatness on manifold side Mass Balance Unit (MBU) Connecting rod Camshaft Intake manifold Exhaust manifold Specification 142.9 to 143.1 mm below 0.1 mm 0.1 to 0.7 mm 0.1 to 0.7 mm 0.08 mm 0.08 mm 0.05 to 0.15 mm 0.5 to 1.5 mm Intake Exhaust Camshaft position sensor Valve Distance between Camshaft position sensor and sprocket Clearance between valve and piston Valve recess Intake Exhaust Intake Exhaust Cylinder block Piston ring Piston protrusion TOP ring end gap 2nd ring end gap 3rd ring end gap Offset Head gasket Piston protrusion 0.475~0.540 0.541 to 0.649 0.650 to 0.745 0.541 to 0.649 mm 0.20 to 0.35 mm 0.35 to 0.50 mm 0.2 to 0.40 mm 0.3 mm 1.2t 1.3t 1.4t 0.1 to 0.35 mm 0.1 to 0.35 mm 0.20 to 1.80 mm Approx. 0.7 mm Approx. 0.8 mm 0.1 to 0.7 mm

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Remark

Backlash End play Axial end play

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2. TIGHTENING TORQUE
Component Main bearing cap Connecting rod cap Rear cover Timing gear cover Size M1162 (small) M1167 (large) M952 M620 M655 M645 Oil pump Flywheel Crankshaft center bolt Oil pan M835SOC M1022 M1850 M620 M635 M685 M6120 M840 HP pump main nut HP pump bolt Cylinder head Camshaft cap M141.5-8-1 M855 M12177 M6 M8 Exhaust stud bolt Exhaust sprocket bolt Screw bolt Coolant temperature sensor Auto tensioner M745 (Low) M1290 (Up) Coolant pump M650 M1140 M24 Bolt Quantity 10 8 6 3 8 3 8 1 18 2 2 2 2 1 3 12 16 4 10 1 1 1 1 1 7 Specified torque (Nm) 555 Nm, 130+10 405 Nm, 90+10 10 1 Nm 10 1 Nm 10 1 Nm 25 2.5 Nm 45 5 Nm, 90+10 200 20 Nm, 180+20 10 1 Nm 10 1 Nm 10 1 Nm 10 1 Nm 25 2.5 Nm 65 5 Nm 25 2.5 Nm 85 8.5 Nm + 270 10 10 1 Nm 25 2.5 Nm 40 4 Nm 30 3 Nm 25 2.5 Nm 20 2.0 Nm 25 2.5 Nm 55 5.5 Nm 10 1.0 Nm 60 to 100 Nm 660 to 720 Nm Remark (Total torque) 80 to 130 Nm 50 to 80 Nm

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Component Hot water inlet pipe Alternator

Size M612 M1090 M10116

Bolt Quantity 2 1 1 4 4 2 6 Bolt Quantity 2 1 2 10 3 1

Specified torque (Nm) 10 1 Nm 25 2.5 Nm 46 4.6 Nm 7.8 to 11.8 Nm 10 1 Nm 25 2.5 Nm 25 2.5 Nm Specified torque 25 2.5 Nm (Nm) 20 5 Nm 10 to 14 Nm 10 1 Nm 40 4 Nm 25 2.5 Nm 25 2.5 Nm 25 2.5 Nm 10 1.0 Nm 17 2.0 Nm 10 1 Nm 10 1 Nm 25 2.5 Nm 25 2.5 Nm 25 2.5 Nm 10 1 Nm 25 2.5 Nm 45 4.5 Nm 20 2 Nm 25 2.5 Nm

Remark (Total torque)

A/C bracket A/C sub bracket Intake manifold Component Oil cooler Knock sensor Cam position sensor Booster pressure sensor Exhaust manifold Turbocharger Support bolt Support nut T/C oil supply pipe

M825 M614 M835 M8110 Size M828 M814 M620 M8 M8

Remark (Total torque)

M8 M6 (block side) M6 (turbo side)

1 1 1 2 2 2 2 2 4 16 1

T/C oil return pipe

M616 (turbo side) M616 (block side)

EGR valve EGR pipe bolt (Intake side) EGR pipe bolt (EGR cooler side) EGR combination bolt

M822 M816 M816 M616 M816

Tensioner pulley Glow plug Vacuum pump M5 M825

4 3

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Component

Size M625

Bolt Quantity 5 1 3 Bolt 21 Quantity 1 1 2 2 1

Specified torque (Nm) 10 1 Nm 10 1 Nm 10 1 Nm Specified torque 10 (Nm) 1 Nm 10 1 Nm 25 2.5 Nm 25 2.5 Nm 10 1 Nm, 120+10 30 3 Nm

Remark (Total torque)

Cooling fan bracket Component Cylinder head cover Oil gauge tube Oil filter Fuel rail Injector clamp bolt High pressure pipe (between HP pump and fuel rail) High pressure pipe (between fuel rail and injector ) Crank position sensor Main wiring Intake duct bracket Power steering pump

M660 M685 Size M635 M616 M835SOC M835SOC M660 M17

Remark (Total torque)

M17

30 3 Nm

M514 M616 M816 M8100

1 5 3 3

8 0.4 Nm 10 1 Nm 25 2.5 Nm 25 2.5 Nm

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3. CHECK AND INSPECTION


1) Cylinder
(1) Compression pressure test
Specified value Compression ratio Test condition Compression pressure Standard Minimum 16.5 : 1 at normal operating temperature (80C) 32 bar 18 bar Maximum 3 bar

Differential limit between cylinders

The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating status.

- Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving components of engine (e.g., belt and cooling fan). - Park the vehicle on the level ground and apply the parking brake. - Do not allow anybody to be in front of the vehicle. 1. Warm the engine up to normal operating temperature (80C). 2. Disconnect the fuel rail pressure sensor connector to cut off the fuel injection. 3. Place the diagram sheet to compression pressure tester.

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4. Remove the glow plugs and install the compression pressure tester into the plug hole.

5. Crank the engine for approx. 10 seconds by using the start motor. 6. Record the test result and measure the compression pressure of other cylinders with same manner. 7. If the measured value is out of specified value, perform the cylinder pressure leakage test.

(2) Cylinder pressure leakage test


Specified value Test condition: normal engine operating temperature (80C) Whole engine at valve and cylinder head gasket at piston ring Specified value below 25% below 10% below 20% If the measured value of the compression pressure test is not within the specifications, perform the cylinder pressure leakage test.

- Perform this test in the sequence of firing order. - Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the combustion chamber)

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(3) Piston protrusion check


Position the piston at TDC and measure the piston protrusion from crank case mating surface. Specified value 0.541 to 0.649 mm

- Measure it at both ends of crankshaft.

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2) Cylinder Head
(1) Cylinder head mating surface check
Specified value Total height "A" Minimum height after machining Flatness Longitudinal direction Transverse direction 142.9 to 143.1 mm 142.4 mm 0.08 mm 0.0 mm below 0.1 mm 0.004 mm 0.1 to 0.7 mm 0.1 to 0.7 mm

Parallel deviation of cylinder head Peak-to valley of surface valve recess "a" Intake valve Exhaust valve

1. Measure the cylinder head height "A".

- If the height is less than the limit, the cylinder head must be replaced.

2. Insert the valves into the valve guides and measure the recesses. Valve recess a 0.1 to 0.7 mm

- If the measured value is out of the specified range, machine the valve seat as much as necessary until the specified value is achieved.

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(2) Cylinder head pressure Leak test


- Removal of cylinder head - Removal of intake and exhaust manifold - Removal of valves 1. Place the pressure plate on a flat-bed work bench.

2. Install the cylinder head on the pressure plate.

3. Immerse the cylinder head with the pressure plate into warm water (approx. 60C) and pressurize with compressed air to 2 bar.

- Examine the cylinder head for air bubbling. If the air bubbles are seen, replace the cylinder head.

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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 - D20DTF 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 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. - Always position the ignition switch to OFF if not required. If not, there can be electrical equipment damages or personal injuries due to short-circuit or ground by mistake. - There should be no leak from fuel injection system (HP pump, fuel hose, high pressure pipe) of the D20DTF engine. So they should be protected from foreign materials. - While removing the engine, do not position the jack and others under the oil pan or engine. To secure the safety, use only safety hook on the engine. - When removing the engine, use only the safety hook on engine and engine hanger. Do not support it with jack under the oil pan. Engine and accessories 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. - While removing the engine, related parts (bolts, gaskets, etc.) should be aligned as a group. - While disassembling/assembling internal components of the engine, well aware of disassembly/assembly section in this manual and clean each component with engine oil and then coat with oil before installation. - While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage. - During service work of removal/installation, be sure to check each connected portions to engine not to make interference.

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Fuel and lubrication system Painted surface of the body can be damaged or rubber products (hose) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system. - If work on the fluid system such as fuel and oil, working area should be well ventilated and mechanic should not smoke. - Gasket or seal on the fuel/lubrication system should be replaced with new 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. 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) Electrical equipment Electrical equipment should be handled more carefully. Currently, the engine is equipped with a lot of electrical equipments so there can be engine performance drops, incomplete combustion and other abnormal symptoms due to short and poor contact. Mechanics should well aware of vehicle's electrical equipment. - If have to work on the electrical equipment, be sure to disconnect battery negative (-) terminal and position the ignition switch to off if not required. - When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury.

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1. BELT SYSTEM
The belt system is a single belt drive system which uses single belt and has components on the oil filter housing as FEAD (Front End Accessories Drive) type. Components with HPS (hydraulic power steering) with EPS (electric power steering)

HPS 1 2 3 4 5 6 7 8 9 10 Crankshaft pulley (DDU) Auto tensioner Tensioner pulley Vacuum pulley A/C compressor pulley Alternator pulley Water pump pulley NO. 1 idler pulley NO. 2 idler pulley Power steering pump

EPS

NO. 3 idler pulley

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2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole in hollow shaft. Components Vacuum pump Pump capacity: 210 cc/rev Speed: 700 to 6,000 rpm Lubrication temperature: -40 to 155C Oil: 5W30 Drive type: Driven by exhaust Camshaft sprocket Brake booster

EGR cooler bypass valve

Exhaust gas goes to combustion chamber without through EGR cooler in engine cooled, and the valve is closed by vacuum pressure.

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3. ENGINE MOUNTINGS
D20DTF engine mounting is 4-point mounting type and supports the engine and transaxle. Front and rear mountings are rubber type and support the torque reaction. Left and right mountings support the power train rods and torque reaction. Additionally, left mounting is hydraulic type and supports the engine vibration. Components Front mounting assembly Location: Front side of transfer axle housing and front side of sub frame Location Front mounting Right mounting assembly Location: Engine block side and body side member Location Right mounting

Left mounting assembly Location: Upper side of transfer axle housing and body side member Location Left mounting

Rear mounting assembly Location: Rear side of transfer axle housing and front side of sub frame Location Rear mounting

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4. INTAKE/EXHAUST SYSTEM
1) Intake Manifold
Intake manifold is installed on the cylinder head with 8 bolts. The variable swirl valve is introduced to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas. Components Intake manifold

2) Exhaust Manifold
Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts. EGR port is integrated in cylinder head. Components Exhaust manifold

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5. CYLINDER HEAD COVER AND OIL SEPARATOR


The cylinder head cover is made by high strength plastic to reduce the weight. The multi twist type oil separator improves the oil consumption. Components PCV valve

Oil separator

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6. CYLINDER HEAD
Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are install in vertical direction. This enables the compact layout in cylinder head assembly.

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Components

Finger follower & HLA

Intake/exhaust Camshafts

Camshaft sprocket

Cylinder head Camshaft position sensor HP pump drive gear Vacuum pump drive

Cylinder head gasket

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7. CHAIN AND GEAR DRIVE SYSTEM


D20DTF engine uses single stage chain drive system. Timing chain drives the exhaust side and gear drive the intake side. Timing chain is single bush type. Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil pump to lubricate the engine. And, MBU (Mass Balance shaft Unit) drive gear drives MBU. Components Chain upper bush Chain type: single bush Chains: 112 EA Exhaust Camshaft sprocket Teeth: 40 EA

Tensioner rail Installed between exhaust Camshaft sprocket and crankshaft sprocket Hydraulic tensioner Contains tensioner housing plug, spring and check valve, and operated by hydraulic pressure Crankshaft sprocket Teeth: 20 EA Mechanical type tensioner Operated by internal spring Clamping rail Installed between exhaust Camshaft sprocket and crankshaft sprocket

Chain lower bush Oil pump sprocket Teeth: 20 EA Chain type: single bush Chains: 60 EA

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Components Intake/exhaust Camshaft assembly

Exhaust Camshaft Connected to vacuum pump

HP pump drive gear

Intake Camshaft

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Timing gear cover case (TGCC)

TGCC

Oil seal

Screw plug

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Mass Balance Unit (MBU) MBU

Crankshaft MBU drive gear

Fuel HP pump HP pump drive gear

HP pump gear

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8. OIL PAN
The oil pan in D20DTF engine improves the noise and vibration. Especially, the oil drainage is very easier than before. The oil level sensor in oil pan monitors the oil level and turns on the oil level warning lamp on the meter cluster when the oil level goes down below the specified value. And, A/C compressor bracket and the oil dipstick tube are mounted on the oil pan. Components

Oil pan assembly Oil drain plug Dust cover Oil level sensor

For details, refer to Chapter "Engine Control" Oil dipstick tube hole A/C compressor bracket

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9. MASS BALANCE SHAFT UNIT (MBU)


The balance shaft in MBU (Mass Balance shaft Unit) improves the NVH performance by decreasing the unbalanced force. Components

Crankshaft drive gear

Mass balance shaft unit

Mass balance shaft unit

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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. Components

Dual mass flywheel

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 Drive plate

Trigger ring

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11. PISTON/CRANKSHAFT/CYLINDER BLOCK


This vehicle is FF driving type and the engine is installed in lateral direction. The crankshaft and the cylinder block convert the compression pressure to the rotating energy. Components

Cylinder block

Piston

Connecting rod Crankshaft

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1. BELT SYSTEM
1) Crankshaft Pulley (Isolation Damper)
(1) Overview
The strut type tensioner automatically adjusts the belt tension to provide the reliability and durability for the system. And, the belt tension is decreased to minimize the friction loss and improve the belt operating noise.

(2) Sectional drawing

Pulley

Axial & radial bearing

Sleeve

Hub

Isolation pulley rubber

Damper rubber

Inertia ring

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(3) Features
1. Rubber damper: Decrease crankshaft torsion 2. Improve belt NHV: Reduce unbalance speed to crankshaft due to irregular combustion 3. Minimize noise: Anti-vibration from crankshaft and belt 4. Post bonded type rubber damper: Improve durability of rubber damper

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2) Pivot Damped Tensioner


(1) Overview
The torque deviation from crankshaft affects the components in belt drive system and the belt movement. The auto tensioner system is to adjust this deviation automatically. In D20DTF engine, one of the mechanical tensioner, pivot damped tensioner is used to keep the damping force, system reliability and durability. The single belt drive system needs to use the automatic belt tensioning device to transfer the power to pulleys effectively. To get this, the tensioner uses the spring and damping unit.

(2) Mounting Location


Pivot damped tensioner

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3) Belt
(1) Belt
The belt length for EPS (Electric Power Steering) equipped vehicle is identical with that for HPS (Hydraulic Power Steering) equipped vehicle. In EPS equipped vehicle, No. 3 idler pulley is installed instead of the hydraulic pump pulley.

(2) Mounting Location


for HPS for EPS

Power steering pump pulley

No.3 idler pulley (No power steering pump) Belt length: 1,980 mm

Belt length: 1,980 mm

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2. VACUUM PUMP
1) Overview and Location
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This pump is single vane type and its displacement is 210 cc/rev. The lubrication oil is supplied through the hole in hollow Camshaft.

2) Operation
Vacuum pump is driven by exhaust Camshaft.

Connecting are for vacuum pump coupling and exhaust Camshaft slot

Oil supply

Vacuum pump

Exhaust Camshaft

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3. ENGINE MOUNTING
1) Mounting Location
Front mounting assembly Location: Front side of transfer axle housing and front side of sub frame Location Front mounting Right mounting assembly Location: Engine block side and body side member Location Right mounting

Left mounting assembly Location: Upper side of transfer axle housing and body side member Location Left mounting

Rear mounting assembly Location: Rear side of transfer axle housing and front side of sub frame Location Rear mounting

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2) Function
Appearance Front mounting: Bracket + Insulator Type and function Type: Rubber type mounting Function: support torque reaction

Rear mounting: Bracket + Insulator

Type: Rubber type mounting Function: support torque reaction

Left mounting: Bracket + Insulator

Type: Rubber type mounting Function: - support power train rod - support torque reaction

Rear mounting: Bracket + Insulator and D-damper Type: Hydraulic type mounting Function: - support power train rod - power train bounce vibration absorber - support torque reaction

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4. INTAKE/EXHAUST MANIFOLD
1) Overview
(1) Intake manifold assembly
The variable swirl valve in intake manifold is operated by swirl valve actuator. The DC motor and position sensor in the actuator controls the swirl vale according to the intake air and driving conditions to optimize the mixture of air and fuel. Features 1. Improves the combustion efficiency by optimizing the turbulence in combustion chamber with DC motor type variable swirl valve (to observe EU5 regulation and improve fuel consumption). 2. Controls the valve opening by duty control in exhaust gas control range (partial load: below 50%, pedal position: below 50% / coolant temperature: 25 to 90C) 3. Introducing electronic throttle body (for EU5), optimizing air-fuel mixture by EGR control, reducing vibration in idling, stabilizing engine vibration when turning OFF engine

(2) Exhaust manifold assembly


The exhaust manifold is designed to increase the reaction speed of turbocharger by effectively transferring the exhaust gas and made by heat resistance material.

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2) Mounting Location
(1) Intake manifold

Intake manifold

Actuator (DC motor type)

to EGR cooler pipe Variable swirl valve

Electronic throttle valve

Intake manifold

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(2) Exhaust manifold

Cylinder head cover

Head protector

Exhaust manifold gasket

Cylinder head

Exhaust manifold

EGR cooler port

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5. OIL SEPARATOR
1) Overview
Oil separator separates the particle in blowby gas to minimize the engine oil consumption and reduces the inflow oil from intake system into the combustion chamber. The separated oil returns to oil pan through cylinder head.

2) Layout

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3) Operation
The first separation will happen when blowby gas passes through the high efficiency Half-twister in cylinder head cover. Then the gas will be separated at Multi-twister. Separated oil returns to oil pan and gas flows into intake manifold through PCV valve.

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6. CYLINDER HEAD ASSEMBLY


1) Cylinder Head
(1) Overview
The cylinder is made by gravity casting and the water jacket is integrated type. The cylinder oil passage is drilled and sealed by cap. The Camshaft bearing cap is also made by casting and installed on the cylinder head.

(2) Features

Closed flow type water jacket (improving cooling performance)

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Conventional air intake port (swirl & tangential port) and variable swirl system Air intake port

Exhaust port Intake port

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2) Camshaft
(1) Overview
Hollow type Camshaft contains cam, octagon cam, HP pump gear and intake/exhaust gears. Camshaft operates the intake/exhaust valves, vacuum pump and HP pump, and transfers the engine oil to vacuum pump through the internal oil passage.

(2) Mounting Location


Intake/Exhaust Camshafts

Exhaust Camshaft

Connected to vacuum pump Intake Camshaft Octagon cam Thrust journal HP pump drive gear

Vacuum pump

HP pump

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3) Valve Assembly (Installed in Cylinder Head)


(1) Features
1. Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash 2. Optimized adjustment of valve clearance reduces the valve noise. 3. Roller type finger follower reduces the friction loss. 4. Simple and compact design reduces the moving operation (improving valve following and fuel consumption at high speed)

(2) Arrangement
Finger follower

Hydraulic lash adjuster

Upper valve spring retainer Valve spring Lower valve spring retainer Exhaust valve Intake valve

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4) Cylinder Head Gasket


(1) Features
1. Sealing the cylinder gas pressure - Peak pressure: 190 bar 2. Minimizing the distortion of engine structure (cylinder head, block): profile stopper, backland stopper 3. Material: MLS (Multi Layer Steel), Gasket (3 layers) 4. Thickness of gasket: 3 types (1.2 /1.3 /1.4 mm)

Thickness marking

Ex: 1.3t

(2) Thickness of cylinder head gasket


There are three types of gasket to managing the compression ratio. Piston protrusion Piston protrusion 0.475 to 0.540 mm 0.541 to 0.649 mm 0.650 to 0.745 mm Thickness 1.2t 1.3t 1.4t

ENGINE ASSEMBLY
korando 2010.10

02-46

0000-00

7. CHAIN DRIVE SYSTEM


1) Chain Drive
(1) Overview
The drive chain is single chain drive system with simple design and variable performance, and it utilizes the hydraulic tensioner to reduce the wave impact generated by the chain. This chain is light weight and has high durability through single bush chain. Shoulder bolts are used for better NHV.

(2) Layout
Chain upper bush Type: single bush Chains:112 EA Exhaust camshaft sprocket Teeth: 40 EA

Tensioner rail Installed between exhaust Camshaft sprocket and crankshaft sprocket Hydraulic tensioner Contains tensioner housing plug, spring and check valve, and operated by hydraulic pressure Crankshaft sprocket Teeth: 20 EA Clamping rail Installed between exhaust Camshaft sprocket and crankshaft sprocket

Mechanical type tensioner Operated by internal spring

Oil pump sprocket Teeth: 20 EA

Chain lower bush Chain type: single bush Chains: 60 EA

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-47

2) Timing Chain and Gear


(1) Timing chain
- Simple layout: optimized timing, enhanced NVH - Single stage layout: minimized chain load Chain upper bush - Single bush type (112 EA) Chain lower bush - Single bush type (60 EA)

(2) Tensioner
Tensioner adjusts the chain tension to keep it tight during engine running. This reduces the wear in guide rail and spoke. Hydraulic tensioner assembly 1. Operating principle - Use the spring tension in tensioner and hydraulic pressure 2. Tensioner type - Compensation and impact absorbing 3. Static and dynamic force - Spring + Hydraulic pressure

Plunger

Check valve

Housing

Spring

ENGINE ASSEMBLY
korando 2010.10

02-48

0000-00

(3) Mechanical Tensioner Assembly


Operating principle - Use only spring tension Tensioner type - Compensation and impact absorbing Static and dynamic force - Spring

(4) Guide rail


The guide rail is used for optimizing the movement of chain drive system. And it also prevents the chain from contacting each other when the chain is loose, and reduces the chain wear. The guide rail is made of plastic, nylon, Teflon, etc. The guide rail is specially required when the distance between two spokes is too great. It pushes the chain with constant force so that the chain can work smoothly. The guide rail is fitted by pins. Tensioner guide rail Installed between exhaust Camshaft sprocket and crankshaft sprocket Clamping guide rail Installed between exhaust Camshaft sprocket and crankshaft sprocket

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-49

(5) Timing gear case cover


Features - Major function: Protecting the chain drive system, minor function: Shielding the chain noise. - Prevent oil leak - Install crankshaft front seal and screw plug on the timing gear case cover.

Name 1 2 3 4 Screw plug Bolt Bolt Bolt

Size

Tightening torque 25 2.5 Nm 10 1.0 Nm 10 1.0 Nm 10 1.0 Nm

M6X40 M6X45 M6X50

A671 997 01 46 Crankshaft front seal

- Do not touch the inner lip of crankshaft front seal. - Be careful not to damage the screw thread when removing the lock pin to release the chain tensioner. - Be careful not to damage the O-ring when installing the screw plug.

ENGINE ASSEMBLY
korando 2010.10

02-50

0000-00

(6) Timing setting


Timing for MBU Mass Balance Unit (MBU) MBU 1. Align the timing marks on the MBU gear and crankshaft sprocket.

Crankshaft MBU drive gear

Timing for Camshaft sprocket and crankshaft sprocket

1. Check timing links (gold color) on the chain. 2. Align the timing link (gold color) on the chain to the timing mark on crankshaft sprocket. 3. Align another timing link (gold color) to the timing mark on camshaft sprocket.

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-51

Timing for HP pump HP pump Camshaft drive gear 1. Align timing marks on intake Camshaft drive gear to HP pump gear.

HP pump gear

ENGINE ASSEMBLY
korando 2010.10

02-52

0000-00

8. OIL PAN
1) Overview
Oil pan is to store the engine oil and cools down the oil temperature. The oil level sensor in oil pan monitors the oil level and turns on the oil level warning lamp on the meter cluster when the oil level goes down below the specified value.

2) Mounting Location
Oil dipstick gauge/tube Oil pump Oil pan assembly

A/C compressor

Oil level switch

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-53

9. MASS BALANCE UNIT (MBU)


1) Features
- Removing the unbalanced reciprocating inertia in in-line 4 cylinder engine and reducing the vehicle booming noise - Location and operation type: Installed on crankshaft and driven by crankshaft - Minimizing the gear noise by gear integrated shaft and counter mass design - Cast iron gear - Improving the gear NVH - Cast iron housing - Improving the gear NVH by minimizing the backlash changes due to heat expansion

2) Layout

Housing

Gear Gear integrated shaft and counter mass

ENGINE ASSEMBLY
korando 2010.10

02-54

0000-00

10. DUAL MASS FLYWHEEL (DMF) & DRIVE PLATE


1) Overview
Flywheel is installed on crankshaft. When starting the engine, this drive the crank train mechanism initially by using the power from the start motor. Function: - Reducing the irregular speed of crankshaft due to unbalanced combustion -> Improving the power train NVH - Improving the driving performance - Reducing the clutch noise by using ball bearing - Improving the durability of DMF by using strong arch spring

2) Layout
Spring guide Drive plate Primary cover

Ring gear

Primary flywheel Internal/external ring Secondary flywheel

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-55

3) Operation
- Compensating the irregular operation of engine: The secondary flywheel operates almost evenly so does not cause gear noises - The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more (less pulsation absorbing effect). - Transaxle protection function: Reduces the torsional vibration to powertrain (transaxle) by reducing the irregularity of engine. Compression stroke Combustion stroke

Small changes from engine (k): Damper increases the torque changes to clutch

Large changes from engine (j): Damper decreases the torque changes to transaxle by absorbing the impact

Torque change curve of engine and drive shaft

ENGINE ASSEMBLY
korando 2010.10

02-56

0000-00

4) Features
Reduced vibration noise from the powertrain by blocking the torsional vibrations Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation Reduced shifting shocks Smooth acceleration and deceleration

5) Advantages
- Improved torque response by using 3-stage type spring: Strengthens the torque response in all ranges (low, medium, and high speed) by applying respective spring constant at each range. - Stable revolution of the primary and secondary wheel by using planetary gear: Works as auxiliary damper against spring changes - Less heat generation due to no direct friction against spring surface: Plastic material is covered on the spring outer surface - Increased durability by using plastic bushing (extends the lifetime of grease)

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-57

11. PISTON/CONNECTING ROD/CRANKSHAFT/CYLINDER BLOCK


1) Piston
(1) Overview
Piston assembly contains piston, #1 ring, #2 ring, oil ring, piston pin and snap ring. The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy.

(2) Layout
Wide bawl type (CR 16.5) Material: B2+ #2 ring

#1 ring Oil ring Snap ring Cooling jet Skirt coating: MoS2

Piston cooling gallery for connecting rod

ENGINE ASSEMBLY
korando 2010.10

02-58

0000-00

(3) Functions
Piston transfers the combustion energy from engine to connecting rod. Especially in the direct injection engine such as D20DTF, it provides the combustion space and largely effects to the engine performance and exhaust gas. Piston ring - #1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank chamber, and prevents the engine oil getting into combustion chamber. - #2 ring: Scrapes the engine oil on the cylinder bore, and prevents the leaked combustion gas from #1 ring from leaking into the crank chamber. - Oil ring: Scrapes the engine oil on the cylinder bore. Piston pin - Connects the piston the connecting rod, and transfers the linear movement of piston to connecting rod to convert it to rotating energy Snap pin - Locks the piston pin.

(4) Assembling the piston


1. Install the piston rings with the "Y" mark on the ring facing upwards. 2. Position the end gap of #1 ring at 180 away from the end gap of #1 ring. 3. Position the end gap of oil ring at 180 away from the end gap of coil spring, and position the end gap of oil ring at 90 away from the end gap of #2 ring.

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-59

2) Connecting Rod
(1) Overview
Connecting rod converts the reciprocating movement of piston to the rotating movement of crankshaft. The big end is connected to connecting rod bearing and the crank pin journal, and the small end is connected to the piston pin.

(2) Components

Piston pin bush

Connecting rod

Connecting rod upper bearing

Connecting lower bearing

Connecting rod cap

Connecting rod cap bolt

ENGINE ASSEMBLY
korando 2010.10

02-60

0000-00

3) Crankshaft
(1) Overview
Crankshaft is installed on the cylinder block. And, the ring gear for Mass Balance Unit is installed on it.

(2) Arrangement
Upper thrust bearing Crankshaft main bearing upper Crankshaft main bearing upper

MBU drive ring gear Crank pin journal Main journal

Lower thrust bearing Crankshaft main bearing lower Crankshaft main bearing lower

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-61

(3) Selection of crankshaft main bearing


Combination between crankshaft upper bearing shell and crankcase basic bearing bore Basic bearing bore mark on oil pan mounting surface Punch mark 1 or Blue mark Punch mark 2 or Blue mark Punch mark 3 or Blue mark Color code of crankshaft bearing shell Blue or White - Blue Yellow or White - Yellow Red or White - Red

Combination between crankshaft lower bearing shell and crankcase basic bearing journal Basic bearing journal mark on crankcase Blue or White - Blue Yellow or White - Blue Red or White - Blue Selection of upper main bearing Mark * ** *** Identification color Blue Yellow Red Color code of crankshaft bearing shell Blue or White - Blue Yellow or White - Yellow Red or White - Red

Selection of lower main bearing Select the lower main bearing for crankshaft bearing cap according to the mark on crankshaft front end. Mark B R V Y W Identification color Blue Red Violet Yellow White

ENGINE ASSEMBLY
korando 2010.10

02-62

0000-00

4) Cylinder Block
(1) Overview
The major dimensions in D20DTF are similar to D20DT. It has two mounting bosses for knock sensor and meets the requirements for EURO5 regulation.

(2) Layout

ENGINE ASSEMBLY
korando 2010.10

0000-00

02-63

(3) Features
Crankcase ventilation For simple manufacturing, the crankcase blowby gas passage and the oil return hole are made by casting on the cylinder block.

ENGINE ASSEMBLY
korando 2010.10

02-64

0000-00

The bottom side of water jacket is desgined as sine wave to strengthen the structure of crankcase. The main flow of coolant starts from outlet port of water pump and goes along the longitudinal direction of engine. The coolant passage from cylinder head to inlet port of water pump is integrated in cylinder head. Water jacket core

The engine oil from oil pump is supplied to the main oil gallery through oil channel, oil filter module and cross bore in cylinder block without using external pipes. This oil is supplied to main bearing, cylinder head and MBU. And, it is sprayed to the chain through the chain tensioner connected to cross bore. Crankcase cross bore for oil supply

ENGINE ASSEMBLY
korando 2010.10

1336-00

02-65

1. Cover - Timing case 2. Sealing - Crankshaft FRT 3. Bolt 4. Tensioner assy - Belt 5. Bolt 7. Cover - Idler pulley

8. Pulley assy - Idler 18.Bolt 23.BRKT - Idler 25.Pulley assy - Idler 27.Plug assy - Screw 28.Cover - Idler pulley

ENGINE ASSEMBLY
korando 2010.10

02-66

1336-04

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. - Remove the crankshaft main cover. 1. Remove the coolant reservoir (A). - Disconnect the coolant hose (B). - Unscrew the mounting bolts (C).

2. Unscrew the mounting bolts (B) for the power steering oil tank (A).

3. Put a floor jack under the engine oil pan.

ENGINE ASSEMBLY
korando 2010.10

1336-04

02-67

4. Remove the MTG bracket on the right side (A). - Unscrew the engine insulator mounting nut (B), engine mounting bracket nut (C) and bolts (D).

5. Remove the MTG on the right side (A). - Unscrew the bolts (B) and the nut (C).

6. Remove the belt. - Raise the jack to clear the area. - Turn the tension release bolt (B) of the belt tensioner assembly (A) (Pivot damped tensioner) clockwise using a special tool to release the tension of the belt tensioner before removing the belt. Special tool: T9941 0010A

ENGINE ASSEMBLY
korando 2010.10

02-68

1336-04

7. Remove the idler pulley cover (A) and remove the idler pulley cover No. 2 (B).

8. Unscrew the bolts (B) and the nut (C).

9. Remove the belt tensioner assembly (A).

10.Install in the reverse order of removal.

ENGINE ASSEMBLY
korando 2010.10

1336-04

02-69

Belt tensioner assembly

1 2 3 4

Belt tensioner Tensioner housing Belt tensioner pulley Belt tensioner pulley cover

ENGINE ASSEMBLY
korando 2010.10

02-70

1336-25

REMOVAL AND INSTALLATION


Disconnect the negative cable from the battery. Remove the engine acoustic cover. Remove the crankshaft main cover. Install a portable jack under the engine.

Idler pulley assembly No. 2

Idler pulley assembly No. 1

1 2 3 4 5 6

Idler pulley cover No. 1 Idler pulley No. 1 Idler pulley No. 1 mounting bolt Idler pulley cover No. 2 Idler pulley No. 2 Idler pulley No. 2 mounting bolt

1. Remove the engine mounting insulator bracket (A) on the right-hand side.

For more information, refer to the section "Engine Mountings" of Chapter "Engine Assembly".

2. Release the tension of the belt tensioner assembly (Pivot damped tensioner) and remove the belt.

For more information, refer to the section "Belt Tensioner Assembly" of Chapter "Engine Assembly".

ENGINE ASSEMBLY
korando 2010.10

1336-25

02-71

Belt idler pulley No. 1 1. Remove the belt idler pulley No. 2 (B). - Lower the jack to clear the area. - Remove the idler pulley cover (A) using a screwdriver.

- Remove the belt idler pulley No. 1 (B).

2. Install in the reverse order of removal. Belt idler pulley No. 2 1. Remove the engine mounting insulator (A) on the right-hand side. - Unscrew the bolts (B) and the nut (C).

2. Remove the idler pulley cover (A) and remove the idler pulley cover No. 2 (B).

ENGINE ASSEMBLY
korando 2010.10

02-72

1130-00

1. Crankshaft 3. Key - Crankshaft pulley 4. Sprocket - Crankshaft 7. Disc - Crankshaft vibration damper 8. Bolt 12.Damper assembly - Isolation

ENGINE ASSEMBLY
korando 2010.10

1130-12

02-73

Disconnect the negative cable from the battery. Remove the engine acoustic cover. Remove the engine under cover. Remove the crankshaft main cover. 1. Remove the coolant reservoir (A). - Disconnect the coolant hose (B). - Unscrew the mounting bolts (C).

2. Unscrew the mounting bolts (B) for the power steering oil tank (A).

3. Install an engine support hanger to the engine hanger.

ENGINE ASSEMBLY
korando 2010.10

02-74

1130-12

4. Remove the MTG bracket on the right side (A). - Unscrew the engine insulator mounting nut (B), engine mounting bracket nut (C) and bolts (D).

5. Remove the front engine mounting insulator (A).

- For more information, refer to the section "Engine Mountings" of Chapter "Engine Assembly".

6 Remove the front engine mounting insulator bracket (A).

7. Remove the starter. - Disconnect the ST connector (B) of the starter while the vehicle is lifted up. - Disconnect the B -terminal (C) of the starter. - Unscrew the bolt (D).

For more details, refer to the section "Starter" of "Starting System".

ENGINE ASSEMBLY
korando 2010.10

1130-12

02-75

8. Lower the engine support hanger (A) making sure not to interfere with the surrounding parts.

9. Fit the flywheel assembly using a special tool (000 000 00 00).

For more details, refer to the section "Starter" of Chapter "Starting System".

10.Unscrew the crankshaft center bolt using a special tool. - Special tool for crankshaft pulley center bolt P/N : 000 000 00 00

11.Remove the isolation damper (A).

12.Install in the reverse order of removal.

ENGINE ASSEMBLY
korando 2010.10

02-76

1130-12

Tightening process for crankshaft center bolt Torque wrench 200 20 Nm Put matchmark Tighten - 1st 9010 Tighten - 2nd 9010

Removal of crankshaft front seal-ring (A) Remove the crankshaft front seal-ring, making sure that the mounting groove of the seal-ring and the crankshaft are not damaged with a screwdriver wrapped with clean cloth.

Installation of crankshaft front seal-ring (A) Mount the crankshaft front seal-ring (A) to the TGCC and install it with a special tool (B).

ENGINE ASSEMBLY
korando 2010.10

1610-00

02-77

1. Pump assembly - Vacuum 3. Bolt

ENGINE ASSEMBLY
korando 2010.10

02-78

1610-01

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. - Remove the engine under cover. 1. Remove the coolant reservoir (A). - Disconnect the coolant hose (B). - Unscrew the mounting bolts (C).

2. Unscrew the mounting bolts (A) for the power steering oil tank.

3. Put a floor jack under the engine oil pan.

Put a floor jack under the engine before removing the engine mountings (RH, MTG) to clear the space.

ENGINE ASSEMBLY
korando 2010.10

1610-01

02-79

4. Remove the engine mounting bracket (A) on the right-hand side. - Unscrew the engine insulator mounting nut (B), engine mounting bracket nut (C) and bolts (D). - Remove the engine mounting bracket (A).

5. Disconnect the brake booster vacuum hose (A).

6. Unscrew the bolts (B) to remove the vacuum pump assembly (A).

Installation of vacuum pump assembly mounting bolt

ENGINE ASSEMBLY
korando 2010.10

02-80

1610-01

Cautions on installing vacuum pump - Replace the sealing (A and B) of the vacuum pump with new ones. - Apply oil to the sealing before installing it, and check the installation status after installing.

- Setting the correct timing makes the exhaust camshaft line up as shown in the figure (A-A'). - When installing the vacuum pump, make sure that it is lined up as shown in the figure (B-B').

ENGINE ASSEMBLY
korando 2010.10

1990-00

02-81

1. Insulator - Engine MTG 2. Insulator - Engine MTG 3. Insulator - Engine MTG FRT 4. Bolt 5. Bolt 6. Bolt - BRKT MTG

8. BRKT - ENGINE MTG 10.Nut - Hex flg_M12x1.25 11.Insulator - Engine MTG RR 12.Bolt 13.Nut 14.Bolt 15.Bolt

ENGINE ASSEMBLY
korando 2010.10

02-82

1330-01

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. - Remove the engine under cover. 1. Disconnect the air duct hose (A). - Disengage the mounting clamp (B). - Remove the intake air inlet duct side (C) of the oil separator. - Disconnect the HFM connector (D). - Disengage the air cleaner assembly mounting clips (E).

2. Remove the ECU/GCU (preheating control unit) and bracket. - Disconnect the ECU connector (A). - Unscrew the bolts (B).

ECU

3. Disconnect the GCU (preheating control unit) connectors (A and B), and remove the ECU assembly. GCU

The GCU connector (B) has locking parts on both sides.

ENGINE ASSEMBLY
korando 2010.10

1330-01

02-83

4. Unscrew the clamp mounting bolts (A) to remove the battery.

5. Remove the bracket at the bottom of the battery (A). - Unlock the connector holders (B). - Unscrew the bolts (C). - Unscrew the bolt (D).

6. Put a floor jack under the transmission.

7. Remove the through bolt installed to the engine mounting bracket.

ENGINE ASSEMBLY
korando 2010.10

02-84

1330-01

8. Unscrew the mounting bolts (B) to remove the MTG (A, LH).

Engine mounting insulator (LH-MTG)

Engine mounting insulator (LH)

Engine mounting insulator (LH)

ENGINE ASSEMBLY
korando 2010.10

1990-02

02-85

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. - Remove the engine under cover. 1. Remove the coolant reservoir (A). - Disconnect the coolant hose (B). - Unscrew the mounting bolts (C).

2. Unscrew the mounting bolts (B) for the power steering oil tank (A).

3. Put a floor jack under the engine oil pan.

ENGINE ASSEMBLY
korando 2010.10

02-86

1990-02

4. Remove the MTG bracket on the right side (A). the engine insulator mounting - Unscrew nut (B), engine mounting bracket nut (C) and bolts (D).

5. Unscrew the mounting bolts (B) and the nut (C) to remove the MTG (A, LH).

Engine mounting insulator (RH-MTG)

ENGINE ASSEMBLY
korando 2010.10

1990-03

02-87

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. - Remove the engine under cover. FRT-MTG (Manual Transmission) FRT-MTG (Automatic Transmission)

The appearance of the front engine mounting insulator is different from each other for the automatic/manual transmissions. But the basic procedures are the same for both transmissions. The description stated here is for the manual transmission. 1. Put a transmission jack under the vehicle.

2. Remove the through bolt installed to the MTG (A, FR).

ENGINE ASSEMBLY
korando 2010.10

02-88

1990-03

3. Unscrew the mounting bolt (A) on the engine mounting insulator.

4. Unscrew the mounting nut (A) on the engine mounting insulator to remove the MTG (B, FR).

FRT-MTG (Manual Transmission)

FRT-MTG (Automatic Transmission)

ENGINE ASSEMBLY
korando 2010.10

1990-11

02-89

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. - Remove the engine under cover. 1. Put a transmission jack under the vehicle.

2. Remove the through bolt installed to the rear engine mounting insulator.

3. Unscrew the mounting bolt (A) on the rear engine mounting insulator.

ENGINE ASSEMBLY
korando 2010.10

02-90

1990-11

Rear engine mounting insulator

ENGINE ASSEMBLY
korando 2010.10

1225-00

02-91

1. Cover - Cylinder head 2. Gasket - Cylinder head cover 3. Bolt 4. Cap assy - Oil filler 14.Hose assy - Blow by outlet

16.Clamp 21.Camshaft assy - Intake 22.Camshaft assy - Exhaust 23.Pin - Cylindrical 24.Cover - Cylinder head 25.Bolt

ENGINE ASSEMBLY
korando 2010.10

02-92

1225-01

- Disconnect the negative cable from the battery. - Remove the engine acoustic cover. 1. Remove the hose assembly (Air cleaner to Turbocharger) (A). - Disengage the mounting clamp (B). - Remove the intake air inlet duct side (C) of the oil separator. - Disconnect the HFM connector (D).

2. Disconnect the booster vacuum hose (A) and EGR bypass vacuum hose (B).

3. Remove the high pressure pipe. - From HP pump to Common rail (A) - From Common rail to Injector (B)

- Replace the fuel supply pipe with a new one. - The openings of the common rail and the injector should be sealed with the sealing caps.

ENGINE ASSEMBLY
korando 2010.10

1225-01

02-93

4. Remove the engine main wiring (A). - Unlock the wiring mounting holder (B). - Unscrew the bolts (C). - Disconnect the main wiring connector on the upper side of the cylinder head cover.

Connectors that should be removed before removing main wiring Wide band oxygen sensor Injector connector Rear EGT sensor Front EGT sensor

Cam position sensor

Pre-heating plug Connector

Variable swirl valve

Fuel rail pressure sensor

ENGINE ASSEMBLY
korando 2010.10

02-94

1225-01

5. Unscrew the clamp mounting bolt (A) to remove the injector. Tool Torx socket 6 mm

C3I [Improved Individual Injector Calibration] C3I code MDP learning Injection nozzle Consists of 20 digits (Numbers (1 to 9) and alphabetical characters except I, O, Q, V) During driving and idling 8 EA

a. C3I code for injector


(A) Injector mark (B) Cylinder head cover mark
ENG NO: 00000000000000 1. 12345678901234567890 2. 12345678901234567890 3. 12345678901234567890 ENG NO: 00000000000000 4. 12345678901234567890

C3I code marked on the upper side of injector

Engine serial number and C3I code for injector are printed on 2 labels

The C3I code is marked on the sides of the injector and the cylinder head, and consists of 20 digits. The C3I code is listed as 20 digits consist of numbers (1 to 9) and alphabetical characters except I, O, Q, V.

ENGINE ASSEMBLY
korando 2010.10

1225-01

02-95

6. Remove the cylinder head cover (A). - Unscrew the bolts for the cylinder head cover slowly in two or more stages to prevent any damage to the cylinder head. - Removal: from the outside to the inside, diagonally - Installation: From the center to the outside, diagonally

7. Install in the reverse order of removal. Cylinder head cover

Cylinder head cover gasket

Replace the cylinder head cover gasket with a new one.

ENGINE ASSEMBLY
korando 2010.10

02-96

1214-00

CYLINDER HEAD GASKET

1. Head assy - Cylinder 5. Plug - Expansion 6. Bolt - Stud 7. Bolt 11.Bolt 12.Sleeve 13.Bolt - Cylinder head 24.Gasket - Cylinder 26.Valve - Intake 27.Valve - Exhaust 28.Ring - Intake valve seat 29.Ring - Exhaust valve seat 31.Guide - Valve 32.Seal - Valve stem 33.Retainer - Valve spring LWR 34.Spring - Valve 35.Retainer - Valve spring UPR 36.Cotter - Valve 39.Follower assy - Finger 40.Adjuster assy - Hydraulic lash

ENGINE ASSEMBLY
korando 2010.10

1214-01

02-97

Disconnect the negative cable from the battery. Remove the engine acoustic cover. Remove the engine under cover. Remove the crankshaft main cover. 1. Align the timing of the crankshaft and the camshaft.

Do not reverse the engine.

TDC mark

- Turn the isolation damper (A) so that the timing mark (B) on the isolation damper and the mark (C) on the timing gear case cover are aligned. Timing case Cover mark

Isolation damper mark

The timing mark is located on the position where the no. 1 cylinder piston is rotated further 90 degrees clockwise from the TDC (D) point.

How to check timing position - Open the oil filler cap and check the camshaft nose position (A) of the intake camshaft. (If the camshaft nose position is incorrect, then turn the crankshaft 1 revolution and align the camshaft nose to 12 o'clock.)

ENGINE ASSEMBLY
korando 2010.10

02-98

1214-01

2. Unplug the drain cock at the bottom of the radiator to drain the coolant completely.

- Never open the cap if the coolant temperature is more than 90 (194) to prevent any burn. - Drain the coolant into a suitable container and do not spill it on the floor. - Avoid the coolant to come in contact with your skin or the vehicle body as anti-freeze is included. In case of skin contact, wash thoroughly with plenty of clean water immediately. - The coolant to be replaced or added should be original coolant with the same specifications. 3. Disconnect the air duct hose (A). - Disengage the mounting clamp (B). - Remove the intake air inlet duct side (C) of the oil separator. - Disconnect the HFM connector (D). - Disengage the air cleaner assembly mounting clips (E).

4. Remove the ECU/GCU (preheating control unit) and bracket. - Disconnect the ECU connector (A). - Unscrew the bolts (B).

ENGINE ASSEMBLY
korando 2010.10

1214-01

02-99

ECU

5. Disconnect the GCU (preheating control unit) connectors (A and B), and remove the ECU assembly. GCU

The GCU connector (B) has locking parts on both sides.

6. Unscrew the clamp mounting bolts (A) to remove the battery.

7. Remove the bracket at the bottom of the battery (A). - Unlock the connector holders (B). - Unscrew the bolts (C). - Unscrew the bolt (D).

8. Remove the duct and hose assembly (Turbocharger to Intercooler) (A). - Disengage the hose clamps on the turbocharger (A) and intercooler (B). - Unscrew the mounting nut for duct (C).

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9. Remove the high pressure pump (A).

For more information about the high pressure pump, see the section "Fuel Supply System".

10.Remove the CDPF assembly (A).

Make sure not to damage the rear exhaust gas temperature sensor when removing it.

For more information about the CDPF, refer to the section "CDPF". 11.Remove the VGT (A).

For more information about E-VGT, refer to the section "Turbocharger".

12.Remove the EGR pipe (A), intake duct (B) and electric throttle body (C).

For more information about E-EGR, refer to the section "EGR System".

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13.Unscrew the mounting bolts (C) of the EGR cooler (A) and the E-EGR valve (B).

14.Release the tension of the belt tensioner assembly (Pivot damped tensioner).

For more information, refer to the section "Belt Tensioner Assembly" of Chapter "Engine Assembly".

15.Remove the idler pulley cover (A) and remove the idler pulley cover No. 2 (B).

16.Remove the vacuum pump.

For more information about the vacuum pump, refer to the section "Vacuum Pump" of Chapter "Engine Assembly".

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17.Remove the high pressure pipe, engine main wiring and cylinder head cover (A). - Unscrew the bolts for the cylinder head cover slowly in two or more stages to prevent any damage to the cylinder head. - Removal: from the outside to the inside, diagonally - Installation: From the center to the outside, diagonally

For more information about the cylinder head cover, refer to the section "Cylinder Head Cover". 18.Unscrew the bolts (B) to remove the variable swirl control valve (A).

- Remove the connecting link (C) to remove the variable swirl control valve (A).

19.Unscrew the bolts (B) to remove the fuel rail assembly (A).

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20.Remove the glow plug (A).

The contact surface of the cylinder block and the cylinder head is lower than the heater of the glow plug. So the glow plug must be removed.

21.Remove the screw plug (A) and release the tension of the hydraulic chain tensioner.

Put a jack under the engine before removing the engine mounting (RH, MTG) to clear the space.

- Compress the chain tensioner with a flat-bladed screwdriver.

Use a piece of cloth not to damage the plug threads.

- Compress the hydraulic chain tensioner (A) using a flat-bladed screwdriver and insert the mounting pin (B) to secure the tensioner. Hydraulic chain tensioner

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22.Remove the cylinder head front cover (A).

Position to pry out front cover

Do not apply excessive force to remove it. Otherwise, chips or foreign materials can enter into the engine.

23.Secure the timing chain to the part (B) as shown in the figure to prevent the timing chain from falling into the cylinder block.

- Tie the timing chain to the clamping rail (C) as shown in the figure.

Tie the chain tightly so as not to fall into the timing gear case.

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24.Secure the spanner seat (A) of the intake camshaft with a 30 mm spanner, and unscrew the exhaust camshaft sprocket bolts (B) to remove the sprocket.

Exhaust camshaft sprocket

Cautions for installation 1. Pull up the timing chain provided that the timing chain is not tilted, so that the chain is aligned to the tensioner rail (A) and the clamping rail (B).

2. Install the camshaft sprocket by aligning the exhaust camshaft sprocket mark (C) to the marking link (copper link) (D) of the timing chain.

3. Fit the exhaust camshaft sprocket (C) to the camshaft (E) and tighten the mounting bolts to the specified torque.

Check the alignment of the timing chain and the clamping/tensioner rails again when installing the camshaft.

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25.Unscrew the mounting bolt (B) to remove the tensioner rail (A).

Arrange the timing chain (C) as shown in the figure to minimize any interference when removing the tensioner rail.

26.Unscrew the camshaft bearing cap bolts (A). - Unscrew the camshaft mounting bolts slowly in two or more stages according to the specific sequence stated below. (1) Intake camshaft: IN, 6, 8 (2) Exhaust camshaft: EX, 2, 4 (3) Intake camshaft: 5, 7, 9 (4) Exhaust camshaft: 1, 3 Tightening torque Always tighten to the specified torque so as not to damage the camshaft. EX, IN bearing cap No. 1 to 9 bearing caps 25 2.5 Nm 10 1.0 Nm

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27.Remove the intake/exhaust camshafts.

Timing marks on intake and exhaust camshafts

Exhaust camshaft:

Intake camshaft:

Align the two timing marks on the intake camshaft gear (A) to the one timing mark on the exhaust camshaft gear (B).

The timing marks are on both sides of the intake and exhaust camshaft gears.

Align the timing marks on the intake/exhaust camshaft sprockets.

28.Remove the camshaft and no. 1 lower cap (A).

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29.Remove the finger follow and HLA device (A).

- Take extreme care because the HLA device is very hot right after the engine is turned off. - If the removed finger follower and HLA device is easily pressed, it means that the oil has been drained. In this case, replace it with a new one.

Apply engine oil before installing. 30.Unscrew the cylinder head shoulder bolts (A, T6 mm).

31.Unscrew the cylinder head bolt (A). - Unscrew the cylinder head bolts in two or more stages according to the specific sequence.

Replace the mounting bolt if it is extended by 0.9 mm or more.

Tighten the bolts in the reverse order of removal in 2 or 3 steps with the specified torque.

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Tightening process for cylinder head bolts Torque wrench 45 5 Nm Put matchmark (Cylinder head/ head bolt) Tighten - 1st 9010 Tighten - 2nd 9010 Tighten - 3rd 9010

Unscrew the mounting bolts for the cylinder head in the sequence shown in the figure below.

- Unscrew the bolts in 2 or more steps. - Apply oil to the head bolt thread. 32.Remove the cylinder head assembly (A). - Turn the cylinder head counterclockwise to make room for removal of the cylinder head, because the space between the intake manifold and the oil filter module is narrow.

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33.Remove the cylinder head gasket (A).

34.Before assembling the cylinder head gasket, apply sealant to the contact surface (C) where the cylinder block (A) and the timing gear case cover (B) meet.

35.Remove the E-EGR valve (A), intake manifold (B) and exhaust manifold (C) from the removed cylinder head.

Cylinder head assembly

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Measuring piston protrusion and Selecting cylinder head gasket Measure the piston tip protrusion and install the cylinder head gasket with the corresponding thickness of the protruded piston. 1. Fit the gauge for piston protrusion (A) to the cylinder block (B) and adjust the zero point.

Special tool P/N: Y99 22 012 2B

Remove the foreign materials and the gasket on the surface of the cylinder block before measuring. 2. Measure the protrusion in the axial direction. Measure each point 3 or more times and calculate the average value (total 8 measurement points).

3. Install the cylinder head gasket with a corresponding thickness of the protruded piston. Protrusion amount of piston 0.475 to 0.540 mm 0.541 to 0.649 mm Cylinder head Gasket thickness mark 0.650 to 0.745 mm Gasket thickness 1.2t 1.3t 1.4t

Gasket thickness 1.3t

Replace the gasket with a new one and make sure that the surface of the steel gasket with marks face upwards.

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Disconnect the positive and negative battery cables. Remove the engine acoustic cover. Remove the front/rear undercover. Remove the front tires. Collect the air conditioner refrigerant using the air conditioner refrigerant draining equipment (refer to "Air Conditioner" section).

Make sure that the fluid and coolant does not come into contact with the body or other parts during the work. 1. Unplug the drain cock at the bottom of the radiator to drain the coolant completely.

- Never open the cap if the coolant temperature is more than 90 (194) to prevent any burn. - Drain the coolant into a suitable container and do not spill it on the floor. - Avoid the coolant to come in contact with your skin or the vehicle body as anti-freeze is included. In case of skin contact, wash thoroughly with plenty of clean water immediately. - The coolant to be replaced or added should be original coolant with the same specifications. 2. Drain the power steering oil. - Disengage the clamp (B) for the power steering cooler pipe at the front right side of the vehicle to disconnect the return pipe (C) and the return hose (A).

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3. Remove the coolant reservoir (A). - Disconnect the coolant return hoses (B) and supply hose (C). - Unscrew the mounting bolts (D).

Be careful so that the residual coolant in the coolant reservoir does not leak.

4. Disconnect the power steering oil supply hose. - Disengage the clamp (A). - Unscrew the hollow bolt (B) securing the oil supply pipe. - Disconnect the hose from the power steering pump.

5. Disconnect the air duct hose (A). - Disengage the mounting clamp (B). - Remove the intake air inlet duct side (C) of the oil separator. - Disconnect the HFM connector (D). - Disengage the air cleaner assembly mounting clips (E).

6. Disconnect the connectors (A) and (B) to remove the ECU/GCU.

Be careful not to bend the pin or let foreign material enter between the pins when connecting the engine ECU connectors.

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- Unscrew the bracket mounting bolts (C). - Remove the fuel hose by disengaging the mounting clip.

ECU

- Disconnect the GCU (preheating control unit) connectors (E) and (F).

GCU

The GCU connector (F) has locking parts on both sides.

7. Unscrew the bracket mounting bolts (A) to remove the battery.

8. Disconnect the 3 connectors from the battery lower bracket.

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9. Remove the battery lower bracket. - Unscrew the bolts (A). - Unscrew the bolt (B).

10.Disconnect the differential pressure sensor connector (A) and disengage the CDPF pressure hose clamps (B).

Before disconnecting the pressure hoses, put matchmarks on each hose so as not to mix up the front and rear hoses. 11.Remove the fuel hoses and brake vacuum hose connected to the fuel filter. - Disconnect fuel supply pipe (A). - Disconnect fuel return pipe (B).

- Disconnect the return hose (B) and drain the residual fuel to a suitable container. - Be careful so that the residual fuel in the fuel hose does not leak out when disconnecting the fuel hose. In case of skin or vehicle body contact, wipe it out thoroughly with a piece of clean cloth. - Disconnect return pipe quick connector (C) from the injector nozzle side. - Disconnect the brake vacuum hose (D).

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12.Disconnect the intercooler hose and pipe. a. Disengage the clamp on the turbocharger hose to disconnect the hose using a pair of clamp pliers. b. Disengage the clamp on the intercooler hose to disconnect the hose using a pair of clamp pliers.

c. Unscrew the mounting bolt (A) to remove it.

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13.Disconnect the selector cable for the automatic transmission. - Unscrew the mounting bolt (A).

14.Disconnect the TGS cable from the automatic transmission cable bracket. - Push the mounting holder (B) in the direction (C) shown in the figure.

Put the gear selector lever to "D" position when removing the transmission selector cable mounting bolt. 15.Disengage the connector (A) and the clamp (B) of the coolant hose to the radiator to remove the coolant hose.

16.Disconnect the engine ground terminal cable (A). - Unscrew the mounting bolt (B) on the intake manifold side.

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17.Slacken the steering column shaft. - Unscrew the joint bolt (A). - Slacken the steering column lower shaft (B) by pushing it in the direction (C).

Put align mark (A) before removing the lower shaft and the gear linkage while the steering wheel is in neutral position. 18.Remove the oil cooler pipes of automatic transmission.

Confirm that no transmission fluid contacts to other objects. 19.Disconnect the intercooler hose (A) from the bottom of the vehicle after unscrewing the screw of the intercooler lower hose.

20.Unscrew the nut (B) and disconnect the pipe (A) from the A/C compressor.

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21.Remove the propeller shaft from the vehicle.

21

For further information, refer to the section "Propeller Shaft" of Chapter "Chassis". 22.Disconnect No. 1 exhaust pipe (A). - Unscrew the mounting nut (B) securing the No. 1 exhaust pipe and the CDPF. - Unscrew the mounting nut (C) connecting the No. 1 exhaust pipe and the No. 1 exhaust pipe. - Remove the No. 1 exhaust pipe from the mounting hanger (D).

Replace the front and rear gaskets with new ones when installing.

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23.Remove the crankshaft main cover (A).

24.Remove the dust cap on the oil pan assembly, and then unscrew the 6 torque converter mounting bolts (13 mm).

Turn the crankshaft clockwise so that the torque converter mounting bolt is positioned at the hole and unscrew the mounting bolts.

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25.Unscrew the stabilizer bar front link upper nut (17 mm).

26.Separate the steering tie rod end and knuckle arm. - Remove the split pin (A) from the tie rod end. - Unscrew the slot nut (17 mm). - Remove the tie rod end from the knuckle arm using a special tool (B).

Replace the split pin with a new one. 27.Undo caulking of the hub nut (30 mm) and remove the hub nut (A).

Replace the hub nut with a new one and caulk the upper part of the hub nut when installing. 28.Separate the lower arm and knuckle arm. - Remove the split pin from the ball joint of the lower arm. - Unscrew the slot nut (24 mm). - Remove the lower arm ball joint from the knuckle arm using a special tool (B).

Replace the split pin with a new one.

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29.Remove the drive shaft (C) from the wheel disc assembly by lifting up the wheel disc assembly (A) in the direction (B).

30.Remove the right drive shaft (A) from the intermediate shaft (B). (Remove the drive shaft from the wheel disc assembly and then from the intermediate shaft, when removing the right drive shaft.)

(Remove the drive shaft from the wheel disc assembly and then from the transmission, when removing the left drive shaft.) 31.Remove the intermediate shaft. - Unscrew the mounting bolts (B) with the right drive shaft (A) removed.

- Remove the intermediate shaft (C) from the transmission.

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32.Place a jack under the front sub frame.

Supporting front sub frame - Place the engine and transmission jack (HJ450) so that the both grooves (A) of the front sub frame are securely supported.

Supporting rear sub frame - Place the engine and transmission jack (HJ450) so that the flat surfaces (B) of the rear sub frame are securely supported.

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33 Unscrew the front left/right mounting bolts (A) for the front sub frame.

34.Unscrew the rear left/right mounting cover bolts (B) for the front sub frame and the mounting bolt.

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35.Support the oil pan assembly bottom with a urethane block (A) to prevent the engine tilting when removing the right engine mounting bracket.

36.Remove the engine mounting brackets from the right and left sides of the engine compartment.

- Unscrew the engine insulator mounting nut (B), engine mounting bracket nut (C) and bolts (D).

- Unscrew the insulator engine mounting (LH) through bolt.

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37.Lower the sub frame jack slowly by being careful not to interfere with other components in the engine compartment.

37

38.Remove the power transfer unit (A).

For further information, refer to the section "AWD" of Chapter "Chassis".

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1. Chain - Bush-UPR 2. Rail assy - Tensioner 3. Rail assy - Clamping 10.Sprocket - Exhaust camshaft 12.Bolt

15.Tensioner assy - Hydraulic 16.Chain - Bush-LWR 17.Bolt 18.Tensioner assy - Mechanical 19.Bolt

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(UPPER CHAIN-BUSH)
- Disconnect the negative battery cable. - Remove the engine acoustic cover and the under cover. 1. Remove the engine and transaxle assembly (sub frame) together.

For further information, refer to the section "Engine and Transaxle Assembly" of Chapter "Engine Assembly".

2. Remove the cylinder head assembly (A).

For further information, refer to the section "Engine overhole" of Chapter "Engine Assembly".

3. Remove the isolation damper (A).

For more information about the crankshaft pulley, refer to the section "Belt System" of Chapter "Engine Assembly".

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4. Remove the oil pan assembly (A).

For more information about the oil pan assembly, refer to the section "Engine Oil Pan" of Chapter "Lubrication System".

5. Remove the timing gear case cover (TGCC). - Unscrew the bolts (A), (B) and (C). Part name A B C Bolt Bolt Bolt Size M6X40 M6X45 M6X50 Tightening torque 10 1.0 Nm 10 1.0 Nm 10 1.0 Nm

Cautions for installation

- Apply sealant to the timing gear case cover. - Sealant P/N: 665 989 50 A0

Height difference specification

0.2 mm or less

- Install the lower front cover and check the height difference with the cylinder block. - Make sure that the engine oil does not leak while the engine oil pan is fitted.

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6. Remove the TGCC carefully by inserting a screwdriver (A) between the TGCC and the cylinder block.

7. Remove the timing chain assembly (A, upper chain-bush).

8. Install in the reverse order of removal.

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Timing mark 1) Isolation damper, Timing gear case cover and Camshaft 1. Align the timing of the crankshaft and the camshaft.

Do not reverse the engine.

TDC mark

- Turn the isolation damper (A) so that the timing mark (B) on the isolation damper and the mark (C) on the timing gear case cover are aligned. Timing case cover mark

Isolation damper mark

The timing mark is located on the position where the no. 1 cylinder piston is rotated further 90 degrees clockwise from the TDC (D) point. - Open the oil filler cap and check the camshaft nose position (A) of the intake camshaft. (If the camshaft nose position is incorrect, then turn the crankshaft 1 revolution and align the camshaft nose to 12 o'clock.)

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2) Install timing chain to exhaust camshaft sprocket 1. Pull up the timing chain provided that the timing chain is not tilted, so that the chain is aligned to the tensioner rail (A) and the clamping rail (B).

2. Install the camshaft sprocket by aligning the exhaust camshaft sprocket mark (C) to the marking link (copper link) (D) of the timing chain.

3. Fit the exhaust camshaft sprocket (C) to the camshaft (E) and tighten the mounting bolts to the specified torque.

Check the alignment of the timing chain and the clamping/tensioner rails again when installing the camshaft.

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3) High pressure pump and Intake camshaft 1. Paint a mark on the point (B, cylinder head) where is parallel to the mark (A) on the high pressure pump drive gear of the cylinder head, after removing the high pressure pump.

4) Crankshaft sprocket and Timing chain

1. Align the copper link (A) of the timing chain to the crankshaft sprocket mark (B) when installing the timing chain.

There are two copper link in the timing chain (upper chain bush). They are symmetrical and have no direction.

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5) Timing marks on intake and exhaust camshafts 1. Align the two timing marks on the intake camshaft gear (A) to the one timing mark on the exhaust camshaft gear (B). Exhaust camshaft: Intake camshaft:

The timing marks are on both sides of the intake and exhaust camshaft gears. 2. Paint marks on the marking point of the high pressure (C) and the adjacent gear (D).

Replace the O-ring with a new one during installation.

3. Align the marks on the cylinder head (B) and the fuel high pressure pump (D) when installing the fuel high pressure pump.

Apply oil around the O-ring when installing the high pressure pump.

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6) Crankshaft gear and Mass balance unit (MBU) 1. Paint a mark on the MBU. - Paint a mark on the MBU (B) while the pin hole (A) of the MBU balance shaft facing downwards.

2. Paint a mark on the point of the crankshaft gear timing (A) .

3. Align the marks on the crankshaft gear and MBU as shown in the figure (A) when installing the MBU. The timing mark (A) on the MBU can be checked under the vehicle (B).

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Chain Drive (D20DTF) 1. Exhaust camshaft sprocket 2. Intake camshaft sprocket 3. Rail assembly-Clamping 4. Tensioner assembly-Mechanical 5. Oil pump sprocket 6. Oil pump chain (Lower chain bush) 7. Crankshaft sprocket 8. Tensioner assembly-Hydraulic 9. Rail assembly-Tensioner 10.Timing chain (Upper chain bush)

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1. Pump assy - Oil pump 6. Ring - Seal 8. Pan assy - Oil 10.Bolt 11.Plug - Drain 21.Bolt 30.Switch assy - Oil level

31.Tube assy - Oil dipstick 32.Gauge assy - Oil dipstick 33.O-ring 34.Bolt 37.O-ring 44.Sealant 45.Cover - Dust

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- Disconnect the negative battery cable. - Remove the engine acoustic cover and the under cover.

1. Unscrew the mounting bolts (A) for the oil dipstick tube.

2. Unscrew the oil drain bolt (A) from the bottom of the vehicle to drain the engine oil.

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3. Unscrew the two lower A/C compressor mounting bolts (A).

4. Remove the oil level sensor (A).

5. Remove the oil pan. - Unscrew the 4 bolts (A) securing the engine and the transmission. - Unscrew the bolts (A), (B), (C), (D), (E) and (F) in the specified sequence in two or more steps.

- Unscrew the 24 bolts (10 mm) and two bolts (12 mm) in the specified sequence in two or more steps. - Tighten the bolts diagonally from the inside to the outside.

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- Be careful not to damage the oil pan. A B C D E F M6X20 18 EA M6X20 18 EA M8X40 2 EA M6X35 2 EA M6X85 2 EA M6X120 2 EA 10 1 Nm 10 1 Nm 25 1 Nm 10 1 Nm 10 1 Nm 10 1 Nm

6. Push the oil dipstick tube to remove the oil pan.

- Apply sealant to the oil pan. Sealant P/N: 665 989 50 A0 - Do not pull out the oil dipstick tube completely from the oil pan. 7. Install in the reverse order of removal. Sealant application location

Make sure that the oil in the oil pan does not leak. When installing: 1. Remove the foreign materials by cleaning the oil pan. 2. Apply the specified sealant on the mounting surface of the oil pan evenly. (DB 2210: 661 989 56 A0) 3. Tighten the oil pan mounting bolts to the specified torque.

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1. Crankshaft 2. Pin - Cylindrical 3. Key - Crankshaft pulley 4. Sprocket - Crankshaft 7. Disc - Crankshaft vibration damper 8. Bolt 12.Damper assy - Isolation 13.Flywheel assy - Dual mass 17.Bolt - Flywheel MTG 18.Plate assy - Drive 19.Plate

23.Bearing set - Crankshaft 24.Bearing set - Thrust 25.Rod assy - Connecting 26.Bushing 27.Bolt 29.Bearing kit - Connecting rod 33.Piston assy 34.Ring set - Piston 35.Ring - Snap 40.Shaft assy - Mass balance 41.Bolt - Balance shaft MTG

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- Disconnect the negative battery cable. - Remove the engine acoustic cover and the under cover. - Remove the oil pan assembly. 1. Remove the oil pan assembly.

For more information about the oil pan assembly, refer to the section "Oil Pan Assembly" of Chapter "Engine Assembly".

2. Remove the MBU (A). - Unscrew the MBU bolts (B).

3. Install in the reverse order of removal.

Unscrew the MBU mounting bolts in the specified sequence in two or more steps as shown in the figure.

Tighten the bolts in the reverse order of removal in 2 or 3 steps with the specified torque.

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Cautions for installation

Paint timing marks on the crank gear and MBU to easily identify.

1. Paint a mark on the MBU. - Paint a mark on the MBU (B) while the pin hole (A) of the MBU balance shaft facing downwards.

2. Paint a mark on the point of the crankshaft gear timing (A) .

3. Align the marks on the crankshaft gear and MBU as shown in the figure (A) when installing the MBU. The timing mark (A) on the MBU can be checked under the vehicle (B).

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- Disconnect the negative battery cable. - Remove the engine acoustic cover and the under cover. 1. Remove the engine and transaxle assembly (sub frame) together.

For further information, refer to the section "Engine and Transaxle Assembly" of Chapter "Engine Assembly".

2. Remove the 6M/T assembly and then clutch disc and cover.

Remove the 6M/T assembly and then clutch disc and cover.

3. Fit the DMF assembly (A) using a special tool (T99110010A).

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4. Unscrew the DMF. - Unscrew the 8 bolts.

5. Install in the reverse order of removal. Dual mass flywheel (DMF) assembly

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Preceding work 1. Remove the sub frame assembly. - Remove the engine and transaxle module. - Make sure that it does not interfere with the surrounding parts in the engine compartment.

2. Remove the power transfer unit (PTU).

For further information, refer to the section "AWD" of Chapter "Chassis".

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3. Unscrew the transmission mounting bolts on the front sub frame, and remove the engine assembly from the front sub frame assembly.

a. Remove the front side transmission mounting (A). - Unscrew the through bolt (B). - Unscrew the mounting bolts (C).

b. Remove the rear side transmission mounting (D). - Unscrew the through bolt (E). - Unscrew the mounting bolts (F).

1. When removing the sub frame and engine & transaxle as a unit, check that it is fitted to the engine and transmission jack securely, for safety reason. 2. If the safety is secured, install the chain to the engine with a engine crane to remove the sub frame.

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4. After removing the engine assembly from the sub frame and remove the surrounding components of engine to install the engine to the engine stand.

Throttle body assembly

Starter assembly

CDPF assembly and bracket

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5. Remove the automatic transmission assembly with the engine crane and transmission jack firmly fitted.

For further information, refer to the section "Transmission" of Chapter "Chassis".

6. Install the engine bracket to the engine assembly and mount the engine assembly to the engine hanger using a jack for engine. Engine bracket on the left

Engine bracket on the right

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2) Disassembling and Assembling


with EPS Idler pulley No. 3

Vacuum pump

Fuel filter

Idler pulley No. 2

Power steering pump

Water pump pulley

Auto tensioner

Alternator

Idler pulley No. 1

Crankshaft pulley A/C compressor

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Remove the engine mounting, alternator connector and air compressor connector. 1. Remove the fan belt. Turn the tension release bolt (B) of the pivot damped tensioner (auto tensioner) clockwise (C) with a tension release tool (A) to release the tension before removing the fan belt.

2. Unscrew the mounting A (17 mm) and B (14 mm) to remove the pivot damped tensioner.

Auto tensioner assembly 1 2 3 4 Belt tensioner Tensioner housing Belt tensioner pulley Belt tensioner pulley cover

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3. Remove the fan belt idle bearing 1 (A) and 2 (B). - Remove the fan belt idler pulley 1 (A) and 2 (B) caps.

For the vehicle with electric power steering (EPS), the idler bearing no. 3 is mounted to the power steering pump position. - Remove the idler pulley no. 1 (A) bolt (T50).

- Remove the idler pulley no. 2 (B) bolt (T50).

Idler pulley assembly No. 2

Idler pulley assembly No. 1

1 2 3 4 5 6

Idler pulley cover No. 1 Idler pulley No. 1 Idler pulley No. 1 mounting bolt Idler pulley cover No. 2 Idler pulley No. 2 Idler pulley No. 2 mounting bolt

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4. Unscrew the 4 mounting bolts (13 mm) for A/C compressor to remove the compressor.

5. Unscrew the mounting bolt A (17 mm) and B (15 mm) to remove the alternator.

Push the bracket bushing in the arrow direction (A) when removing the alternator assembly.

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6. Remove the power steering pump. - Remove the bolt (13 mm) and nut (13 mm).

Confirm that no power steering oil is leaking.

For the vehicle with ESP, idler pulley no. 3 is mounted instead of power steering pump. - Unscrew the two lower mounting bolts (12 mm).

- Remove the power steering pump assembly using a flat-bladed screw driver.

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7. Remove the turbocharger oil pipe.

a. Remove the oil supply pipe. - Disconnect the oil supply pipe screw fitting (A, 17 mm) on the cylinder block. - Unscrew the hollow bolt (B, 14 mm) securing the oil supply pipe.

Replace the copper washer and gasket with new ones when installing. b. Remove the oil return pipe. - Unscrew the two return pipe hexagon bolts (C, 5 mm) on the turbocharger. - Unscrew the two return pipe hexagon bolts (D, 5 mm) on the cylinder block.

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8. Remove the turbocharger support bar. Unscrew the bolt (A, 12 mm) and nut (3 mm). Unscrew the bolt (B, 13 mm).

9. Remove the turbocharger. Unscrew the turbocharger bolt (A, 13 mm). Unscrew the two nuts (B, 13 mm).

Replace the 3-hole exhaust gasket with a new one when installing.

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10.Unscrew the two bolts (14 mm) and remove the engine hanger bracket (A).

11.Remove the 3 hexagon bolts (14 mm) and remove the exhaust protect cover (B).

12.Unscrew the 10 bolts (14 mm) to remove the exhaust manifold.

Replace the exhaust gasket with a new one when installing. Part number: 6711420380

Unscrew the nuts slowly in two or more stages to prevent distortion of the exhaust manifold and cylinder head.

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Unscrew the nuts in accordance with the sequence shown below in several steps. - Unscrew the nuts in accordance with the sequence shown below in several steps.

When installing the exhaust manifold, tighten the nuts in the reverse order of removal.

13.Remove the high pressure pipe. - From high pressure pump to fuel rail assembly high pressure pump - From fuel rail assembly to injector high pressure pump

Seal the openings of the injector nozzle and the common rail with a plastic bag or tape after disconnecting the fuel supply pipe.

Replace the pipe with a new one.

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Cam position sensor

Fuel temperature sensor

IMV valve

Coolant temperature sensor

Fuel rail pressure sensor

Variable swirl valve

E-VGT Actuator T-MAP sensor

EGR valve

Knock sensor No. 1

EGR bypass

Knock sensor No. 2

Crank position sensor

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14.Remove the main wiring. - Unscrew the 4 main wiring harness mounting bolts (10 mm).

- Remove the main wiring.

Be careful not to damage the cable and connector.

15.Unscrew the bolt (10 mm) to remove the oil dipstick tube.

16.Unscrew the two intake duct side bolts (A, 10 mm) and two E-EGR cooler side bolts (B, 13 mm) to remove the EGR cooler pipe.

Replace the gasket with a new one.

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17.Remove the intake duct. - Unscrew the 3 bolts (A, 13 mm) to remove the intake duct bracket.

- Unscrew the 3 bolts (B, 13 mm) to remove the intake duct.

18.Remove the E-EGR bypass solenoid valve and vacuum hose.

Disconnect the vacuum hose.

19.Remove the E-EGR cooler. - Disengage the clamp (A) and disconnect the E-EGR cooler outlet hose. - Unscrew the mounting bolts (B) of the EGR. - Unscrew the E-EGR cooler bolts (C).

Make sure that the coolant in the oil cooler does not leak.

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22.Remove the E-EGR valve. - Disconnect the E-EGR valve cooler hose (A).

- Unscrew the bolt (B).

- Unscrew the nut (C) with a spanner.

Make sure that the coolant in the E-EGR valve does not leak.

E-EGR body

E-EGR connector

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21.Unscrew the 8 bolts (13 mm) to remove the intake manifold.

Replace the gasket with a new one.

Unscrew the bolts slowly in two or more stages to prevent distortion of the intake manifold and cylinder head. Unscrew the nuts in accordance with the sequence shown below in several steps.

When installing, tighten in the reverse order of removal in 2 or 3 steps with the specified torque.

When installing, tighten in the reverse order of removal.

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22.Remove the oil cooler assembly. - Disengage the clamp and disconnect the oil cooler inlet hose.

- Unscrew the 7 bolts (13 mm) to remove the oil filter assembly. No. A B C Size M8X40 M8X120 M8X140 Specified torque 25 2.5 Nm 25 2.5 Nm 25 2.5 Nm

NO. 1

NO. 2

23 Remove the knock sensor No. 1 and No. 2. - Unscrew the bolts (A).

When installing the knock sensor, the No. 1 and No. 2 cylinder wirings should face 3 o'clock, and No.3 and No.4 cylinder wirings should face 9 o'clock. NO. 1 NO. 2

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24.Unscrew the 3 hexagon bolts (6 mm) to remove the fuel high pressure pump.

Check the belt timing marks before removing the fuel high pressure pump.

25.Unscrew the two hexagon bolts (6 mm) to remove the common rail.

26.Remove the injector. a. Unscrew the two Torx socket bolts (6 mm) to remove the injector clamp.

b. Remove the injector using a special tool. Special tool: 000 000 00 00

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Engine serial number and C3I code for injector are printed on labels on cylinder head cover Check the C3I code when replacing injectors.

Always check the C3I code for each cylinder with the SIW diagnostic device.

C3I [Improved Individual Injector Calibration] C3I code MDP learning Injection nozzle Consists of 20 digits (Numbers (1 to 9) and alphabetical characters except I, O, Q, V) During driving and idling 8 EA

a. C3I code for injector


(A) Injector mark (B) Cylinder head cover mark
ENG NO: 00000000000000 1. 12345678901234567890 2. 12345678901234567890 3. 12345678901234567890 ENG NO: 00000000000000 4. 12345678901234567890

C3I code marked on the upper side of injector

Engine serial number and C3I code for injector are printed on 2 labels

The C3I code is marked on the sides of the injector and the cylinder head, and consists of 20 digits. The C3I code is listed as 20 digits consist of numbers (1 to 9) and alphabetical characters except I, O, Q, V.

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27.Unscrew the 3 bolts (10 mm) to remove the coolant outlet pipe.

- Unscrew the two bolts (10 mm) to remove the coolant inlet pipe.

28.Remove the glow plugs.

29.Remove the cylinder head cover (A). - Unscrew the 17 bolts (10 mm). - Unscrew the bolts for the cylinder head cover slowly in two or more stages to prevent any damage to the cylinder head. - Removal: from the outside to the inside, diagonally - Installation: From the center to the outside, diagonally

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30.Remove the vacuum pump (A). - Unscrew the 13 bolts (B, 10 mm).

Setting the correct timing (A) of the crankshaft and camshaft makes the slot of the vacuum pump parallel to B-B'. Make sure that it is lined up as shown in the figure (B-B').

B B

Crankshaft timing

Camshaft timing

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31.Remove the front cover (A). - Unscrew the 5 bolts (B, 10 mm).

Position to pry out front cover

Do not apply excessive force when prying out the front cover, as it can cause entry of foreign material and engine body damage. 32.Remove the engine mounting lower bracket (A). - Unscrew the 3 bolts (B, 17 mm).

33.Fit the chain tensioner. - Remove the chain tensioner plug cap (A).

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- Compress the hydraulic chain tensioner by pushing a flat-bladed screwdriver (B) in the direction (C).

Use a piece of cloth not to damage the plug threads.

- Fit and secure the mounting pin (D) by inserting it to the hydraulic chain tensioner compressed by the flat-bladed screwdriver.

34.Secure the octagon spanner seat (A) of the intake camshaft with a 30 mm spanner, and unscrew the exhaust camshaft sprocket bolts (B) to remove the sprocket.

Exhaust camshaft sprocket

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35.Secure the timing chain as shown in the figure (A) to prevent the chain from falling into the cylinder block.

36.Unscrew the hexagon bolt (T50) to remove the clamping rail on the tensioner side.

When removing the clamping rail, put aside the chain so as not to interfere with it as shown in the figure.

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37.Remove the camshaft bearing cap (A). - Unscrew the camshaft mounting bolts slowly in two or more stages according to the specific sequence stated below. (1) Intake camshaft: IN, 6, 8 (2) Exhaust camshaft: EX, 2, 4 (3) Intake camshaft: 5, 7, 9 (4) Exhaust camshaft: 1, 3 Tightening torque EX, IN bearing cap Always tighten to the specified torque so as not to damage the camshaft. No. 1 to 9 bearing caps 25 2.5 Nm 10 1.0 Nm

38.Remove the intake/exhaust camshafts.

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Timing marks on intake and exhaust camshafts

Exhaust camshaft:

Intake camshaft:

Align the two timing marks on the intake camshaft gear (A) to the one timing mark on the exhaust camshaft gear (B).

The timing marks are on both sides of the intake and exhaust camshaft gears.

Align the timing marks on the intake/exhaust camshaft sprockets.

39.Remove the camshaft and no. 1 lower cap (A).

40.Remove the finger follower and HLA device (A). - Take extreme care because the HLA device is very hot right after the engine is turned off. - If the removed finger follower and HLA device is easily pressed, it means that the oil has been drained. In this case, replace it with a new one.

Apply engine oil before installing.

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41.Unscrew the cylinder head shoulder bolts (A, T6 mm).

42.Remove the cylinder head bolts (A). - Unscrew the cylinder head bolts in two or more stages according to the specific sequence. Cylinder head bolt wrench

Unscrew the mounting bolts for the cylinder head in the sequence shown in the figure below.

- Unscrew the bolts in 2 or more steps. - Apply oil to the head bolt thread.

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Tightening process for cylinder head bolts Torque wrench 45 5 Nm Put matchmark (Cylinder head/ head bolt) Tighten - 1st 9010 Tighten - 2nd 9010 Tighten - 3rd 9010

43.Remove the cylinder head gasket (A).

Cylinder head Gasket thickness mark

Protrusion amount of piston 0.475 to 0.540 mm 0.541 to 0.649 mm Gasket thickness 1.3t 0.650 to 0.745 mm

Gasket thickness 1.2t 1.3t 1.4t

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44.Remove the crankshaft pulley. a. Lock the flywheel and tighten the crankshaft pulley mounting center bolt (27 mm) with a special tool.

45.Remove the bracket for A/C compressor.

46.Run the engine and remove the oil level switch (29 mm). Tool: Long socket 29 mm

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47.Remove the engine oil pan. a. Unscrew the oil pan mounting bolt by checking the specifications of the bolt. b. Carefully remove the oil pan. Tightening torque M6x20 18 EA M8x40 2 EA M6x35 2 EA M6x85 2 EA M6x120 2 EA Nm 101 251 101 101 101

Sealant application location

Make sure that the oil in the oil pan does not leak. When installing: 1. Remove the foreign materials by cleaning the oil pan. 2. Apply the specified sealant on the mounting surface of the oil pan evenly. (DB 2210: 661 989 56 A0) 3. Tighten the oil pan mounting bolts to the specified torque.

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48.Remove the drive plate. a. Fit the drive plate with a special tool and unscrew the bolts.

b. Remove the Drive plate A and B.

49.Remove the crankshaft position sensor. a. Remove the dust cover (A) and crank angle sensor wiring.

b. Unscrew the mounting bolts and remove the position sensor (A) and trigger ring (B). Tool: Hexagon L wrench, 5 mm

Do NOT keep the trigger ring near the magnetic attach driver and any magnet.

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50.Remove the mass balance unit. a. Remove the (A).

Unscrew the MBU mounting bolts in the specified sequence in two or more steps as shown in the figure.

Tighten the bolts in the reverse order of removal in 2 or 3 steps with the specified torque.

Check the timing marks on the crankshaft and MBU.

51.Remove the crankshaft rear seal cover - Unscrew the 5 bolts (10 mm).

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52.Remove the timing gear case cover (TGCC). - Unscrew the bolts (A), (B) and (C). Part name A B C Bolt Bolt Bolt Size M6X40 M6X45 M6X50 Tightening torque 10 1.0 Nm 10 1.0 Nm 10 1.0 Nm

- Remove the timing gear case cover (TGCC).

Cautions for installation

- Apply sealant to the timing gear case cover. - Sealant P/N: 665 989 50 A0

Height difference specification

0.2 mm or less

- Install the lower front cover and check the height difference with the cylinder block. - Make sure that the engine oil does not leak while the engine oil pan is fitted.

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53.Remove the timing chain.

Check the timing marks on the timing chain and the crankshaft before removing.

54.Remove the clamping rail assembly. Tool: T45

55.Remove the hydraulic chain tensioner (A). - Unscrew the bolt (B).

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56.Remove the mechanical tensioner assembly. - Pull the tensioner to (A) position and insert the fixing pin (B) to secure it.

- Unscrew the bolt (T35) to remove the chain tensioner.

57.Remove the oil pump assembly (A) and lower chain bush (B). - Unscrew the 3 oil pump mounting bolts. Tool: Hexagon bit socket, 6 mm

- Tilt the oil pump in the direction (A) and remove the oil pump assembly and lower chain bush together.

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58

58.Remove the piston assembly. a. Put marks on the piston rod cap and connecting rod cap so as not to mix up. Use the cylinder #1 as a reference.

b. Remove the carbon on the cylinder block.

If an excessive force is applied to remove the piston assembly without removing the carbon on the cylinder block, the inside surface of the cylinder and piston assembly can be scratched to the piston ring can be damaged. c. Unscrew the No. 1 and No. 4 bearing cap bolts and remove the piston assembly.

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d. Turn the crankshaft 180 and remove the No. 2 and No. 3 piston assembly as described in c and d.

Piston assembly - Remove the snap ring from the piston and remove the piston pin. - Remove the piston and connecting rod. - Remove the piston ring from the piston and put it together.

Replace the piston, bearing and snap ring with new ones. Part name 1 2 3 4 5 6 7 8 9 10 Piston Connecting rod Connecting rod cap Connecting rod upper bearing Connecting rod lower bearing Piston pin Snap ring Top ring Second ring Oil ring

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59.Remove the crankshaft. - Remove the bolts slowly in 2 or more steps in the same sequence as removing the crankshaft main bearing caps to remove the main journal bearing caps.

Put marks on the crankshaft main journal bearing caps before removing it.

Remove the crankshaft main journal caps in the specified sequence.

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60.The No. 3 main journal bearing cap is equipped with the thrust bearing. Install it with the oil hole facing outwards.

61.Remove the crankshaft.

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3) Carried out checks


(1) V-Belt
Put a chalk mark on the belt. Check the belt for any damage by rotating the engine.

Replace the belt if any damage is found as described below:

1. Rubber piece in the belt rib base 2. Dust or sand

3. Rib shaped in wedge 4. Exposed belt cord on the rib base

5. Torn tension cord 6. Worn outer tension cord

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7. Stripped rib on belt base

8. Cracked rib in lateral direction 9. Torn rib

10.Cracked rib in several lateral directions

11.Crack on back side of belt in lateral direction

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(2) Cylinder Block

Measuring cylinder block bore 1. Wipe out the cylinder bore. 2. Measure the bore size in axial direction and vertical direction on 3 points (1, 2, 3) with a bore gauge.

Measuring points 1, 2, 3 A. Axial direction B. Vertical direction a. Piston position at TDC b. Piston position at BTDC c. Oil ring position between TDC and BTDC

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Measuring crankshaft bearing bore Measure the bore of the crankshaft bearing with a bore gauge.

- Measure the values at 2 points (1, 2). Measure the values at the A, B and C as shown in the figure. - If the average value of B and C is less than the value of A, then it can be used as actual average value. If the average value of B and C is greater than the value of A, then the value of A can be used as actual average value.

Crankshaft Journal Measure the bore of the crankshaft bearing journal with a micro meter.

- Measure the values at 3 points (A, B, C) and calculate the average value. - If the average values of the bearing bore and journal diameter are not within the specified range, replace the bearing shell.

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(4) Piston and Connecting Rod


Install the compression ring and oil ring to the piston using a special tool.

The opening section of the piston oil ring should be positioned at an interval of 120.

- Install the no.1 and no. 2 compression rings with the marks facing upwards. - Thickness of no. 1 piston ring > Thickness of no. 2 piston ring - Put the oil ring with the opening section positioned on the other side of the base opening. - The oil ring has no direction. - Make sure that the openings of the piston are not overlapped.

Measuring oil ring and compression ring clearances Piston ring 1. Check the piston ring for damage, wear and crack. Replace a damaged ring with a new one. 2. When removing the piston, the piston ring should be replaced together. 3. Measure the clearance between the piston ring and ring groove. No. 1 compression ring No. 2 compression ring No. 3 oil ring 0.20 to 0.35 mm 0.35 to 0.50 mm 0.20 to 0.40 mm

* Piston ring free gap No. 1 compression ring: 11.0 mm No. 2 compression ring: 10.5 mm No. 3 compression ring: 7.0 mm

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4) Engine Overhole
1. Clean the cylinder bore, connecting rod, connecting rod bearing shell and piston thoroughly with compressed air.
Top of cylinder block Bottom of cylinder block

1. Head bolt seat 2. Oil return groove 3. Coolant passage groove

4. Oil jack 5. Crankshaft main bearing No. 6. Oil return groove

The oil spray nozzle injects the oil to the inside of the piston. Make sure that the oil spray nozzle pipe does not contact the connecting rod.

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2. Select the crankshaft main bearing. a. There are five punch marks on the bottom of the cylinder block (oil pan contact surface). These punch marks match to the mounting locations of each main bearing. Therefore, select the crankshaft upper main bearing according to these punch marks. b. Select the lower main bearing that is engaged to the crankshaft bearing cap by the mark on the crankshaft sprocket mounting surface.

Bottom of cylinder block

Mounting surface of crankshaft sprocket

Selecting crankshaft upper bearing Bearings selection according to pin punch mark Item * ** *** Color Blue Yellow Red Main bearing diameter (mm) 68.500~68.506 68.506~68.513 68.513~68.519 Item V W R G B

Selecting crankshaft lower bearing

Color Purple White Red Yellow Blue

Main bearing diameter (mm) 63.9400~63.945 63.945~63.950 63.950~63.955 63.955~63.960 63.960~63.965

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3. Install the main bearing to the crankshaft upper side. - Check the color of new main bearing and match it to the key groove (A) of the cylinder block. Install the bearing with the oil groove (B) aligned.

- Apply the engine oil to the upper bearing shell.

Make sure the oil holes of the cylinder block body are aligned with the oil holes of the bearing.

4. Fit the crankshaft to the cylinder block.

5. Install the upper thrust bearing to the No. 3 main journal.

- Install the thrust bearing so that its oil groove (A) faces outward. - Remove the foreign materials on the thrust bearing. - Insert the bearing after applying the engine oil.

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6. Remove the main journal bearing caps.

- Install the No. 3 main journal bearing cap and thrust bearing (A).

- The No. 3 main journal bearing cap is equipped with the thrust bearing. Therefore make sure that the oil groove (B) faces outwards when installing.

Install it so that the part (A) of the main journal bearing cap faces the intake manifold.

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- Tighten the main journal bearing cap mounting bolt to the specified torque.

The appearance of the No. 2 and No. 5 main bearing cap bolts are different from each other. - Paint marks on the cap bolts after 1st tightening.

295 - Angle-tighten the bolts to 130 10 further in order at 2nd tightening.

Check the status and angle of the tightened bolt after 2nd tightening.

- Measure the end play of the crankshaft and adjust the thrust bearing so that the end play is within the specification.

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Selecting piston oversize Top of piston Top of cylinder block

Engine

Piston Part No. 671 030 06 17 671 037 07 01 Marking No. A X B +5 +10

Cylinder bore A X B -

D20DTF

671 037 08 01 671 037 09 01 671 037 10 01 671 037 11 01

7. Install the piston assembly.

Replace the piston, bearing and snap ring with new ones.

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a. Apply engine oil to the piston surface and piston ring before installing.

- Stagger the piston rings so that the ring end gaps are approx. 120 deg apart. - Make sure to install the piston and shell at the correct locations.

b. Insert the piston assembly No. 1 and No. 4 to the cylinder using a tool.

Check the () mark on top of the piston and make sure that this arrow faces the no. 1 cylinder while it is parallel to the crankshaft. Pay attention to the piston direction.

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If the piston reaches to BTDC with installed in the opposite direction, the oil jet can be damaged.

Oil jet groove

8. Install the no. 1 and no. 4 caps while paying attention to the direction.

Make sure that the correct bearing cap and shell are mounted. a. Turn the crankshaft 180 and install the No. 2 and No. 3 pistons in the same way as the no. 1 and no. 4 pistons. b. Tighten the connecting rod cap bolts to the specified torque for the 1st tightening and put matchmarks on each connecting rod cap in the same way as before.

c. Angle-tighten them to 90 10 further and check the tightened status.

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9. Fit the crankshaft sprocket into the key groove.

10.Install the engine oil pump assembly and lower chain bushing. a. Tilt the oil pump assembly in the direction (A) and remove the oil pump assembly.

b. Tighten the 3 wrench bolts (5 mm) to the specified torque.

11.Install the mechanical tensioner assembly (A). - Tighten the bolt (T45) to the specified torque.

- Mount the chain clamping rail (B) and tighten the two mounting bolts (T45) to the specified torque.

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12.Install the hydraulic tensioner assembly (A). - Tighten the 2 wrench bolts (5 mm) to the specified torque.

13.Align the timing marks (copper mark) on the timing chain and crankshaft sprocket to install.

Align the copper links of the timing chain.

Timing of camshaft sprocket and crankshaft sprocket

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14.Mount the timing chain gear case cover (TGCC) and tighten the 10 mounting bolts (10 mm) to the specified torque. - Unscrew the bolts (A), (B) and (C). Part name A B C Bolt Bolt Bolt Size M6X40 M6X45 M6X50 Tightening torque 10 1.0 Nm 10 1.0 Nm 10 1.0 Nm

Apply sealant to the timing case cover. Sealant part No.:

Height difference specification

0.2 mm or less

- Install the lower front cover and check the height difference with the cylinder block. - Make sure that the oil in the oil pan does not leak.

Tie the chain to the chain guide hole so that the chain is not displaced from the crankshaft sprocket.

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15.Install the mass balance unit. a. Tighten the 6 mounting bolts in the specified sequence in two or more steps.

Unscrew the MBU mounting bolts in the specified sequence in two or more steps as shown in the figure.

Tighten the bolts in the reverse order of removal in 2 or 3 steps with the specified torque.

Checking MBU timing mark

Align the marks on the crankshaft gear and MBU as shown in the figure (A) when installing the MBU.

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16.Install the crank position sensor assembly.

Do NOT keep the trigger ring near the magnetic attach driver and any magnet.

a. Install the crankshaft with a tool.

b. Install the crank position sensor assembly carefully, so that the inner oil seal is not damaged, and tighten the 6 mounting bolts (10 mm) to the specified torque.

c. Install the crank position sensor.

Check the height difference.

Height difference specification

0.2 mm or less

d. Measure the crank position sensor air gap with a thickness gauge. Air gap specification 0 mm or less

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17.Install the drive plate A and B.

a. Fit the crankshaft with a special tool (T9911 0010A).

Special tool: T9911 0010A

b. Screw the mounting bolts in two or more stages according to the specific sequence diagonally.

c. Put matchmarks after 1st tightening.

d. Check the status and angle of the tightened bolt after 2nd tightening.

Check the mating surface of the ring gear where the pinion gear contacts for wear.

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18.Install the oil pan. Nm M6x20 18 EA M8x40 2 EA M6x35 2 EA M6x85 2 EA M6x120 2 EA 101 251 101 101 101

a. Tighten the 24 bolts (10 mm) and two bolt (12 mm) in the specified sequence in two or more steps. b. Tighten the bolts diagonally from the inside to the outside.

Sealant application location

Make sure that the oil in the oil pan does not leak. When installing: 1. Remove the foreign materials by cleaning the oil pan. 2. Apply the specified sealant on the mounting surface of the oil pan evenly. (DB 2210: 661 989 56 A0) 3. Tighten the oil pan mounting bolts to the specified torque.

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c. Check the height difference of the engine oil pan and tighten the bolts to the specified torque. Height difference specification 0.2 mm or less

19.Install the front oil seal (A) for the timing gear case cover (TGCC).

- Mount the crankshaft front seal-ring (A) to the TGCC and install it with a special tool (B).

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20.Install the crankshaft pulley.

a. Fit the flywheel using a special tool (T9911 0010A).

Special tool: T9911 0010A

b. Tighten the crankshaft pulley center bolt (27 mm) to the specified torque with a special tool.

c. Put matchmarks after 1st tightening. d. Check the status and angle of the tightened bolt after 2nd tightening.

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21.Install the cylinder head gasket after measuring the thickness of the protruded piston with a special tool.

a. Fit a tool.

b. Fit a dial gauge to the top of the cylinder block and adjust the zero point.

Remove the foreign materials and the gasket residual on the surface of the cylinder block before measuring. c. Measure the piston protrusion values in the axial direction of the crankshaft and calculate the average value.

Measure each point 3 or more times and calculate the average value (total 8 measurement points). d. Measuring points (8 points)

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e. Install the cylinder head gasket with a corresponding thickness of the protruded piston. Protrusion amount Gasket Grade of piston 0.475 to 0.540 mm 0.550 to 0.640 mm 0.650 to 0.745 mm 1.2t 1.3t 1.4t

Replace the gasket with a new one and make sure that the surface of the steel gasket with marks face upwards.

Cylinder head Gasket thickness mark

Gasket thickness 1.3t

22.Install the cylinder head. - Tighten the cylinder head bolts to the specified torque in the specified sequence.

Tightening process for cylinder head bolts Torque wrench 45 5 Nm Put matchmark (Cylinder head/ head bolt) Tighten - 1st 9010 Tighten - 2nd 9010 Tighten - 3rd 9010

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Tightening sequence

- Screw the cylinder head bolts in two or more stages according to the specific sequence. - Apply oil on the threads of the cylinder head bolt before installing. - Make sure to insert the new washer first.

- Tighten the 3 wrench bolts (6 mm) for the cylinder head to the specified torque.

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23.Install the HLA device and finger follower after applying engine oil.

- Bleed the system if the vehicle remains stopped for a long time. - Fit over the locating pin.

24.Fit the no. 1 lower cap in the correct direction.

Pay attention to the installation direction.

25.Install the intake and exhaust camshafts.

Align the timing marks on the intake and exhaust camshaft sprockets.

When installing: 1. Align the timing marks on the intake and exhaust camshaft gears. 2. Position the No.1 intake camshaft with its nose at 12 o'clock.

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26.Install the camshaft bearing cap. - Tighten the bearing cap mounting bolts slowly in two or more stages from the inside to the outside. Tightening torque EX, IN bearing cap No. 1 to 9 bearing caps 25 2.5 Nm 10 1.0 Nm

Always tighten to the specified torque so as not to damage the camshaft.

27.Insert the tensioner clamping rail (A).

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28.Install the timing chain.

Cautions for installation a. Pull up the timing chain provided that the timing chain is not tilted, so that the chain is aligned to the tensioner rail (A) and the clamping rail (B).

b. Install the camshaft sprocket by aligning the exhaust camshaft sprocket mark (C) to the marking link (copper link) (D) of the timing chain.

c. Fit the exhaust camshaft sprocket (C) to the camshaft (E) and tighten the mounting bolts to the specified torque.

Check the alignment of the timing chain and the clamping/tensioner rails again when installing the camshaft.

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29.Secure the octagon spanner seat (A) of the intake camshaft with a 30 mm spanner, and tighten the exhaust camshaft sprocket bolts (B) to the specified torque.

Exhaust camshaft: Sprocket 30.Tighten the bolts (T45) for the tensioner clamping rail to the specified torque.

Timing mark points - Turn the crankshaft clockwise 2 or 3 rotations after installing the exhaust camshaft sprocket and check the timing marks are aligned. Crankshaft pulley In the correct timing position for the crankshaft pulley, the timing marks of the intake/exhaust sprockets and the intake no. 1 camshaft nose should face 12 o'clock, with the piston of the no. 1 cylinder turned 90 degrees clockwise from the TDC mark.

Intake/Exhaust sprockets

Intake no. 1 camshaft nose

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31.Install the high pressure pump.

Apply sealant around the O-ring when installing the high pressure pump. Sealant part No.: O-ring Replace the O-ring with a new one during installation. a. Tighten the 3 hexagon wrench bolts (5 mm) to the specified torque.

Align the timing mark on the high pressure pump gear with the one on the intake camshaft gear.

- The timing mark on the high pressure pump should be turned clockwise 2.5 pitches. - Check the timing marks when installing.

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32.Remove the tensioner fixing pin to apply tension to the timing chain.

- Tighten the tensioner screw cap to the specified torque.

33.Install the engine mounting lower bracket (A). - Tighten the 3 bolts (B, 17 mm) to the specified torque.

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34.Install the front cover (A). - Apply sealant and tighten the 5 front cover bolts (10 mm) to the specified torque. - Install the crank position sensor (B).

35.Install the vacuum pump. Tighten the 3 vacuum pump mounting bolts (10 mm) to the specified torque.

The O-ring for the vacuum pump should be replaced with a new one.

B B

Setting the correct timing (A) of the crankshaft and camshaft makes the slot of the vacuum pump parallel to B-B'. - When installing the vacuum pump, make sure that it is lined up as shown in the figure (B-B').

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36.Fit the cylinder head cover to the cylinder head and tighten the 17 cylinder head cover bolts (10 mm) in two or more steps to the specified torque.

Unscrew the bolts for the cylinder head cover slowly in two or more stages to prevent any damage to the cylinder head cover. 37.Install the injector. Tighten the two injector clamp mounting bolts (6 mm) to the specified torque while securing two injectors with one mounting clamp.

Always check the C3I code for each cylinder with the SIW diagnostic device. C3I [Improved Individual Injector Calibration] C3I code MDP learning Injection nozzle Consists of 20 digits (Numbers (1 to 9) and alphabetical characters except I, O, Q, V) During driving and idling 8 EA

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a. C3I code for injector


(A) Injector mark (B) Cylinder head cover mark
ENG NO: 00000000000000 1. 12345678901234567890 2. 12345678901234567890 3. 12345678901234567890 ENG NO: 00000000000000 4. 12345678901234567890

C3I code marked on the upper side of injector

Engine serial number and C3I code for injector are printed on 2 labels

The C3I code is marked on the sides of the injector and the cylinder head, and consists of 20 digits. The C3I code is listed as 20 digits consist of numbers (1 to 9) and alphabetical characters except I, O, Q, V.

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38.Install the 4 glow plugs. Tool: Long socket 10 mm

39.Install the fuel rail assembly (A). Tighten the two bolts (12 mm) to the specified torque.

40.Install the coolant pipe. Tighten the 4 bolts (10 mm) to the specified torque.

NO. 1

NO. 2

41.Install the knock sensor No. 1 and No. 2. Tighten the two bolts to the specified torque.

When installing the knock sensor, the No. 1 and No. 2 cylinder wirings should face 3 o'clock, and No.3 and No.4 cylinder wirings should face 9 o'clock.

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42.Install the oil filter assembly. Tighten the 8 bolts (13 mm) to the specified torque. No. A B C Size M8X40 M8X120 M8X140 Specified torque 25 2.5 Nm 25 2.5 Nm 25 2.5 Nm

43.Secure the oil cooler inlet and outlet hoses with clamps.

Make sure that the clamp is positioned at A when connecting the outlet hose.

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44.Install the intake manifold. Tighten the 8 bolts (13 mm) to the specified torque.

- Replace the gasket with a new one. Part number: 6711410580 - Unscrew the bolts slowly in two or more stages to prevent distortion of the intake manifold and cylinder head.

Tighten the intake manifold bolts to the specified torque.

Assemble in the reverse order of disassembly.

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45.Install the EGR valve assembly. Tighten the 3 bolts (13 mm) to the specified torque.

a. Tighten the upper bolts (13 mm) with a spanner.

46.Connect the E-EGR assembly cooler hose.

47.Install the E-EGR cooler assembly. - Tighten the two bolts (A, 13 mm). - Tighten the two bolts (B, 13 mm). - Engage the mounting clamps (C).

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48.Install the intake duct. - Tighten the 3 bolts (A, 13 mm) to the specified torque.

49.Install the intake duct bracket. - Tighten the 3 bolts (B, 13 mm) to the specified torque.

50.Install the EGR pipe. - Tighten the two bolts (A, 10 mm) on the intake duct and two bolts (B, 13 mm) on the E-EGR cooler to the specified torque.

51.Install the oil dipstick gauge (A).

Fit the new O-ring to the dipstick gauge before installing.

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52.Connect the main engine wiring. Tighten the 4 bolts (10 mm) to the specified torque and connect the sensor connectors.

53.Install the fuel pipe. Fit and torque tighten the 8 nuts (17 mm) on the fuel supply pipe between the cylinder and common rail, and two nuts (17 mm) on the fuel supply pipe between the common rail and HP pump.

- Replace the fuel supply pipe with a new one. - The openings of the fuel rail assembly should be sealed with the sealing caps. Identifying fuel pipe From Common rail to Injector From HP fuel pump to common rail

The appearance of the no. 1 and no. 3 cylinder fuel pipes are the same with the no. 2 and no. 4 cylinder fuel pipe.

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54.Install the exhaust manifold. Tighten the 10 mounting nuts (14 mm) in the specified sequence in two or more steps.

- Replace the exhaust gasket with a new one when installing. - Unscrew the nuts slowly in two or more stages to prevent distortion of the exhaust manifold and cylinder head.

Unscrew the nuts on the exhaust manifold in accordance with the sequence shown below in several steps.

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55.Install the exhaust protector cover. Tighten the 3 hexagon bolts (14 mm) to the specified torque.

56.Install the engine hanger bracket. Tighten the two bolts (14 mm) to the specified torque.

57.Install the turbocharger. Tighten the turbocharger bolt (A, 13 mm) and two nuts (B, 13 mm) to the specified torque.

Replace the 3-hole exhaust gasket with a new one when installing. Part number: 6710910180 A B

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58.Install the turbocharger support bar. Tighten the bolt (A, 12 mm) on the turbocharger to the specified torque. Tighten the bolt (B, 13 mm) on the cylinder block to the specified torque.

59.Install the turbocharger oil supply and return pipes.

a. Connect the oil supply pipe. - Tighten the oil supply pipe screw fitting (A) on the cylinder block to the specified torque. - Tighten the hollow bolt (B) for the oil supply pipe to the specified torque.

Replace the gasket and copper washer with new ones. Part No.: 9777110140 b. Connect the oil return pipe. - Tighten the bolts C and D to the specified torque.

Replace the gasket with a new one. Part No.: 6651870080 Part No.: 6611863080

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60.Install the power steering pump. Tighten the 3 mounting bolts (13 mm) to the specified torque.

61.Install the alternator. Tighten the mounting bolt A (17 mm) and B (15 mm) to the specified torque.

62.Tighten the 4 mounting bolts (13 mm) for A/C compressor to the specified torque.

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63.Install the idler pulley No. 1 Tighten the mounting bolt (T50) to the specified torque.

64.Install the idler pulley No. 2 Tighten the mounting bolt (T50) to the specified torque.

65.Install the fan belt auto tensioner. Tighten the mounting bolt A (17 mm) and B (14 mm) to the specified torque.

66.Fit the belt. - Turn the belt tensioner tension release bolt counterclockwise to compress the tensioner and install the fan belt.

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