SsangYong Korando 2010–2011 Service & Wiring Manual Set

Use the wiring sections alongside the component tests to trace a fault through its power supply, connectors and associated assembly. The workshop sections provide the related inspection, removal and repair procedures.

Engine repair procedures cover the D20DTF diesel. The engine-ECU replacement section refers to a separate service manual for the full ECU coding and backup process.

E-coupling disassembly is limited to the specified flange-yoke and dust-seal work; the internal exploded view does not authorize a complete coupling overhaul.

Searchable Workshop Text and Wiring Detail

Text search and circuit labels: The 47 workshop PDFs contain searchable text and embedded bookmarks. Wiring-file search coverage varies, and four of the eight wiring PDFs have bookmarks. EWL_402 has no searchable text, while most circuit labels in EWL_403 cannot be searched. Small wiring labels require zooming.

The ZIP download contains 55 printable English PDFs totaling 2,460 pages, including 39 memo pages, 22 blank pages and one BCM diagnostic-guide placeholder page.

Diesel Engine, Drivetrain and Vehicle-System Service

This selected coverage overview highlights the main workshop areas. Other included topics range from parking-aid self-diagnosis to sunroof zero-point reset.

• Engine repair: Step-by-step engine removal and overhaul, cylinder-head and timing-chain work, plus separate cooling and lubrication service sections.

• Diesel fuel and emissions: Low- and high-pressure fuel tests, injector backleak checks, C3I calibration information, E-VGT turbocharger diagnosis, E-EGR and CDPF operation.

• Transmission service: WM6F1 internal disassembly and assembly, M11 valve-body and torque-converter work, fluid checks, TCU initialization and adaptive reset procedures.

• AWD and axles: PTU disassembly, E-coupling replacement, rear differential inspection and adjustment, drive-shaft boot replacement and propeller-shaft service.

• Brakes and steering: Brake inspection, ABS/ESP bleeding, sensor calibration, EPS initialization and fault codes, plus hydraulic steering pressure and preload checks.

• Suspension and body: Strut, spring, arm and subframe replacement; body dimensions, welding locations, sealing points, panel gaps and interior trim removal.

• Electrical and cabin systems: Starting and charging diagnosis, BCM key coding, FATC self-diagnosis, airbag component replacement and system-specific wiring diagrams.

Suited to technicians with diesel diagnostic experience, a compatible scan tool, lifting equipment and the specified service tools.

D20DTF Overhaul and Fuel-System Diagnosis

Internal engine coverage extends to cylinder-bore and crankshaft-journal measurement, piston selection, bearing installation and mass balance unit service. Cooling and lubrication chapters add coolant-system checks and radiator, water-pump, oil-pump and oil-cooler replacement procedures.

The overhaul instructions identify piston orientation as a damage-sensitive detail: an incorrectly installed piston can strike and damage the oil jet.

Fuel-system test charts distinguish injector backleak from pump pressure or supply-flow problems. Together with the electrical checks, these tests support diagnosis before major fuel components are removed. The engine-control sections explain C3I injector calibration, minimum drive pulse learning and the signals used for fuel, boost and emissions control.

M11 Controls, Manual Transmission and AWD Work

The M11 operating sections explain the Lepelletier arrangement of single and double planetary gearsets. The TCU under the driver’s seat uses accelerator position, input/output speed and temperature signals to manage gear selection, clutch pressure and line pressure.

TGS lever coverage includes shift lock and manual-mode selection. Component-specific DTC tables identify adaptive-memory, solenoid-current, sensor, gear-engagement and CAN faults. Service material adds valve-body solenoid removal, torque-converter replacement, adaptive reset, green-offset activation and the subsequent adaptive drive cycle.

The WM6F1 instructions go further into internal gear, synchronizer, shaft and differential work, including spacer and snap-ring selection. Clutch coverage includes SATIC and the concentric slave cylinder; repeated clutch removal and installation can activate the self-adjusting mechanism and cause premature disc wear.

Chassis, Body and Electrical Fault Tracing

ABS/ESP material combines hydraulic circuit diagrams with scan-tool bleeding and sensor initialization. Steering coverage distinguishes EPS coding and steering-angle initialization from HPS pump-pressure testing, bleeding and rack preload adjustment.

Body repair references provide welding and sealing locations, dimensional checks and panel-gap charts. Separate sections cover exterior panels, trim, seats and restraint components.

Electrical examples include Starting/Charging, ECU (D20DTF EU-V), TCU (6-A/T), ABS/ESP and CAN circuit sheets, supported by Connector/Ground layouts. BCM content covers operating logic, key coding and replacement; its diagnostic-guide page is a placeholder rather than a troubleshooting guide.

Review the manual’s lifting and fuel-system precautions before work on heavy powertrain assemblies or pressurized common-rail components.

Examples of Mounting Torques and Engine Inspection Limits

For M11 reassembly, the torque table lists 85.0–100 Nm for engine-side transaxle mounting bolts and 25.0–30.0 Nm for the oil drain plug.

D20DTF inspection data specifies cylinder-head flatness below 0.1 mm and mass balance unit gear backlash of 0.05–0.15 mm. These are selected entries from the component specifications accompanying the engine inspection and overhaul sections.