coolant reservoir SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

02-4
2330-01 Intercooler
Changed the bracket and core size
3030-01 Clutch pedal
Add clutch ECU switch
2130-07 Coolant reservoir
Changed the appearance and capacity
(2.8 L)
8410-02 Fuse box in engine
compartment
Changed the layout of relays
2. INTERIOR
Old
New
Old
New
OldNew
OldNew
Interlock
switch
7410-12 Seat logo
Old
New

02-70000-00
1719-09 Acoustic cover
Changed the design1543-01 Steering pump assembly
Introduced reservoir integrated tpe steering
pump
D20DTR (Actyon Sports)
OldNew
OldNew
OldNew
Power steering pump
Old
New
1533-30 Coolant outlet pipe
OldNew
Coolant temperature sensor hole
EGR cooler
outlet
Coolant temperature sensor hole
EGR cooler outletCoolant outlet pipe
1520-21 Coolant outlet port
Changed the location of coolant
temperature sensor and deleted the
coolant outlet port from turbocharger
1793-23 EGR cooler & coolant outlet
hose

01-6
3. ENGINE COMPARTMENT LAYOUT
Do not work on the engine compartment while the engine, radiator, exhaust manifold, muffler
or catalytic converter is hot. Always turn the engine off and allow it to cool before starting the
maintenance.
Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary.
Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine. -
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Power steering fluid
reservoirBrake fluid reservoir
Fuse & relay
Engine oil
dipstick gaugeWasher fluid
reservoir cap Engine oil filler cap
Air cleaner
Operating vehicle with insuffi cient amount of oil can damage the engine. Make sure the
engine oil level is correct and add oil if necessary.
Coolant reservoir

01-90000-00
(3) Cautions before service
Prolonged exposure to the engine oil make cause a skin cancer or an irritation.
Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the
used engine to make contact with your skin.
Make sure to wear the protection gloves and goggle when handling the engine oil. If contact
happens, rinse affected areas immediately with plenty of water. Do not wash it with gasoline or
solvent. If irritation persists, consult a doctor.
Improperly disposed engine oil can pollute the environment. Dispose used engine oil in
accordance with local environmental regulations. -
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(5) Tightening the fastener
If fine dust or foreign material enters into DI engine's fuel system, there can be serious
damages between HP pump and injectors. So, be sure to cover removed fuel system
components with cap and protect removed parts not to be contaminated with dirt. (Refer to
cleanness in this manual while working on DI engine fuel system)
When working on the fuel line between priming pump and injector (including return line),
always plug the openings with caps to prevent foreign materials or dust from entering to the
openings and connections.
The HP fuel supply pipe (HP pump to fuel rail) and HP fuel pipe (Fuel rail to injector)
should be replaced with new ones when removed. 1.
2.
3. Scalding hot coolant and steam could be blown out under pressure, which could cause serious
injury. Never remove the coolant reservoir cap when the engine and radiator are hot.
(4) Lubrication system
3) Fuel and Oil System
If work on the fluid system such as fuel and oil, working area should be well ventilated and
smoking should be prohibited.
Gasket or seal on the fuel/lubrication system should be replaced with new ones and bolts and
nuts should be tightened as specified. -
-Clean the mating surfaces before tightening.
Place the marks with paint to tighten by angle if the angle wrench is not available. -
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08-31520-00
1. SPECIFICATION
Unit Description Specification
Cooling system Type Water cooling, forced circulation
Coolant Capacity approx. 8.5 L
Radiator Core size 555W x 582.4H x 27T (over 326,250mm2)
Flow type Cross flow
Min. cooling capacity over 68,000 kcal/h
Antifreeze Type Long life coolant
Mixing ratio
(water:antifreeze)50 : 50
Cooling fan module Type Electric
CapacityØ472 x 400W x 5B
Control type PWM type
Coolant reservoir Capacity over 1.5 L
Circulation Closed roof type
Pressure cap Screw type, 1.4bar
Vacuum valve Screw type, 1.4bar
Thermostat Type Wax pallet type
Opening temperature90˚C
Fully open temperature100˚C
Valve lift 8 mm

08-51520-00
1) Coolant Level Check
Park the vehicle on level ground and apply the parking brake. Stop the engine and wait until it is
cooled down.
The coolant level should be between the MAX and MIN mark on the coolant reservoir.
Check the coolant level. If the level is below the “MIN” mark, immediately add coolant. 1.
2.
Scalding hot coolant and steam could be blown out under pressure, which could cause
serious injury. Never remove the coolant reservoir cap when the engine and radiator are hot.
Avoid any direct contact of the coolant to the painted body of the vehicle. -
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MAX
MIN

08-6
2) Leak Test
Release the pressure in the system by
loosening the pressure cap of the coolant
reservoir slightly. Then, remove the pressure
cap completely. 1.
Never open the cap until the coolant
temperature becomes under 90℃ to
prevent any burn.
Add the coolant so that the coolant level is
between MAX and MIN mark on the
coolant auxiliary tank.
Connect the tester to the tank filler and
apply pressure (1.4 bar).
Check all the coolant hoses, pipes and
connections for leaks when the pressure of
the tester drops, and replace or tighten, if
necessary. 2.
3.
4.
3) Thermostat
Immerse the thermostat into the water. Heat
the water and check the valve opening
temperature.
Valve opening
temperature 90±2℃

08-71520-00
3. CAUTIONS
If 100% of anti-freeze is added, the water pump vane can be damaged and thermal
conductivity can be decreased resulting in poor circulation in the cooling system which leads
to overheated engine.
Use of non-recommended coolant could cause damage to the cooling system and
overheating of the engine.
Opening the coolant reservoir cap while the engine is running or hot can cause burns by hot
steam or water.
To open the coolant reservoir cap, wrap the cap with a wet towel or thick cloth after the
engine is cooled down sufficiently.
If cool water is added to the heated engine, the engine or radiator can be deformed.
The anti-freeze in the coolant can damage the painted surface, so avoid the contact of the
coolant to the painted body.
The anti-freeze and water should be mixed in proper mixture ratio. Never add only water
when adding coolant.
If the anti-freeze content is too low, the coolant can be frozen while the engine can be
overheated if anti-freeze content is too high. -
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08-8
Oil filter module
Thermostat
When the engine coolant
reaches 90℃, the thermostat
starts to open (fully open at
100℃) and lets the coolant
flow to the radiator to
maintain the engine
temperature.
Water pump
The water pump is driven by the engine drive belt and
supplies the coolant to each area of the engine.
Coolant reservoir
Long life coolant is used.
1. SYSTEM DESCRIPTION
1) Overview
Water pump
Impeller vane Sealing

01-131113-01
Leakage Test ▶
Warm the engine up to normal operating temperature.
Disconnect the negative battery cable.
Remove the spark plugs.
Check the coolant level by opening the coolant reservoir cap and replenish if insufficient.
Open the engine oil filler cap.
Connect the tester to air pressure line and adjust the scale of tester.
Install the connecting hose to spark plug hole.
Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
Connect the connecting hose to tester and measure the leakage volume after blowing up
5 bar of compressed air. -
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Measure the leakage volume in the completely opening condition of throttle valve by pulling
the acceleration cable. -
Perform the pressure test according to the firing order. -
Firing Order: 1 - 3 - 4 - 2 -
Compare the leakage pressure with the specifications. -