SSANGYONG NEW ACTYON SPORTS 2013 Owner's Manual

01-4
2. MAJOR COMPONENTS
Front view ▶
Vacuum pump
Oil filter assembly
Camshaft position sensor
Power steering pump pulley
Water pump pulley
Alternator pulley
Idler pulley No. 2
A/C compressor pulley
Auto tensioner
Idler pulley No. 1
Isolation damper
Rear view ▶
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Oil pressure switch

01-50000-00
Right view ▶
Front exhaust gas temperature
sensor
Oil dipstick tube &
gauge assembly
E-VGT actuator
E-VGT turbocharger
Coolant screw plug
Oil drain plug
Left view ▶
Thermostat assembly
Variable swirl valve assembly
E-EGR valve
E-EGR solenoid valve
EGR cooler
Electronic throttle body
Oil cooler assembly

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

01-70000-00
1) Service Interval
2) Specification and Capacity
Engine oilSpecification Quality class: Ssangyong genuine engine oil (Total Quartz INEO ECS
5W 30, SK ZIC SY 5W 30) or oil Approved by MB Sheet 229.51
Capacity approx. 6.0 litter
Engine
coolantSpecification Ssangyong genuine coolant Anti-Freeze SYC-1025
Capacity approx. 8.5 litter
Severe condition
Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance below
16 km when the outside temperature remains below freezing
Driving in a hilly or mountainous terrain, sandy, or dusty area
High load driving such as trailer towing
Taxi, patrol service or delivery service (extended idling and excessive driving with low speed) -
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-
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DescriptionDaily
inspectionWeekly
inspectionService interval
Engine oil & oil
filterInspection - EU Change every 20,000 km or 12 months
(The service interval should be shortened
under severe conditions)
General Change every 15,000 km or 12 months
(The service interval should be shortened
under severe conditions)
Coolant Inspection - Change every 200,000 km or 5 years
Air cleaner
element- Inspection Diesel EU Change every 20,000 km (The
service interval should be
shortened under severe
conditions)
General Clean every 7,500 km, change
every 15,000 km (The service
interval should be shortened
under severe conditions)
Gasoline Clean every 15,000 km, replace every
60,000 km (The service interval should be
shortened under severe conditions)
Fuel filter - - EU Change every 40,000 km (Draining water
from fuel filter: whenever replacing the
engine oil)
General Change every 45,000 km (Draining water
from fuel filter: whenever replacing the
engine oil)

01-8
4. CAUTION WHEN SERVICING THE ENGINE
1) Cleaness
Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be great
cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding surfaces
when assemblying the components. Every component should be disassembled and reassembled in
accordance with the correct sequences. Before servicing the engine, the negative cable should be
diconnected from the battery. Otherwise, some electric or electronic components could be damaged.
2) Servicing
(1) Lifting up the vehicle
Always keep the safety precautions.
To prevent the vehicle from rolling down, put the chocks under the tires (when using a 4-post lift).
Make sure to support the correct lifting points (when using a 2-post lift) -
-
-
(2) Exhaust system
Wear the safety glove when removing the exhaust pipe.
Make sure that the exhaust pipe is cooled before removing it. -
-Before service work, be sure to disconnect battery negative (-) terminal to prevent damages by bad
wire and short.
To prevent the foreign material from getting into engine cylinder, cover the inlet of air cleaner if the
air cleaner has been removed -
-

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. -
-
-
(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. -
-

01-10
5. STANDARD BOLTS SPECIFICATIONS
Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified
as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.
Observe standard tightening torque during bolt tightening works and can adjust torque to be
proper within 15 % if necessary. Try not to over max. allowable tightening torque if not required to
do so.
Determine extra proper tightening torque if tightens with washer or packing.
If tightens bolts on the below materials, be sure to determine the proper torque. 1)
2)
3)
4)
Aluminum alloy: Tighten to 80 % of above torque table.
Plastics: Tighten to 20 % of above torque table. -
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01-110000-00
6. TIGHTENING TORQUE
NameSizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Main bearing cap M12×82 10 55±5Nm,
180˚ Not-reusable
Connecting rod cap M9×52 8 40±5Nm,
90˚+10˚ 50 ~80Nm
Crankshaft rear seal M6×20 6 10±1Nm -
Oil pump M8×35 3 25±2.5Nm -
Drive plate M10×22 8 45±5Nm,
90˚+10˚ Not-reusable
Isolation damper center bolt M18×50
1 200±20Nm,
180˚+20˚ 660 ~ 720Nm
Not-reusable
Oil pan M6×20 18 10±1Nm -
M6×35 2 10±1Nm -
M6×85 2 10±1Nm -
M6×120 2 10±1Nm -
M8×40 2 25±2.5Nm -
Mounting nut for high pressure pump M14×1.5-8-1
1 65±5Nm -
Mounting bolt for high pressure pump M8×30
3 25±2.5Nm -
Cylinder head M13×150 12 85Nm
270°±10° -
Camshaft cap M6×30 16 10±1Nm -
M8×60 4 25±2.5Nm -
Exhaust stud bolt 10 15±1.5Nm -
Exhaust sprocket M8x16.5 1 25±2.5Nm -
Chain tensioner screw plug M8x1.5
1 25±2.5Nm -
Coolant temperature sensor 1
20±2.0Nm -
Belt auto tensioner M8×30(LOW) 1 25±2.5Nm -
M10×75(U
pper) 1 55±5.5Nm -
Water pump M6×25 7 10±1.0Nm -

01-12
T/C oil supply pipeM161 25±2.5Nm
(Fitting Screw) -
M10 1 17±2.0Nm
(Hollow Bolt) -
T/C oil return pipe M6×16(to block) 2 10±1Nm -
M6×16
(to turbocharger) 2
10±1Nm -
EGR valve M8×303 25±2.5Nm -
Name SizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Hot water inlet pipe M6×12210±1Nm -
Alternator M10×901(LO) 25±2.5Nm -
M10×116 1(HI) 46±4.6Nm -
Air conditioner compressor M8×85
425Nm -
Air conditioner bracket M6×25410±1Nm -
Intake manifold M8×35225±2.5Nm -
M8×110 625±2.5Nm -
Oil filter module M8×40625±2.5Nm -
M8×80 125±2.5Nm -
M8×140 225±2.5Nm -
Knock sensor M8×28220±5Nm -
Camshaft position sensor M8×14
110~14Nm -
T-MAP pressure sensor M6×20
110±1Nm -
Exhaust manifold M81040±4Nm -
Turbocharger M8325±2.5Nm -
T/C support bolt M8 x 35125±2.5Nm
(Turbo Side) -
M8 x 16 125±2.5Nm
(Block Side) -

01-130000-00
NameSizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Idler pulley/tensioner pulley 1
45±4.5Nm -
Glow plug M5 4 20±2Nm -
Vacuum pump M6×25 3 10±1Nm -
Timing gear case cover M6×40 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head cover M6×35 21 10±1Nm -
Oil dipstick gauge cover M6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel rail M8×25 2 25±2.5Nm -
Injector clamp bolt M6×44 2 9±1.0Nm
130˚±10˚ -
High pressure pipe
(between high pressure pump and fuel rail assembly) M17 1
30±3Nm -
High pressure pipe
(between fuel rail assembly and injector) M17 4
30±3Nm -
Crankshaft position sensor M5×14
1 8±0.4Nm -
Main wiring M6×16 5 10±1Nm -
Intake duct M8×25 425±2.5Nm -
Power steering pump M8×100 3 25±2.5Nm -
Cylinder head front cover M6×10
5 10±1Nm -
Ladder frame M8×355 30±3Nm
-
EGR pipe bolt
(to air duct) M6×16
2 10±1Nm -
EGR pipe bolt
(to EGR cooler) M8×25
225±2.5Nm -