coolant SSANGYONG NEW ACTYON SPORTS 2013 Service Manual

01-4
2. MAJOR COMPONENTS
Front view â–¶
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 â–¶
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 â–¶
Front exhaust gas temperature
sensor
Oil dipstick tube &
gauge assembly
E-VGT actuator
E-VGT turbocharger
Coolant screw plug
Oil drain plug
Left view â–¶
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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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)

01-90000-00
(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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01-110000-00
6. TIGHTENING TORQUE
NameSizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Main bearing cap M12×82 10 55±5Nm,
180Ëš Not-reusable
Connecting rod cap M9×52 8 40±5Nm,
90Ëš+10Ëš 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,
90Ëš+10Ëš Not-reusable
Isolation damper center bolt M18×50
1 200±20Nm,
180Ëš+20Ëš 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 -

02-4
2. TIGHTENING TORQUE
ComponentSizeBolt
Quantity Specified torque
(Nm) Remark
(Total torque)
Main bearing cap M12×8210 55±5Nm,
180Ëš Not re-usable
Connecting rod cap M9×52840±5Nm,
90Ëš+10Ëš 50 to 80 Nm
Rear cover M6×20610 ± 1 Nm -
Oil pump M8×35SOC 325 ± 2.5 Nm -
Drive plate M10×22845 ± 5 Nm,
90Ëš+10Ëš Not re-usable
Crankshaft center bolt M20×851200 ± 20 Nm,
180Ëš+20Ëš 660 to 720 Nm
Not re-usable
Oil pan M6×201810 ± 1 Nm -
M6×35 210 ± 1 Nm -
M6×85 210 ± 1 Nm -
M6×120 210 ± 1 Nm -
M8×40 225 ± 2.5 Nm -
HP pump main nut M14×1.5-8-1165 ± 5 Nm -
HP pump bolt M8×55325 ± 2.5 Nm -
Cylinder head M13×1501285Nm
270°±10° -
Camshaft cap M6×301610 ± 1 Nm -
M8×60 425 ± 2.5 Nm -
Exhaust stud bolt 1015±1.5Nm -
Exhaust sprocket bolt M8 x 16.5 1 25±2.5Nm-
Chain tensioner screw bolt M8 x 1.5
125±2.5Nm -
Coolant temperature sensor 1
20±2.0Nm -
Auto tensioner M8×30(LOW) 125±2.5Nm -
M10×75(Upper) 155±5.5Nm -
Coolant pump M6×50 110±1.0Nm -

02-110000-00
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
For safe and correct works, you must observe the working procedures and instructions in this
manual. And, use the designated tools as follow:
Engine stand / Heavy duty engine jack
To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while
servicing in engine compartment.
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.
Do not allow the foreign material get into the fuel injection system.
When removing the engine, use only the safety hook on engine and engine hanger. Do not support
the bottom of oil pan with a jack.
Engine and accessories â–¶
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Completely drain the engine oil, coolant and fuel from engine before removal.
Before disassembling/assembling the engine components, carefully read the working procedures in
this manual.
Make sure to keep the specified tightening torques during installation.
Clean and properly lubricate the parts before reassembly.
Carefully check that there are not any interference while servicing. -
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02-250000-00
Location of Expansion Plugs
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
FrontRear
Coolant expansion plug (M21)
Oil gallery expansion plug (M10)
Intake side

02-48
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.
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
Water jacket core