2012 SSANGYONG NEW ACTYON SPORTS Service Manual

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. -
-

01-110000-00
6. CODING AND INITIALIZATION
1) Engine Variant Coding
Unit Selection Description Remarks
PTC auxilary heater NO For PTC auxilary heater
equipped vehicle, select
"YES".-
YES YES
Glow plug Relay (K-line) Select "AQGS". -
AQGS (CAN) AQGS (CAN)
Transmission 6-speed M/T "DSI 6 AT" is selected
automatically.Select
5-speed A/T (DC 5 AT) -
6-speed A/T (DSI 6 AT) Select
Pressure sensor for
A/C refrigerantNO Select the appropriate
system.-
Type Pressure
sensor for A/C
refrigerant
Immobilizer NO Select "YES" if the vehicle
has immobilizer.-
YES YES
Vehicle speed input
typeCAN Select "CAN" if the vehicle
has ABS or ESPCAN
WIRE -
Fan 2 relays Select "PWM". -
PWM fan PWM fan
Auto cruise NO Select "YES" if the vehicle
has cruise contro.-
YES YES
G-sensor NO 2WD ABS & Non-ABS: NO
4WD ABS & ESP: YESSelect
YES Select

01-12
1. SPECIAL SERVICE TOOLS
Name & Part number Tool How to use (on vehicle)
Part number: T99410010A
Name: Belt tension adjuster
Use to release tension
without removing belt when
replacing pulley or pump.
How to use (on engine)
Part number: T9941 0010A
Name: Flywheel fixing device
Use to fix flywheel or drive
shaft to prevent engine from
rotating when removing
crankshaft pulley

01-130000-00
Part number: Y9922 082B,
W9911 0230A, Y9922 018
Name: Valve spring
complete
Use: Used to compress the
valve spring.
Y9922 082B W99110230A
Part number: Y9922 018
Name: Remover
Use to remove the valve
stem seal.
Part number: Y9922 008
Name: Installer
Use to install the valve stem
seal.
Name & Part number Tool How to use

01-14
Name & Part number Tool How to use
Part number: Y9922 012
Name: Dial gauge
Use: Used to measure the
protrusion of piston.
Part number: Y9922 0172B
Name: Piston install guide
Use: Used to slide the piston
into cylinder.
Part number: W9911 0120A
Name: Inserting guide
Use: Used to install the rear
crankshaft oil seal.
Part number: T9918 0010A
Name: Injector remover
(Euro-V)

01-150000-00
No부품명 수량 사진
6 Main nut - A 1
7 Main bolt - A 1
No Part name Amount Tool
1 Injector remover set 1
2 Main bar 1
3 Cross bar 2
4 Main bolt holder 1
5 Ball bearing 1
Components ▶