2012 SSANGYONG NEW ACTYON SPORTS Service Manual

01-16
No Part name Amount Tool
8 Injector holder - A 1
9 Injector - B 1
10 Injector holder cover 1
11 Bar holder assembly 2
12 Support mounting bolt 4
13 Main support 4

01-170000-00
Name: Oil pan gasket
remover
Use to separate oil pan and
minimize damage when
removing oil pan.
Name: Torque angle gauge
Use to angle-tighten correctly
after torque-tightening
Name & Part number Tool How to use
Name: Engine stand (1 tone
or more)
Use to fix the removed engine
or engine with transmission.
Name: Engine crane (1 tone
or more)
Use to move the engine
module (including
transmission) to working
space or engine stand.
2. NORMAL EQUIPMENTS

01-18
Name & Part number Tool How to use
Name: High pressure pump
gear & nut remover
Use to remove & install the
high pressure pump sprocket.
Name: Adapter & gauge
Use to measure the
compression pressure by
inserting it into glow plug
hole.

02-30000-00
1. SPECIFICATION
Unit Description Specification Remark
Cylinder head Height 142.9 to 143.1 mm -
Flatness below 0.1 mm -
Valve protrusion Intake valve 0.1 to 0.7 mm -
Exhaust valve 0.1 to 0.7 mm -
Flatness on manifold
sideIntake manifold 0.08 mm -
Exhaust manifold 0.08 mm -
Connecting rod End play 0.5 to 1.5 mm -
Camshaft Axial end play Intake 0.1 to 0.35 mm -
Exhaust 0.1 to 0.35 mm -
Camshaft
position sensorDistance between Camshaft position
sensor and sprocket0.20 to 1.80 mm -
Valve Clearance between
valve and pistonIntake Approx. 0.7 mm -
Exhaust Approx. 0.8 mm -
Valve recess Intake 0.1 to 0.7 mm -
Exhaust -
Cylinder block Piston protrusion 0.541 to 0.649 mm -
Piston ring TOP ring end gap 0.20 to 0.35 mm -
2nd ring end gap 0.35 to 0.50 mm -
3rd ring end gap 0.2 to 0.40 mm -
Offset 0.3 mm -
Head gasket Piston protrusion 0.475~0.540 1.2t -
0.541 to 0.649 1.3t -
0.650 to 0.745 1.4t -

02-4
2. TIGHTENING TORQUE
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Main bearing capM12×8210 55±5Nm,
180˚Not re-usable
Connecting rod capM9×52840±5Nm,
90˚+10˚50 to 80 Nm
Rear coverM6×20610 ± 1 Nm-
Oil pumpM8×35SOC325 ± 2.5 Nm-
FlywheelM10×22845 ± 5 Nm,
90˚+10˚60 to 100 Nm
Crankshaft center boltM20×851200 ± 20 Nm,
180˚+20˚660 to 720 Nm
Not re-usable
Oil panM6×201810 ± 1 Nm-
M6×35210 ± 1 Nm-
M6×85210 ± 1 Nm-
M6×120210 ± 1 Nm-
M8×40225 ± 2.5 Nm-
HP pump main nutM14×1.5-8-1165 ± 5 Nm-
HP pump boltM8×55325 ± 2.5 Nm-
Cylinder headM13×15012 85Nm
270°±10°-
Camshaft capM6×301610 ± 1 Nm -
M8×60425 ± 2.5 Nm -
Exhaust stud bolt 1015±1.5Nm-
Exhaust sprocket boltM11×40130 ± 3 Nm -
Chain tensioner screw
boltM38×1.5 125±2.5Nm -
Coolant temperature
sensor120±2.0Nm -
Auto tensionerM8×30(LOW) 125±2.5Nm -
M10×75(Upper) 155±5.5Nm -
Coolant pumpM6×50 110±1.0Nm -

02-50000-00
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Hot water inlet pipeM6×16 2 10±1Nm -
AlternatorM10×90 1 25±2.5Nm -
M10×116 1 46±4.6Nm -
A/C bracketM8×25 4 7.8~11.8Nm -
A/C sub bracketM6×25 4 10±1Nm -
Intake manifoldM8×35 2 25±2.5Nm -
M8×110 6 25±2.5Nm -
Oil filter moduleM8×40 6 25±2.5Nm -
M8×20 1 25±2.5Nm -
M8×140 2 25±2.5Nm -
Knock sensorM8×28 2 20±5Nm -
Cam position sensorM8×14 1 10~14Nm -
Booster pressure
sensorM6×20 2 10±1Nm -
Exhaust manifold M8 10 40±4Nm -
Turbocharger M8 3 25±2.5Nm -
Support bolt 1 25±2.5Nm -
Support nut M8 1 25±2.5Nm -
T/C oil supply pipe M6(block side) 1 10±1.0Nm -
M6(turbo side) 1 17±2.0Nm -
T/C oil return pipeM6×16(turbo side)2 10±1Nm -
M6×16(block side)2 10±1Nm -
EGR valveM8×22 2 25±2.5Nm -
EGR pipe bolt
(Intake side)M8×16 2
25±2.5Nm -
EGR pipe bolt
(EGR cooler side)M8×16 2 25±2.5Nm -
EGR combination boltM6×16 4 10±1Nm -
M8×16 16 25±2.5Nm -
Idle pulley/Tensioner
pulley1 45±4.5Nm -

02-6
Component SizeBolt
QuantitySpecified torque
(Nm)Remark
(Total torque)
Glow plug M5 4 20±2Nm -
Vacuum pumpM8×25 3 10±1Nm -
Timing gear case coverM12×55 3 85±8.5Nm -
M6×25 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head coverM6×35 21 10±1Nm -
Oil gauge tubeM6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel railM8×35SOC 2 25±2.5Nm -
Injector clamp boltM6×60 2 10±1Nm,
120˚+10˚ -
High pressure pipe
(between HP pump and
fuel rail)M17 1 30±3Nm -
High pressure pipe
(between fuel rail and
injector)M17 4 30±3Nm -
Crank position sensorM5×14 1 8±0.4Nm -
Main wiringM6×16 5 10±1Nm -
Intake duct M8x25 4 25±2.5Nm -
Power steering pumpM8×100 3 25±2.5Nm -
Cylinder head front
coverM6×10 5 10±1Nm -
Ladder frameM8×16 5 30±3Nm -
Oil pumpM8×35 3 25±2.5Nm
-

02-70000-00
3. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value ▶
Compression ratio16.5 : 1
Test conditionat normal operating temperature (80˚C)
Compression pressureStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston
ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating
status.
Before cranking the engine, make sure that the test wiring, tools and persons are keeping
away from moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
-
-
Measurement ▶
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Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Remove the air cleaner duct and glow plugs. -
-
-
Place the diagram sheet to compression
pressure tester and install it into the plug
hole. 1.