2012 SSANGYONG NEW ACTYON SPORTS oil

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)

01-8
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) -
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(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 -
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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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01-14
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)

01-170000-00
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

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 -