2012 SSANGYONG NEW ACTYON SPORTS oil

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
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02-8
(2) Cylinder pressure leakage test
If the measured value of the compression pressure test is not within the specifications, perform
the cylinder pressure leakage test.Specified value ▶
Perform this test in the sequence of firing order.
Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the
engine oil into the combustion chamber) -
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Test condition: normal engine operating
temperature (80˚C)Specified value
Whole engine below 25%
at valve and cylinder head gasket below 10%
at piston ring below 20%
Crank the engine for approx. 10 seconds
by using the start motor. 2.
Record the test result and measure the
compression pressure of other cylinders
with same manner. 3.
If the measured value is out of specified
value, perform the cylinder pressure
leakage test. 4.

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 ▶
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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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02-12
Electrical equipment ▶
Electric devices should be handled more carefully.
Currently, the engine has a lot of electric devices. there could be poor engine performance,
incomplete combustion and other abnormal symptoms due to short circuit or poor contact.
Before work on engine and each electrical equipment, be sure to disconnect battery negative
(-) terminal.
When replacing the electric device, use only genuine part and check the conditions of
connections and grounds. Loosened connection or ground make cause a fire and personal
injury. -
-Fuel and lubrication system ▶
Do not allow the fluid and engine oil to make contact with the body paintwork and hoses.
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.
After removal/installation works, be sure to check whether there is leak on the connecting
section. -
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If fine dust or foreign material enters into DI engine's fuel system, there can be serious damages
in HP pump and injectors. Thus, be sure to plug the inlets of removed fuel line 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)

02-170000-00
Brake booster and naster
cylinderVacuum pump
Pump capacity: 210 cc/rev
Camshaft speed: 375 to 3,000 rpm
Lubrication temperature: -40 to
155°C
Oil: 5W30
Drive type: Driven by exhaust
Camshaft sprocket
2. VACUUM PUMP
Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid.
This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied
through the hole in hollow shaft.
Components ▶
EGR cooler bypass valve
This valve is controlled by ECU.
When the engine is cooled, the
exhaust gas goes to combustion
chamber without passing
through EGR cooler because the
valve is closed by vacuum
pressure.

02-18
1) Location
2) Operation
The vacuum pump is engaged to the exhaust camshaft.
Connection between vacuum
pump and exhaust camshaft
Oil supply and driving
Vacuum pumpExhaust camshaft

02-22
Rear view
5. CYLINDER HEAD COVER AND OIL SEPARATOR
The cylinder head cover is made by high strength plastic to reduce the weight. The multi twist type
oil separator improves the oil consumption.
Components ▶
1) Cylinder Head Cover
Front view
Cylinder head cover

02-230000-00
2) Oil Separator
Oil separator separates the particle in blow-by gas to minimize the engine oil consumption and
reduces the inflow oil from intake system into the combustion chamber. The separated oil returns
to oil pan through cylinder head.
Oil separator
Blow-by outlet hose
(1) Overview
(2) Layout