2012 SSANGYONG NEW ACTYON SPORTS engine

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) -
-
-
-
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) -
-
-
(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. -
-

01-110000-00
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

01-170000-00
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

02-70000-00
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 ▶
<007e0088009900940047009b008f008c0047008c0095008e00900095008c0047009c00970047009b00960047009500960099009400880093004700960097008c00990088009b00900095008e0047009b008c00940097008c00990088009b009c0099008c00
47004f005f005700b6006a00500055>
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.

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) -
-
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.