2012 SSANGYONG NEW ACTYON SPORTS service

04-138210-01
3) Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank
through a pointer. Note that this vehicle doesn't have a service hole for checking the fuel sender
connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is
removed. The power supply and resistance value should be measured at the connector in front of
the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be
defective; if so, replace the fuel sender.
Low fuel warning lamp comes on when:
The fuel level drops to 9 L or less. The lamp goes off if the fuel level reaches 9.5 L or more.This table shows the tolerance and resistance value changes by fuel level in normal
conditions. Therefore, the differences that can be occurred by the road conditions and fuel
fluctuations are ignored.

05-38310-00
1. SPECIFICATIONS
AmountSpecification
EU General
Exterior lamp Headlamp Low beam / High
beam2 H4(60W) /
H4(55W)←
Turn signal lamp 2 PY21W←
Position lamp 2 W5W←
Front fog light 2 H27W←
DRL 2 P21W←
Side repeater 2 LED←
Rear
combination
lampStop (tail) lamp 2 P21W(5W)←
Turn signal lamp 2 PY21W←
Back-up lamp 1/2 P21W/1 P21W/2
Rear fog light 1 P21W -
License plate lamp 2 W5W←
Interior lamp Front room lamp 2 8W←
Glove box lamp 1 5W←
Center room lamp 2 10W←
Door courtesy lamp 2 5W←Description
The surface of lamps can get foggy when raining or washing the vehicle. This is normal and is
a result of the temperature difference between inner and outer surface of lamp cover.
However, if water gets into the lamp, have the system checked at Ssangyong Authorized
Service Center.

01-53680-01
2. FEATURES AND SPECIFICATIONS
1) Specifications
Description DSI M78 (6-speed) Remarks
Gear ratio1st 3.53:1
2nd 2.14:1
3rd 1.48:1
4th 1.16:1
5th 0.87:1
6th 0.68:1
Reverse 3.09:1
Transmission flui
dFluid Fuchs FES 209-3292 ATF
Capacity Approx. 9.5 L
Change interval Check the fluid at every
30,000 km or 1 year, and
change it if necessary.Under the severe driving
conditions, change the fluid
at every 60,000 km.
Resistance of oil
temperature
sensor-20 430.7 ~ 533.9 kΩ
0 146.8 ~ 175.7 kΩ
20 56.74 ~ 65.86 kΩ
100 3.201 ~ 3.399 kΩ
Gear position
sensor1 -
2 -
3 -
D 2.686 kΩ ± 8%
N 5.036 kΩ ± 8%
R 8.953 kΩ ± 8%
P 16.786 kΩ ± 8%
Severe driving conditions? *
Towing a trailer or off-road driving (Inspect the
leak of fl uid at any time, occasionlly)
Taxi, patrol service or delivery service
(extended idling and excessive driving with low
speed)
Frequent stop-and-go traffi c, extended idling,
short driving distance -
-
-Driving in a hilly or mountainous terrain,
sandy, or dusty area
Driving frequently at high speed over 170
km/hour
Driving frequently in area where heavy
traffi c under the ambient temperature
above 32°C -
-
-

01-16
4. LIMP HOME MODE
In case of transmission malfunction ▶
If a serious fault occurs in the automatic transmission, the TCU enters the limp home
mode to secure safe driving and protect the automatic transmission.
As power is no longer supplied to the solenoid, the current basic function (P, R, N, D) is
maintained and the 4th gear can be maintained only by the operation of the hydraulic
system without electrical operation.
The ECU communicates with other electric modules with CAN. If a serious fault occurs, the
transmission automatically enters the limp home mode for service.
The TCU monitors all factors which can affect to the performance of the transmission and
diagnose the system according to OBD II regulation. 1.
2.
3.
4.
In case of overheated transmission ▶
The TCU enters the limp home mode when the batter voltage drops below 8 V.
If the transmission is overheated, the shift pattern is changed to the hot mode to cool the
transmission more efficiently.
While the transmission is overheated, the selector lever symbol and engine temperature
warning lamp on the instrument cluster blink until the transmission is cooled down to the
normal operation temperature. If the transmission is excessively overheated, the gear
cannot be shifted but remains in the neutral position. 1.
2.
3.
Towing the vehicle with A/T ▶
The best way to transport the vehicle is to load it to a truck and transport it, especially if the
vehicle is 4WD.
If towing the vehicle with the propeller shaft connected, the transmission or oil pump of
transfer case may malfunction, resulting in internal damage due to poor lubrication. -

02-33170-01
Description Specification
Gear ratio 1st 4.489 : 1
2nd 2.337 : 1
3rd 1.350 : 1
4th 1.000 : 1
5th 0.784 : 1
6th 0.679 : 1
Reverse 4.253 : 1
Synchronizer
ring type1st T: Triple-cone
2nd T: Triple-cone
3rd T: Triple-cone
4th S: Single-cone
5th D: Double-cone
6th S: Single-cone
Reverse T: Triple-cone
Shifting Type Floor change type
Gear selector
lever position
Transmission
fluidType HD MTF 75W/85 (SHELL) or HK MTF 75W/85(SK)
Capacity
Sercive interval Inspect and replenish every 60000 km or 3 years (under
severe driving conditions, change every 120,000 km)
1. SPECIFICATION
Reversing:
High-force type
What’s the severe conditions?
Towing a trailer or off-road driving (Inspect
the leak of fluid at any time, occasionlly)
Taxi, patrol service or delivery service
(extended idling and excessive driving with
low speed)
Frequent stop-and-go traffic, extended
idling, short driving distance -
-
-Driving in a hilly or mountainous terrain,
sandy, or dusty area
Driving frequently at high speed over 170
km/hour
Driving frequently in area where heavy
traffic under the ambient temperature
above 30°C -
-
-

02-4
Part No. & Name Appearance Description
Part No.: SSM00203-
005
Name:
Main shaft 1st sleeve
installer
Part No.: SSM00203-
006
Name:
Main shaft reverse
sleeve installer
Part No.: SSM00203-
002
Name:
Main shaft 5th sleeve
installer
Part No.: SSM00203-
003
Name:
Oil seal installerInstall the extension housing oil seal
Part No.: SSM00203-
004
Name:
Oil seal installerInstall the control shaft oil seal
2. SPECIAL SERVICE TOOLS
Install the main shaft reverse sleeve and
bearing
Install the main drive pinion assembly front
ball bearing
Install the main shaft double angular ball
bearing
Install the 3rd & 4th synchronizer hub
Install the main shaft 5th gear
Install the main shaft 6th gear -
-
-
-
-
-Install the main shaft 1st gear sleeve
Install the drive pinion assembly front ball
bearing
Install the main shaft double angular ball
bearing -
-
-
Install the main shaft 5th gear sleeve
Install the counter shaft 6th gear sleeve
Install the counter shaft reverse gear
Install the main shaft ball bearing -
-
-
-

08-10
2. FRONT SUSPENSION (DOUBLE WISHBONE)
Advantage ▶
The advantage of a double wishbone suspension is that it is fairly easy to work out the effect
of moving each joint, so the kinematics of the suspension can be tuned easily and wheel
motion can be optimized.
It is also easy to work out the loads that different parts will be subjected to which allows more
optimized lightweight parts to be designed.
They also provide increasing negative camber gain all the way to full jounce travel unlike the
MacPherson strut which provides negative camber gain only at the beginning of jounce travel
and then reverses into positive camber gain at high jounce amounts. 1.
2.
3.
Disadvantage ▶
The disadvantage is that it is slightly more complex than other systems like a MacPherson strut.
Due to the increased number of components within the suspension setup it takes much longer to
service and is heavier than an equivalent MacPherson design. 1.
2. Double wishbone suspension is an independent suspension design using two (occasionally parallel)
wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the
chassis and one joint at the knuckle. The shock absorber and coil spring mount to the wishbones to
control vertical movement. Double wishbone designs allow the engineer to carefully control the
motion of the wheel throughout suspension travel, controlling such parameters as camber angle,
caster angle, toe pattern, roll center height, scrub radius, scuff and more.
Lower arm Upper arm Shock absorber Stabilizer

09-34850-01
1. SPECIFICATION
Unit Description Specification
Front brake Type Ventilated disc
Outer diameter of discØ294 mm
Inner diameter of caliper cylinderØ43.0 x 2 mm
Thickness of disc 28 mm (wear limit: 25.4 mm)
Area of brake pad Above 60 cm2
Pad wear indicator Mechanical type
Rear brake Type Solid disc
Outer diameter of discØ299 m
Thickness of disc 10.4 mm (wear limit: 8.5 mm)
Area of brake pad Above 28.8 cm2
Pad wear indicator Mechanical type
Brake booster Type Vacuum assist type
Size8” + 9” (Tandem)
Master cylinder Type Tandem type(integrated level sensor)
Inner diameter of cylinderØ26.99 mm
Brake pedal Maximum operating stroke 150 mm
Pedal ratio 4 : 1
Free play 3 to 10 mm
Parking brake Type Mechanically expanded rear lining
Operating type Hand operated type
Inner diameter of drumØ190 mm
Brake oil Specification DOT 4
Capacity 0.7 to 0.8 liters
Service Interval: Change the brake oil at every 2 years
DOT?
It is the quality grade of brake fluid established by US Department of Transportation.