2013 SSANGYONG NEW ACTYON SPORTS Service Manual

01-16
Unit Selection Description
Brake system ESP Select "ABS" or "ESP".
ABS
TCS
NO
SSPS NO Select "YES".
YES
TPMS NO Select "NO".
YES
T/M type MT Select "M/T" or "DSIH 6 AT".
DC AT
DSIH 6 AT
Vehicle code Rodius / Stavic Select "Rodius".
Rexton
Korando C
Actyon sports
Kyron
ECU coding status ECU not coded Select "ECU coded".
ECU coded
Signal not valid
Not defind

02-30000-00
1. SPECIFICATION
Unit Description Specification Remark
Cylinder head Height 131.9 to 132.1 mm -
Flatness below 0.1 mm -
Valve recess Intake valve 0.6 to 1.0 mm -
Exhaust valve 0.6 to 1.0 mm -
Flatness on manifold
sideIntake manifold 0.08 mm -
Exhaust manifold 0.08 mm -
Connecting rod End play 0.05 to 0.31 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 1.12 mm -
Exhaust 1.09 mm -
Cylinder block Piston protrusion 0.475 to 0.745mm -
Piston ring TOP ring end gap 0.20 to 0.40 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
ComponentSizeBolt
Quantity Specified torque
(Nm) Remark
(Total torque)
Main bearing cap M12×8210 55±5Nm,
180˚ Not re-usable
Connecting rod cap M9×52840±5Nm,
90˚+10˚ 50 to 80 Nm
Rear cover M6×20610 ± 1 Nm -
Oil pump M8×35SOC 325 ± 2.5 Nm -
Drive plate M10×22845 ± 5 Nm,
90˚+10˚ Not re-usable
Crankshaft center bolt M20×851200 ± 20 Nm,
180˚+20˚ 660 to 720 Nm
Not re-usable
Oil pan M6×201810 ± 1 Nm -
M6×35 210 ± 1 Nm -
M6×85 210 ± 1 Nm -
M6×120 210 ± 1 Nm -
M8×40 225 ± 2.5 Nm -
HP pump main nut M14×1.5-8-1165 ± 5 Nm -
HP pump bolt M8×55325 ± 2.5 Nm -
Cylinder head M13×1501285Nm
270°±10° -
Camshaft cap M6×301610 ± 1 Nm -
M8×60 425 ± 2.5 Nm -
Exhaust stud bolt 1015±1.5Nm -
Exhaust sprocket bolt M8 x 16.5 1 25±2.5Nm-
Chain tensioner screw bolt M8 x 1.5
125±2.5Nm -
Coolant temperature sensor 1
20±2.0Nm -
Auto tensioner M8×30(LOW) 125±2.5Nm -
M10×75(Upper) 155±5.5Nm -
Coolant pump M6×50 110±1.0Nm -

02-50000-00
ComponentSizeBolt
Quantity Specified torque
(Nm) Remark
(Total torque)
Hot water inlet pipe M6×16 2 10±1Nm -
Alternator M10×90 1 25±2.5Nm -
M10×116 1 46±4.6Nm -
A/C bracket M8×25 4 7.8~11.8Nm -
A/C sub bracket M6×25 4 10±1Nm -
Intake manifold M8×35 2 25±2.5Nm -
M8×110 6 25±2.5Nm -
Oil filter module M8×40 6 25±2.5Nm -
M8×20 1 25±2.5Nm -
M8×140 2 25±2.5Nm -
Knock sensor M8×28 2 20±5Nm -
Cam position sensor M8×14 1 10~14Nm -
Booster pressure sensor M6×20 2 10±1Nm -
Exhaust manifold M810 40±4Nm -
Turbocharger M83 25±2.5Nm -
Support nut M81 25±2.5Nm -
T/C oil supply pipe M161 25±2.5Nm
(Fitting Screw) -
M10 1 17±2Nm
(Hollow Bolt) -
T/C oil return pipe M6×16(turbo side) 2 10±1Nm -
M6×16(block side) 2 10±1Nm -
EGR valve M8×30325±2.5Nm -
EGR pipe bolt (Intake side) M6×16
2 10±1Nm -
EGR pipe bolt
(EGR cooler side) M8×25
2 25±2.5Nm -
Support bolt M8×35125±2.5Nm
(Turbo Side) -
M8×16 125±2.5Nm
(Block Side) -

02-6
ComponentSizeBolt
Quantity Specified torque
(Nm) Remark
(Total torque)
Glow plug M5 4 20±2Nm -
Vacuum pump M6×253 10±1Nm -
Timing gear case cover M12×55 3 85±8.5Nm -
M6×25 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head cover M6×35 21 10±1Nm -
Oil gauge tube M6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel rail M8×35SOC 2 25±2.5Nm -
Injector clamp bolt M6×60 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 sensor M5×14 1 5±1.0Nm -
Main wiring M6×16 5 10±1Nm -
Intake duct M8x25 4 25±2.5Nm -
Power steering pump M8×100 3 25±2.5Nm -
Cylinder head front cover M6×10 5 10±1Nm -
Ladder frame M8×16 5 30±3Nm -
Oil pump M8×35 3 25±2.5Nm -
EGR Cooler
MTG Bolt M8×16
225±2.5Nm -
M8×70 225±2.5Nm -
Idle pulley/Tensioner pulley 1
45±4.5Nm -

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.

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.

02-90000-00
Position the piston at TDC and measure the
piston protrusion from crank case mating
surface.
(3) Piston protrusion check
Specified value 0.475~0.745mm
Measure it at both ends of crankshaft. -