2013 SSANGYONG NEW ACTYON SPORTS fuel pressure

01-4
2. MAJOR COMPONENTS
Front view ▶
Vacuum pump
Oil filter assembly
Camshaft position sensor
Power steering pump pulley
Water pump pulley
Alternator pulley
Idler pulley No. 2
A/C compressor pulley
Auto tensioner
Idler pulley No. 1
Isolation damper
Rear view ▶
E-EGR valve
Fuel temperature sensor
Fuel HP pump assembly
Coolant temperature sensor
IMV valve Crankshaft position sensor
Oil pressure switch

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. -
-

01-130000-00
NameSizeNumbers of
fastener Tightening
torque (Nm) Note (total
tightening torque)
Idler pulley/tensioner pulley 1
45±4.5Nm -
Glow plug M5 4 20±2Nm -
Vacuum pump M6×25 3 10±1Nm -
Timing gear case cover M6×40 7 10±1Nm -
M6×45 1 10±1Nm -
M6×50 3 10±1Nm -
Cylinder head cover M6×35 21 10±1Nm -
Oil dipstick gauge cover M6×16 1 10±1Nm -
Oil filter cap 1 25±2.5Nm -
Fuel rail M8×25 2 25±2.5Nm -
Injector clamp bolt M6×44 2 9±1.0Nm
130˚±10˚ -
High pressure pipe
(between high pressure pump and fuel rail assembly) M17 1
30±3Nm -
High pressure pipe
(between fuel rail assembly and injector) M17 4
30±3Nm -
Crankshaft position sensor M5×14
1 8±0.4Nm -
Main wiring M6×16 5 10±1Nm -
Intake duct M8×25 425±2.5Nm -
Power steering pump M8×100 3 25±2.5Nm -
Cylinder head front cover M6×10
5 10±1Nm -
Ladder frame M8×355 30±3Nm
-
EGR pipe bolt
(to air duct) M6×16
2 10±1Nm -
EGR pipe bolt
(to EGR cooler) M8×25
225±2.5Nm -

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. -
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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.

02-270000-00
3) Valve Assembly (Installed in Cylinder Head)
(1) Features
Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash
Optimized adjustment of valve clearance reduces the valve noise.
Roller type finger follower reduces the friction loss.
Vertical installation.
Simple and compact design reduces the moving operation (improving valve following and fuel
consumption at high speed) 1.
2.
3.
4.
5.
(2) Arrangement
Hydraulic lash adjuster
Upper valve spring retainer
Lower valve spring retainer
Valve spring
Exhaust valveIntake valve
Finger follower

03-32210-01
1. SPECIFICATION
Description Specification
Fuel Diesel
Fuel filterType Fuel heater + priming pump + water
separator integrated type
Filter type Changeable filter element type
Water accumulating capacity 200 cc
Heater capacity 250W 13.5V
Injector System pressure 1800 bar
High pressure fuel
pumpType Eccentric cam/Plunger type
Operating type Gear driven type
Normal operating temperature-40 ~ 125˚C
Operating pressure 1800 bar
Operating temperature-30 ~ 120˚C
Low pressure fuel
pumpType Vane type
Gear ratio (pump/engine) 0.5 : 1
Pressure 6 bar
Fuel tankCapacity 75 L
Material Steel
Fuel sender Single sender type
Change interval EU every 40,000 km
GEN every 45,000 km
Water separation
intervalEU every 20,000 km
GEN every 15,000 km

03-4
2. MAINTENANCE AND INSPECTION
1) Maintenance Procedures for DI Engine Fuel System
Always keep the workshop and lift clean (especially, from dust).
Always keep the tools clean (from oil or foreign materials).
Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
Wash your hands and do not wear working gloves. 1.
2.
3.
Follow the below procedures before starting service works for fuel system.
If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing
caps to perform the diagnosis for DI engine fuel system in this manual. At this point, thoroughly clean
the related area in engine compartment. 4.
Clean the engine compartment before starting service works.
Tool kit for high pressure lineTook kit for low pressure line