SsangYong Actyon Sports II. Manual — part 7

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)

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(2) Exhaust system

Wear the safety glove when removing the exhaust pipe.

Make sure that the exhaust pipe is cooled before removing it.

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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

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01-9

0000-00

(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.

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Clean the mating surfaces before tightening.

Place the marks with paint to tighten by angle if the angle wrench is not available.

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01-10

5. STANDARD BOLTS SPECIFICATIONS

Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified

as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.

Observe standard tightening torque during bolt tightening works and can adjust torque to be

proper within 15 % if necessary. Try not to over max. allowable tightening torque if not required to

do so.

Determine extra proper tightening torque if tightens with washer or packing.

If tightens bolts on the below materials, be sure to determine the proper torque.

1)

2)

3)

4)

Aluminum alloy: Tighten to 80 % of above torque table.

Plastics: Tighten to 20 % of above torque table.

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01-11

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6. TIGHTENING TORQUE

Name

Size

Numbers of

fastener

Tightening

torque (Nm)

Note (total

tightening

torque)

Main bearing cap

M12×82

10

55±5Nm,

180˚

Not-reusable

Connecting rod cap

M9×52

8

40±5Nm,

90˚+10˚

50 ~80Nm

Crankshaft rear seal

M6×20

6

10±1Nm

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Oil pump

M8×35

3

25±2.5Nm

-

Drive plate

M10×22

8

45±5Nm,

90˚+10˚

Not-reusable

Isolation damper center

bolt

M18×50

1

200±20Nm,

180˚+20˚

660 ~ 720Nm

Not-reusable

Oil pan

M6×20

18

10±1Nm

-

M6×35

2

10±1Nm

-

M6×85

2

10±1Nm

-

M6×120

2

10±1Nm

-

M8×40

2

25±2.5Nm

-

Mounting nut for high

pressure pump

M14×1.5-8-1

1

65±5Nm

-

Mounting bolt for high

pressure pump

M8×30

3

25±2.5Nm

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Cylinder head

M13×150

12 85Nm

270°±10°

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Camshaft cap

M6×30

16

10±1Nm

-

M8×60

4

25±2.5Nm

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Exhaust stud bolt

10

15±1.5Nm

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Exhaust sprocket

M8x16.5

1

25±2.5Nm

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Chain tensioner screw

plug

M8x1.5

1

25±2.5Nm

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Coolant temperature

sensor

1

20±2.0Nm

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Belt auto tensioner

M8×30(LOW)

1

25±2.5Nm

-

M10×75(Upper)

1

55±5.5Nm

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Water pump

M6×25

7

10±1.0Nm

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