kyron + actyon_ltg(060303)-1

124
PYUNGTAEK, KOREA Labor Time Guide FOREWORD This LTG (Labor Time Guide) has been prepared for the purpose of implementing the terms of the current Dealer Sales and Service Agreement and is intended solely for the purpose of computing the compensa- tion payable by SsangYong Motor Co.,Ltd. to the au- thorized SsangYong dealers for the performance of warranty, policy and campaign adjustment and other work authorized and performed for the account of SsangYong Motor Co., Ltd. This use of this guide for any other purpose is neither intended not authorized by SsangYong Motor Co., Ltd. Please read the introduction of this guide thoroughly to acquaint with SsangYong warranty system. All time allowances in this guide are subject to change at any time by SsangYong Motor Co., Ltd. based on time studies by the company related to improved methods, techniques or equipment or other advances in the industry. SECTION INDEX A. GENERAL INFORMATION 1. ENGINE (Diesel) ENGINE (Gasoline) 2. SUSPENSION 3. DRIVE LINE & AXLE 4. BRAKES 5. TRANSMISSION & TRANSFER CASE 6. STEERING 7. H.V.A.C (Heating, Ventilation & Air Conditioning) 8. RESTRAINTS 9. BODY & ACCESSORIES 10. PAINT 11. OTHERS

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Page 1: KYRON + ACTYON_LTG(060303)-1

PYUNGTAEK, KOREA

Labor Time Guide

FOREWORD

This LTG (Labor Time Guide) has been prepared for

the purpose of implementing the terms of the current

Dealer Sales and Service Agreement and is intended

solely for the purpose of computing the compensa-

tion payable by SsangYong Motor Co.,Ltd. to the au-

thorized SsangYong dealers for the performance of

warranty, policy and campaign adjustment and other

work authorized and performed for the account of

SsangYong Motor Co., Ltd.

This use of this guide for any other purpose is neither

intended not authorized by SsangYong Motor Co.,

Ltd.

Please read the introduction of this guide thoroughly

to acquaint with SsangYong warranty system.

All time allowances in this guide are subject to change

at any time by SsangYong Motor Co., Ltd. based on

time studies by the company related to improved

methods, techniques or equipment or other advances

in the industry.

SECTION INDEX

A. GENERAL INFORMATION

1. ENGINE (Diesel)

ENGINE (Gasoline)

2. SUSPENSION

3. DRIVE LINE & AXLE

4. BRAKES

5. TRANSMISSION & TRANSFER CASE

6. STEERING

7. H.V.A.C (Heating, Ventilation &Air Conditioning)

8. RESTRAINTS

9. BODY & ACCESSORIES

10. PAINT

11. OTHERS

Page 2: KYRON + ACTYON_LTG(060303)-1
Page 3: KYRON + ACTYON_LTG(060303)-1

SECTION A

GENERAL INFORMATION

1. INTRODUCTION ...............................................................................5

2. HOW TO READ THIS MANUAL ......................................................6

3. HOW TO USE THIS MANUAL .........................................................9

4. PAINT REPAIR ...............................................................................10

5. DEFECT CODE ..............................................................................11

6. ABBREVIATION .............................................................................13

7. MAIN GROUP CODE......................................................................14

Page 4: KYRON + ACTYON_LTG(060303)-1
Page 5: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

5

1. INTRODUCTION

1-1. PAGE LAYOUT

This Labor Time Guide is designed for convenient and accurate use. In order to provide easy location of

operations, the layout has been structured in reading sequence with the corresponding illustration.

1-2. TYPES OF OPERATION

Major Operation

The Labor Operation Codes consist of seven digits. All operation numbers having “0” in the seven digit of

operation number are classified as “major” operations. A major operation time allowance is sufficient to

do the work described as a single operation.

Supplementary Operation (Adds)

All operation numbers having an alphabetical letter in the seventh digit of the operation number are

classified as “Supplementary” operations.

These operations cannot be used as single operation and must be used as additions to the major

operation.

1-3. TIME ALLOWANCES

The time allowances published in this guide have been determined by performing the operation a suffi-

cient number of times to establish an average time or to determine that a fair and equitable time has

been developed. Standard technician’s hand tools and dealer essential and available tools are used in

performing time studies. No power operated tools are used for time studies.

Procedures outlined in Service Manuals, other Service Publications and standard shop practices are

used as a guide when performing the work necessary to establish time allowances.

The time allowance includes the actual time required to perform the operation plus an additional allow-

ance to provide for operating variables.

Time allowances include time to remove and reinstall manufacturer optiones and accessories but do not

include time to remove and reinstall special or aftermarket equipment.

“Repair diagnosis” time is include in all published labor time operations when it is required to perform

the operation.

It is the responsibility of the dealer’s qualified service staff to assist technicians in “customer problem

analysis” and “symtom diagnosis”.

Page 6: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

6

2. HOW TO READ THIS MANUAL

1B - DIESEL ENGINE MECHANICAL

131

1

67

GASKET, CYLINDER HEAD - REPLACE

HEAD, CYLINDER - REPLACE

HEAD, CYLINDER - OVERHAUL

VALVE (ONE CYLINDER) - REPLACE

C - Valves (each additional)

43A3B

5.0

5.0

7.6

7.6

0.1

1

2

3

Operation DescriptionNO.

1312300

1312500

1312600

1312700

131270C

OperationCode

KYRON

D27DT D20DTREMARK

2

3.0

5.0

7.5

7.0

0.1

-

-

-

-

-

5

ACTYON

Page 7: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

7

Auxiliary Code

0

A

B.....

.....

.....

R

Description

Major operation

Supplementary operation

1) Section

Refer to the main group code in this chapter.

2) Illustration Number

The illustration number corresponds to the reference number on the illustration.

3) Operation Description

3A. Major Operation

The description corresponding to each operation number names the parts or component concerned, anddescribes what kind of operation is to be performed.

3B. Supplementary Operation

The description corresponding to each operation number names the parts or component concerned, anddescribes the additional operation for removing and reinstalling optional equipment such as power steering,air conditioning, etc., when major operation is performed on the vehicle with optional equipment.

4) Operation Code

The operation code consist of seven digits.

Main group code

Basic code

Auxiliary code

Main Group Code

The main group code consists of 3 digits which indicates the area of the vehicle where the repair wasperformed.

Basic Code

The basic code is a 3-digit serial number to each specific operation.

Auxiliary Code

The Auxiliary Code indicates the type of repairs as shown below :

Page 8: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

8

Major Operation

The numeric code “0” represents a major operation.

Supplementary Operation (ADD)

The numerical code “A”~“R” represents supplementary work of where time is required additionally for theincidental repair work of the parts or components related to the originally intended repair.

5) Operation Times

The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1hour and6 minutes).

Enter the operation time on the warranty claim in the same manner.

6) Model Code

This code represents the vehicle model.

Vehicle model

KYRONACTYON

7) Engine Type

This designation represents engine types.

D20DT : Direct Injection Diesel Engine

D27DT : Direct Injection Diesel Engine

G23D : M161 Gasoline Engine

G32D : M162 Gasoline Engine

Page 9: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

9

1312700 VALVE - REPLACE 7.0

131270C VALVES (EACH ADDITIONAL) 0.1

Operation Time Total 7.1

3. HOW TO USE THIS MANUAL

The operation time in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1hour and 6 minutes).

Enter the operation time on the warranty claim in this manner.

Example : (When supplementary work is performed in addition to the intended repair)

Model : KYRON & ACTYON

Major operation : Valve replacement

Supplementary Work : Valves (Each Additional)

Step 1 : First find ENGINE MECHANICAL – CYLINDER HEAD in MAIN GROUP INDEX and then the page(Engine 1C-15) for valve from among them.

Step 2 : On page Engine 1C-15, note the operation code for Valve. (Replacement)

Major Operation : VALVE - REPLACE 1312700 7.0

Supplementary Work : C - Valves (each additional) 131270C 0.1

Operation Code 1312700 & 131270C

Operation Time Total 7.0 + 0.1 = 7.1

3.0

5.0

7.5

7.0

0.1

1312300

1312500

1312600

1312700

131270C

GASKET, CYLINDER HEAD - REPLACE

HEAD, CYLINDER - REPLACE

HEAD, CYLINDER - OVERHAUL

VALVE (ONE CYLINDER) - REPLACE

C - Valves (each additional)

5.0

5.0

7.6

7.6

0.1

1

2

3

Operation DescriptionNO.Operation

Code

KYRON

D27DT D20DTREMARK

-

-

-

-

-

ACTYON

Page 10: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

10

Type

COLOR COAT

REFINISH

POLISHING

Description

PAINT EXPOSED SURFACES

Top-coat entire surface, including small dents that have been straightened(without filling in). Itsoperation should be used when correcting painting conditions such as thin paint, color mismatchor surface scratches not extending beyond the prime coat.

PAINT NEW PART

This operation involves sanding out a defect to expose a local area of bare metal, prime locally andthen apply color coat.

This applies to those paint repairs that require a repair to the prime coat before the color coat is applied.

POLISH THE SURFACES

4-4. HOW TO USE OPERATION CODE ON PARTIAL PAINTING

Use the operation code of the relevant part and enter “P” on PF column in Ssangyong Claim Report.

For example, in case of partial painting on hood in CHAIRMAN model, make out Ssangyong Claim Report as follows;

PF OPERATION CODE HOURP 9836080 3.1

4. PAINT REPAIR

4-1. INSTRUCTION

The time allowances herein for painting operations are established on the basis of techniques andmaterial required for quality work both in appearance and durability.

The basis for determining the paint time allowances is a “Paintable Surface”.

1. After dents have been removed from sheet metal parts and the parts welded they are stored totheir neutral shape.

2. Welding and soldering joints, overlapping seams formed by partial replacement and surfacessmoothed with fillers are ground down using P80-120 grain sandpaper.

3. And when the painter does not need to apply more than 3 coats of knife-edge putty to the sur-faces to be painted.

4-2. LABOR TIME

The time allowances for paint work consider all cases such as material preparation time, actual workingprocess, and material allowances, which are necessary for a proper and professional paint job. It shallbe noted material allowances are converted to hours and included in the operation time, also.

According to the character of paint process and size of area to be painted, the kinds and quantity of thematerial will be varied in the course of paint.

The material allowances consist of mixed paint and additional material such as masking tape, sandingpaper, cleaning solvent and etc. needed for the operation of each step.

INCLUDES ; moving the vehicle / mixing all materials / color blending / equipment cleaning / color spraysample / repainting time on clear coat / masking / sanding / cleaning / spraying / removingof the masking and polishing.

EXCLUDES; removal and reinstallation of body attaching parts.

4-3. REPAIR TYPE

Page 11: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

11

5. DEFECT CODE

5-1. NATURE CODE

Hard start, no start

Poor idle

Surge, hesitate, stumble

Engine noise, engine knoking noise

Choke malfunction

Engine stalled (general)

Excessive fuel consumption

Excessive oil consumption

Overheated

Shift shock

Engine run-on

Flooded, overflowing

Poor acceleration, uneven acceleration

Abnormal combustion

Lack of engine power

Percolation

Improper exhaust gas (black smoke, white smoke)

Backfire, afterfire

Vapor lock

Blocked

Shuddering, pulsation, vibration, chattering

Slippage (slipping)

Difficult engagement

Difficult disengagement

Abnormal shifts

Impossible shifts

Squeaking, squealing, abnormal(wind)noise

Dragging

Pulls

Stalled while driving

Stalled while idling

Stalled between shifts

Stalling during sudden braking

Fails to reach normal operating temperature

RPM too low

RPM too high

Jumping-out

Improper synchronizing

Oil diluted

Misfire

N41

N42

N43

N44

N45

N46

N47

N48

N49

N50

N51

N52

N53

N54

N55

N56

N57

N58

N59

N60

N61

N62

N63

N64

N65

N66

N67

N68

N69

N70

N71

N72

N73

N74

N75

N76

N77

N78

N80

N82

Sponge pedal

Unstable steering

Excessive shock

Poor release

Unusual tire wear

Misaligned or mismatched

Weak

Hard to turn

Impossible to turn

Vehicle bouncing

Deteriorated

Distorsion, rainbow, waving

Color mismatched

Defective chrom plate, defective painting

Rust, corrosion, perforation

Glazed

Loose, poor fit

Bubbles

Vehicle vibration

Excessive vibration

Dead battery

Inaccurate (meter, gauge, etc.)

Poor sound (horn, radio, etc.)

Overcharged, discharged

Electrical failures

Blown fuse

Warning light on

Intermittent operation

Pulls to left or right

Poor AM reception / interference

Oil leak, oil entering

Water leak, water entering

Leaks-other (air, fuel, refrigerant, vacuum)

Poor FM reception / interference

Radio / CD does not operate properly

Tape deck does not operate properly

Improper memory

Improper volume control

Head lamp improperly aimed

Loosening, failing-off, sagged

N01

N02

N03

N04

N05

N06

N07

N08

N09

N10

N11

N12

N13

N14

N15

N16

N17

N18

N19

N20

N21

N22

N23

N24

N25

N26

N27

N28

N29

N30

N31

N32

N33

N34

N35

N36

N37

N38

N39

N40

Page 12: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

12

N83

N84

N85

N86

N87

N88

N90

N91

N92

N93

N94

N95

N96

N97

N98

N99

Gas leak, gas entering

Improper opening and/or closing

Grabbed

Poor maneuverability

Insufficient brake

Brake judder

Color rainbow, color waving

Interference or hitting

Inoperative

High/low operating effort

Special policy

Glass cracked

Glass broken

Glass chipped

Glass scratched

Undefined

5-2. CAUSE CODE

Scored, scratched or chipped

Frozen (temperature)

Peeling, comimg-off

Rusty, corroded

Split, cut or torn

Broken or cracked

Porous, pin holes, cavity

Bent, kinky, twisted, distorted, wraped or wrinkled

Stripped - bolts, holes, nuts

Soiled

Weakened, loss of tension or resilience(spring, cushion, etc.)

Abnormal wear

Out of balance

Out of round

Loose or improper connection

Open circuit or short circuit

Burnt or burned - out

Grounded or shorted

R19

R20

R21

R22

R23

R24

R25

R26

R27

R28

R31

R32

R33

R34

R35

R36

R99

R01

R02

R03

R04

R05

R06

R07

R08

R09

R10

R11

R12

R13

R14

R15

R16

R17

R18

Improperly machined

Faulty casting

Improper clearance, back lash, free play

Lack of lubricants

Improper welding or soldering, welding or solder-ing omitted

Improper tightening, fit or assembly

Sticks, binds, seized

Foreign material, clogged

Improper sealing, sealer omitted or skipped

Improper adjustment

Incorrect part

Improperly installed

Improperly routed

Missing part

Flaw in material

Contaminants

Undefined

Page 13: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

13

6. ABBREVIATION

Air conditioning

Antilock brake differential

Adjust

Assembly

Auto transaxle

Color coat print

Check

Clean

Double overhead camshaft

Electrical control system

Exhaust gas recirculation

Idle air control

Instrument panel

Load conscious reducing valve

MAP

MAT

M/T

OH

PLA

POL

RAD

REF

REKES

RI

RP

TPS

T/C

T.O.D

A/C

ABD

ADJ

ASSY

A/T

CC

CHK

CLN

DOHC

ECS

EGR

IAC

I/P

L.C.R.V

Manifold absolute pressure

Manifold air temperature

Manual transaxle

Overhaul

Plating

Polishing

Radiator

Refinish paint

Remote keyless entry system

Reinstall

Replacement

Throttle position sensor

Transfer case

Torque on demand

5-3. PAINT CODE

Oversprayed, drip

Undersprayed, bare

Color mismatched

Low Gloss

Mottled, cloudy

Sags or runs

Pin hole

Peeling, scaling

Orange peel

Slow drying

Thin no paint

Wavy

Tape mark, touch mark

Chemical damage

Acid rain

P19

P20

P21

P22

P23

P24

P25

P26

P27

P30

P31

P32

P33

P34

P99

P01

P02

P03

P04

P05

P06

P07

P11

P12

P13

P14

P15

P16

P17

P18

Atmospheric fallout

Polishing mark, sanding mark

Touch up

Dust, dirt

Poor welding

Rust

Blistered

Chipped

Cracked

Surface scratch

Scab corrosion

Dent

Rust perforation

Discolored, faded

Undefined

Page 14: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

14

111 Engine Unit

113 Belt System

121 Engine Block

122 Crankshaft & Piston

123 Oil Pan & Pump

131 Cylinder Head

132 Cam Support & Shaft

133 Timing Cover & Chain Drive

136 Injeceion Pipe

138 Engine & Transaxle Mount

139 Vacuum System

141 Radiator

143 Cooling Fan

145 Radiator Hose & Pipe

148 Thermostat & Water Pump

154 Alternator Unit

156 Starter

157 Battery

158 Fuse & Relay

170 Fuel Filter & Line

171 Fuel Tank

172 Fuel Line

182 Accelerator Control

190 Common Rail System

191 Air Intake System

193 Intake Manifold

194 Exhaust Manifold

196 Exhaust Pipe Line

197 Turbo Charger Assembly

198 Sensors

(20p)

(35p)

(39p)

(43p)

(47p)

1B -DSL

1D -DSL

1E -DSL

1F -DSL

1G -DSL

Diesel Engine Mechanical

Engine Cooling

Engine Electrical

Engine Controls

Engine Intake & Exhaust

7. MAIN GROUP CODE

The first 3 digits of 7 digit code classify the units to be serviced into main groups.

SECTION SUB - SECTION MAIN GROUP CODE PAGE

1. DIESEL ENGINE

Page 15: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

15

1. GASOLINEENGINE

111 Engine Unit

113 Belt System

121 Engine Block

122 Crankshaft & Piston

123 Oil Pan & Pump

131 Cylinder Head

132 Cam Support & Shaft68

133 Timing Cover & Chain Drive

138 Engine & Transaxle Mount

139 Vacuum System

141 Radiator

143 Cooling Fan

144 Oil Cooler

145 Radiator Hose & Pipe

148 Thermostat & Water Pump

151 Ignition Cable

154 Alternator Unit

156 Starter

157 Battery

158 Fuse & Relay

171 Fuel Tank

172 Fuel Line & Oil Line

173 Canister & Fuel Vacuum

181 Fuel Injection

182 Accelerator Control

186 Emission Control

191 Air Intake System

193 Intake Manifold

194 Exhaust Manifold

196 Exhaust Pipe Line

(56p)

(72p)

(77p)

(82p)

(89p)

1C -GSL

1D -GSL

1E -GSL

1F -GSL

1G -GSL

Gasoline Engine

Mechanical

Engine Cooling

Engine Electrical

Engine Controls

Engine Intake & Exhaust

SECTION SUB - SECTION MAIN GROUP CODE PAGE

Page 16: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

16

213 Knuckle & Hub

214 Front Shock Absorber

215 Control Arm

231 Rear Axle & Stabilizer

232 Rear Shock Absorber

241 Wheels

321 Axle Shaft Parts

323 Propeller Shaft

425 Brake Pipe

428 Brake Pedal & Mount

431 Master Cylinder & Booster

445 Front Brake

456 Rear Brake

462 Rear Brake

478 Parking Brake

519 Auto Transmission Controls

541 BTR M74 I

542 BTR M74 II

543 BTR M74 III

544 BTR M74 IV

551 Auto Transmisson I

556 Auto Transmisson II

557 Auto Transmisson III

558 Auto Transmisson IV

559 Auto Transmisson V

561 Manual Transmission

563 Transmission Gear

566 Gear Shift Cover & Fork

569 Shift Control

581 Clutch Parts

582 Hydraulic Clutch

583 Clutch Pedal

591 Transfer Case (Part Time)

621 Power Steering Gear

623 Power Steering Pipe Line

641 Steering Wheel

643 Steering Column

647 Tie Rod

(94p)

(100p)

(106p)

(110p)

(114p)

(116p)

(117p)

(118p)

(120p)

(122p)

(127p)

(128p)

(134p)

(141p)

(147p)

(150p)

(155p)

(157p)

2C

2D

2E

3A

4A

4B

4D

4E

4F

4G

5A

5B

5D

5E

5F

5G

6A

6E

Front Suspension

Rear Suspension

Tires & Wheel

Drive Line & Axle

Hydraulic Brake

Master Cylinder & Booster

Front Brake

Rear Brake

Anti-Lock Brake System

Parking Brake

Auto Transmission Controls

BTR M74 Auto Transmission

Auto Transmission

Manual Transmission

Clutch

Transmission Case

Power Streering Gear

Streering Wheel & Column

2. SUSPENSION

3. DRIVE LINE &AXLE

4. BRAKES

5. TRANSMISSION& TRANSFERCASE

6. STEERING

SECTION SUB - SECTION MAIN GROUP CODE PAGE

Page 17: KYRON + ACTYON_LTG(060303)-1

GENERAL INFORMATION - A

17

711. Air Distribution

713. Evaporator

714. Blower

732. Compressor

733. Compressor Mount

734. A/C Hose & Pipe Line

735. A/C Control Switch & Sensor

812. Rear Seat Belt

822. Rear Seat Belt

832. Air Bag System

833. Immobilizer

911. Wiring Harness

916. Front Lamp

918. Rear Lamp

921. Washer System

923. Wiper System

925. Instrument Cluster

928. Electrical Parts

929. STICS & Auto Cruise

931. Instrument Panel

932. Switch

933. Instrument Parts

934. Console

935. Front Door Trim

936. Rear Door Trim

938. Pillar Trim

939. Floor Carpet & Panel

941. Front Seat

942. Rear Seat

946. Glass & Out Side Mirrors

951. Emblem & Lettering

952. Mud Guard

956. Front Bumper

957. Rear Bumper

(162p)

(166p)

(173p)

(175p)

(178p)

(180p)

(184p)

(186p)

(188p)

(192p)

(206p)

(208p)

(210p)

(212p)

7A

7B

8A

8B

9A

9B

9D

9E

9F

9G

9H

9L

9M

9O

H.V.A.C (Air Distribution)

H.V.A.C (Control)

Seat Belts

S.R.S (Supplemental InflatableRestraints)

Body Wiring System

Lighting System

Wiper & Washer System

Inst. Driver System

Audio & Anti-theft System

Interior Trim

Seats

Glass & Mirrors

Exterior Parts

Bumpers & Fascias

7. H.V.A. C(Heating,Ventilation &Air Conditioning)

8. RESTRAINTS

9. BODY &ACCESSORIES

SECTION SUB - SECTION MAIN GROUP CODE PAGE

Page 18: KYRON + ACTYON_LTG(060303)-1

A - GENERAL INFORMATION

18

961a Front Door & Lock

961b Front Window Lifter

961c Front Weatherstrip

963a Rear Door & Lock

963b Rear Window Lifter

963c Rear Weatherstrip

965 Electric Door Lock

966 Fuel Filler Lock

967 Trunk Lid Lock & Tailgate Lock

968 Car Lock

971 Headlining & Roof Panel

972a Sunshade & Inside Mirror

972b Sun Roof

973. Hood Panel

974 Front Panel

975 Fender Panel

976 Dash Panel & Cowl

977 Grille

978 Trunk Lid Panel & Spoiler

979 Side Trim

10a KYRON

10a ACTYON

11 Others

(214p)

(226p)

(230p)

(236p)

(240p)

(241p)

(245p)

9P

9Q

9R

9S

10A

11

Doors

Roof

Body Front End

Body Rear End

Paint Exterior

Others

9. BODY &ACCESSORIES

10. PAINT

11. OTHERS

SECTION SUB - SECTION MAIN GROUP CODE PAGE

Page 19: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE

1B. (DSL) DIESEL ENGINE MECHANICAL ........................................20111. ENGINE UNIT ................................................................................................. 20113. BELT SYSTEM ............................................................................................... 21121. ENGINE BLOCK ............................................................................................. 22122. CRANKSHAFT & PISTON ............................................................................. 24123. OIL PAN & PUMP .......................................................................................... 26131. CYLINDER HEAD ........................................................................................... 28132. CAM SUPPORT & SHAFT ............................................................................ 30133. TIMING COVER & CHAIN DRIVE ................................................................. 31136. INJECEION PIPE ............................................................................................ 32138. ENGINE & TRANSAXLE MOUNT .................................................................. 33139. VACUUM SYSTEM ........................................................................................ 34

1D. (DSL) ENGINE COOLING..............................................................35141. RADIATOR ...................................................................................................... 35143. COOLING FAN ............................................................................................... 36145. RADIATOR HOSE & PIPE ............................................................................. 37148. THERMOSTAT & WATER PUMP ................................................................. 38

1E. (DSL) ENGINE ELECTRICAL ........................................................39154. ALTERNATOR UNIT ....................................................................................... 39156. STARTER ........................................................................................................ 40157. BATTERY ........................................................................................................ 41158. FUSE & RELAY.............................................................................................. 42

1F. (DSL) ENGINE CONTROLS ..........................................................43170. FUEL FILTER & LINE .................................................................................... 43171. FUEL TANK .................................................................................................... 44172. FUEL LINE ...................................................................................................... 45182. ACCELERATOR CONTROL .......................................................................... 46

1G. (DSL) ENGINE INTAKE & EXHAUST ...........................................47190. COMMON RAIL SYSTEM .............................................................................. 47191. AIR INTAKE SYSTEM.................................................................................... 48193. INTAKE MANIFOLD ....................................................................................... 49194. EXHAUST MANIFOLD.................................................................................... 50196. EXHAUST PIPE LINE ..................................................................................... 51197. TURBO CHARGER ASSEMBLY ................................................................... 52198. SENSORS....................................................................................................... 53

SECTION 1

Page 20: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

20

DSLENGINE UNIT111

1B - DIESEL ENGINE MECHANICAL

1

2

ENGINE ASSEMBLY (M/T) - OVERHAUL

ENGINE ASSEMBLY (A/T) - OVERHAUL

ENGINE ASSEMBLY (M/T) - REPLACE

ENGINE ASSEMBLY (A/T) - REPLACE

Operation DescriptionNO.

1110100

1110300

1110800

1110900

OperationCode

KYRON

D20DTD27DTREMARK

D20DT

ACTYON

16.3

17.3

7.6

8.5

16.4

17.3

7.6

8.5

16.3

17.3

7.6

8.5

Page 21: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

21

1B1D

1E1F

1G

DSL113 BELT SYSTEM

1

2

3

4

5

6

7

8

BELT, PULLEY - REPLACE

PULLEY ASSEMBLY, IDLER - REPLACE

BELT TENSIONER, ABSORBER ASSEMBLY - REPLACE

PULLEY, COOLING FAN - REPLACE

SEALING, CRANKSHAFT (FRONT) - REPLACE

TENSIONER ASSY, BELT - REPLACE

TIMING CASE - REPLACE

TIMING GASKET - REPLACE

Operation DescriptionNO.

1132210

1132500

1132530

1132600

1132700

1132800

1132900

1132910

ACTYON

D20DTD27DTREMARK

OperationCode D20DT

KYRON

0.4

0.4

0.5

0.4

1.3

0.6

11.3

14.3

0.4

0.5

0.6

0.4

1.3

0.6

11.3

11.3

0.4

0.4

0.5

0.4

1.3

0.6

11.3

14.3

Page 22: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

22

DSLENGINE BLOCK121

Page 23: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

23

1B1D

1E1F

1G

1

2

3

4

5

6

7

8

1210200

1210300

1210700

121070A

1210800

1211100

1211200

1211110

1211300

1211310

OIL LEVEL INDICATOR AND/OR O-RING - REPLACE

TUBE, OIL LEVEL INDICATOR - REPLACE

PLUG, EXPANSION - REPLACE

A - Replace each additional

PLUG, CYLINDER BLOCK DRAIN - REPLACE

BLOCK, CYLINDER - REPLACE

BALL, PLUG OIL CHANNEL - REPLACE

SEMI BLOCK (SHORT BLOCK), CYLINDER - REPLACE

SEALING, CRANKSHAFT (REAR) - REPLACE M/T

A/T

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.2

0.4

4.1

0.1

0.3

15.4

1.0

16.8

3.1

3.5

0.2

0.4

4.1

0.1

0.3

15.4

1.0

16.8

3.1

3.5

0.2

0.4

4.1

0.1

0.3

15.2

1.0

16.8

3.1

3.6

Page 24: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

24

DSLCRANKSHAFT & PISTON122

Page 25: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

25

1B1D

1E1F

1G

BEARING, CRANKSHAFT MAIN (ONE) - REPLACE

A - Replace each additional

BEARING, CRANKSHAFT THRUST - REPLACE

BEARING, GROOVED BALL (M/T) - REPLACE

FLYWHEEL (M/T) - REPLACE

A - Flywheel ring gear (M/T)

FLYWHEEL (A/T) - REPLACE

A - Flywheel ring gear (AT)

RING, PISTION – REPLACE

A - Replace each additional

PIN, PISTON - REPLACE

A - Replace each additional

SNAP RING, PISTON - REPLACE

PISTON - REPLACE

A - Replace each additional

BUSHING, CONNECTING ROD - REPLACE

A - Replace each additional

CONNECTING, ROD - REPLACE

A - Replace each additional

BEARING, CONNECTING ROD - REPLACE

A - Replace each additional

CRANKSHAFT - REPLACE A/T

M/T

1220600

122060A

1220610

1220900

1221700

122170A

1221900

122190A

1222200

122220A

1222300

122230A

1222400

1222500

122250A

1222600

122260A

1222700

122270A

1222800

122280A

1222900

1222910

1

2

3

4

5

6

7

8

9

10

11

12

13

Operation DescriptionNO.Operation

CodeREMARKNO.

OperationCode

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

14.8

0.1

14.8

5.4

3.3

3.8

6.8

0.8

14.7

0.2

14.6

0.2

14.6

15.0

0.1

14.6

0.2

15.0

0.1

14.6

0.1

14.4

13.8

15.4

0.1

15.4

5.4

3.5

3.7

6.6

0.8

15.0

0.2

15.0

0.2

14.6

14.6

0.1

14.6

0.2

14.6

0.1

14.6

0.1

15.4

14.5

15.4

0.1

15.4

5.4

3.5

3.7

6.6

0.8

15.0

0.2

15.0

0.2

14.6

14.6

0.1

14.6

0.2

14.6

0.1

14.6

0.1

15.4

14.5

Page 26: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

26

DSLOIL PAN & PUMP123

Page 27: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

27

1B1D

1E1F

1G

1231300

1231510

1231700

1232600

1232670

1232680

1232690

1234100

1235000

1235100

1

2

3

4

5

6

7

8

9*

10*

PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE

PAN AND/OR GASKET, OIL (A/T) - REPLACE

PUMP, ENGINE OIL - REPLACE

SPROCKET, OIL PUMP - REPLACE

CHAIN, OIL PUMP ROLLER - REPLACE

OIL JET - REPLACE

TENSIONER, OIL PUMP ROLLER CHAIN - REPLACE

PLATE, OIL BUFFLE - REPLACE

GUIDE TUBE, OIL LEVEL - REPLACE

GAUGE, OIL LEVEL - REPLACE

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.3

4.2

2.4

2.9

6.5

2.1

11.8

-

0.4

0.2

0.3

4.2

3.5

3.8

6.5

3.6

11.8

3.8

0.4

0.2

0.3

2.1

2.4

2.9

6.5

2.1

11.8

-

0.4

0.2

Page 28: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

28

DSLCYLINDER HEAD131

Page 29: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

29

1B1D

1E1F

1G

Operation DescriptionNO.Operation

CodeREMARK

ACTYON

D20DTD27DT

1

2

3

4

5

6

7

8

9

10

11

12

13

GASKET, CYLINDER HEAD - REPLACE

GASKET, CYLINDER HEAD - OVERHAUL

HEAD, CYLINDER - REPLACE

HEAD, CYLINDER - OVERHAUL

VALVE (ONE CYLINDER) - REPLACE

A - Valves (each additional)

VALVE GUIDE - REPLACE

A - Replace each additional

SPRING CAP AND/OR SEAL, VALVE - REPLACE

A - Replace each additional

BOLT, CYLINDER HEAD (ONE) - REPLACE

A - Replace each additional

CAP, CAMSHAFT BEARING - REPLACE

A - Replace each additional

FINGER FOLLOWER

ADJUSTER, CAMSHAFT - REPLACE

VALVE COTTER - REPLACE

A - Replace each additional

RETAINER, VALVE SPRING - REPLACE

A - Replace each additional

SEAL, VALVE GUIDE - REPLACE

A - Replace each additional

BOLT WASHER, CYLINDER HEAD - REPLACE

1312300

1312310

1312500

1312600

1312700

131270A

1312810

131281A

1312900

131290A

1313800

131380A

1315600

131560A

1314000

1314100

1314200

131420A

1314300

131430A

1314400

131440A

1314500

D20DT

KYRON

5.3

7.0

5.3

7.8

5.2

0.1

3.0

0.1

2.8

0.1

1.3

0.1

2.6

0.1

3.2

2.2

2.8

0.1

2.8

0.1

6.7

0.3

-

4.9

7.0

4.9

7.9

5.7

0.1

2.8

0.1

3.0

0.1

1.2

0.1

2.6

0.1

3.2

3.3

3.0

0.1

3.0

0.1

6.3

0.3

1.2

5.3

7.0

5.3

7.8

5.2

0.1

3.0

0.1

2.8

0.1

1.3

0.1

2.6

0.1

3.2

2.2

2.8

0.1

2.8

0.1

6.7

0.3

-

Page 30: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

30

DSL

1

2

3

4

5

6

7

8

COVER, CYLINDER HEAD - REPLACE

CAMSHAFT - REPLACE

A - Replace each additional

CAP AND/OR GASKET, OIL FILLER - REPLACE

OIL, SEPERATOR ASSY - REPLACE

BRACKET, OIL SEPERATOR - REPLACE

HOSE, BLOW BY INLET - REPLACE

HOSE, BLOW BY INLET - RECLAMPING

HOSE, BLOW BY OUTLET - REPLACE

HOSE, OIL RETURN - REPLACE

1322110

1322300

132230A

1322700

1322800

1322900

1323000

1323001

1323100

1323200

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

CAM SUPPORT & SHAFT132

D20DT

KYRON

1.3

2.9

2.4

0.2

0.2

0.2

0.2

0.2

0.2

0.2

1.6

2.9

2.4

0.2

0.2

0.2

0.2

0.2

0.2

0.2

1.3

2.9

2.4

0.2

0.2

0.2

0.2

0.2

0.2

0.2

Page 31: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

31

1B1D

1E1F

1G

DSLTIMING COVER & CHAIN DRIVE133

BELT OR CHAIN, TIMING - REPLACE

SPROCKET, CAMSHAFT TIMING - REPLACE

A - Replace each additional

CHAIN TIGHTENER - REPLACE

RAIL ASSY, SLIDING - REPLACE

RAIL ASSY, GUIDE UPER - REPLACE

1332500

1333300

133330A

1337300

1332600

1332700

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

1

2

3

4

5

D20DT

KYRON

6.5

2.4

0.3

0.4

5.4

2.4

6.5

2.4

0.3

0.4

5.4

2.4

6.5

2.4

0.3

0.4

5.4

2.4

Page 32: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

32

DSLINJECEION PIPE136

PLUG, PRE - HEATING - REPLACE

A - Replace each additional

1365800

136580A

1

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.1

0.1

0.1

0.1

0.1

0.1

Page 33: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

33

1B1D

1E1F

1G

DSLENGINE & TRANSAXLE MOUNT

1

2

3

4

5

MOUNT, ENGINE (FRONT) - REPLACE One

Two

BRACKET, ENGINE MOUNT (FRONT) - REPLACE One

Two

STOPPER, ENGINE MOUNTING - REPLACE

CROSS MEMBER, REAR ENGINE MOUNTING - REPLACE

CROSS MEMBER, FRONT AXLE MOUNTING - REPLACE

1380200

1380210

1380400

1380410

1380420

1380440

1380600

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.5

1.0

0.6

0.9

0.3

0.3

0.3

0.5

1.0

0.6

0.9

0.3

0.3

0.3

0.5

1.0

0.6

0.9

0.3

0.3

0.3

138

Page 34: KYRON + ACTYON_LTG(060303)-1

1B (DSL) - DIESEL ENGINE MECHANICAL

34

DSLVACUUM SYSTEM139

1390100

1390110

1

2

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

VACUUM PUMP ASSEMBLY - REPLACE

O-RING, VACUUM PUMP ASS’Y

D20DT

KYRON

1.9

0.7

1.9

0.7

1.9

0.7

Page 35: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

35

1B1D

1E1F

1G

DSLRADIATOR141

1D - ENGINE COOLING

1

2

3

4

COOLANT - REPLACE

COCK OR PLUG, RADIATOR DRAIN - REPLACE

RADIATOR ASSEMBLY - REPLACE

COOLING SYSTEM - FLUSH

1410100

1410300

1410500

1411700

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.5

1.0

1.3

0.5

0.5

1.0

1.3

0.5

0.5

1.0

1.3

0.5

Page 36: KYRON + ACTYON_LTG(060303)-1

1D (DSL) - ENGINE COOLING

36

DSLCOOLING FAN143

1

2

3

4

5

SHROUD, RADIATOR FAN - REPLACE

COOLING FAN-SHROUD

BLADE, FAN - REPLACE

CLUTCH, FAN - REPLACE

COOLING FAN PULLEY

1430700

1431710

1431600

1431700

1431730

Operation DescriptionNO.Operation

Code

KYRON

D20DTD20DTREMARK

ACTYON

D27DT

0.5

0.3

0.5

0.5

0.7

0.5

0.3

0.5

0.5

0.7

0.5

0.3

0.5

0.5

0.7

Page 37: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

37

1B1D

1E1F

1G

DSLRADIATOR HOSE & PIPE145

1

2

3

4

5

6

RESERVOIR, RADIATOR COOLANT - REPLACE

HOSE, MAKE UP - REPLACE

HOSE, UPPER ENGINE COOLANT - REPLACE

HOSE, LOWER ENGINE COOLANT - REPLACE

HOSE AND/OR TUBE, DEAERATION - REPLACE

A - Replace each additional

CAP ASSY - RESERVOIR TANK - REPLACE

1450400

1450600

1450700

1450800

1451400

145140A

1450420

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.3

0.3

0.3

0.5

0.3

0.1

0.2

0.3

0.3

0.3

0.5

0.3

0.1

0.2

0.3

0.3

0.3

0.5

0.3

0.1

0.2

Page 38: KYRON + ACTYON_LTG(060303)-1

1D (DSL) - ENGINE COOLING

38

DSLTHERMOSTAT & WATER PUMP148

1

2

3

4

5

6

THERMOSTAT AND/OR GASKET DIESEL - REPLACE

PORT AND/OR GASKET, COOLANT OUTLET - REPLACE

WATER PUMP AND/OR GASKET - REPLACE

WATER PUMP ASS’Y- REPLACE

WATER PUMP ASS’Y- REPLACE

PULLEY, WATER PUMP - REPLACE

1480400

1480600

1481200

1481250

1481260

1481270

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.8

1.2

1.5

1.5

1.5

0.4

0.8

1.4

1.9

1.5

1.5

0.4

0.8

1.2

1.5

1.5

1.5

0.4

Page 39: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

39

1B1D

1E1F

1G

DSLALTERNATOR UNIT154

1E - ENGINE ELECTRICAL

PULLEY AND/OR FAN, ALTERNATOR - REPLACE

ALTERNATOR ASSEMBLY - REPLACE

ALTERNATOR ASSEMBLY - OVERHAUL

BRACKET, ALTERNATOR MOUNTING - REPLACE

1540100

1541700

1541900

1544100

1

2

3

4

Operation DescriptionNO.Operation

Code

KYRON

D20DTD20DTREMARK

D27DT

ACTYON

0.6

0.7

1.5

0.9

0.8

0.7

1.5

0.9

0.6

0.7

1.5

0.9

Page 40: KYRON + ACTYON_LTG(060303)-1

1E (DSL) - ENGINE ELECTRICAL

40

DSLSTARTER156

1

2

MOTOR ASSEMBLY, STARTER DIESEL - REPLACE

SWITCH, STARTER MOTOR MAGNETIC - REPLACE

1561000

1562700

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

KYRON

D20DT

0.5

0.8

0.5

0.8

0.5

0.8

Page 41: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

41

1B1D

1E1F

1G

DSLBATTERY157

1

2

3

4

BATTERY - REPLACE

RETAINER AND/OR BOLTS, BATTERY - REPLACE

CARRIER, BATTERY - REPLACE

CABLE - BATTERY GROUND

1570300

1570500

1571100

1571200

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.2

0.2

0.3

0.3

0.2

0.2

0.3

0.3

0.2

0.2

0.3

0.3

Page 42: KYRON + ACTYON_LTG(060303)-1

1E (DSL) - ENGINE ELECTRICAL

42

DSLFUSE & RELAY158

1

2

3

4

5

6

RELAY - REPLACE

Fog Lamp

Enable (ABS)

Window Wiper Motor

Head Lamp

Other Relays

Turn Signal

Preheating Time

COVER, FUSE BOX - REPLACE

BOX, REALY & FUSE - REPLACE

FUSE - REPLACE

CONTROL UNIT - P/WINDOW AUTO DOWN - REPLACE

BOX, IP FUSE - REPLACE

1580200

1580500

1580900

1581100

1581500

1582100

1582200

1582300

1582700

1583700

1584700

1585700

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.1

0.4

0.2

0.5

0.5

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.1

0.4

0.2

0.5

0.5

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.1

0.4

0.2

0.5

0.5

Page 43: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

43

1B1D

1E1F

1G

DSL170 FUEL FILTER & LINE

1

2

3

4

5

6

7

8

9

10

FILTER ASSY, FUEL - REPLACE

BRACKET, FUEL FILTER - REPLACE

PUMP, FUEL PRIMING - REPLACE

HOSE, PRIMING PUMP TO FILTER - REPLACE

HOSE, FUEL RETURN - REPLACE

HOSE, SUPPLY PIPE TO PRIMING PUMP - REPLACE

TUBE ASSY, FUEL FILTER TO PUMP - REPLACE

TUBE ASSY, FUEL FILTER - REPLACE

WATER SEPERATOR - REPLACE

WATER SEPERATOR - HOSE

1700100

1700200

1700300

1700400

1700500

1700600

1700700

1700800

1700910

1700920

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

1F - ENGINE CONTROLS

D20DT

KYRON

0.3

0.3

0.2

0.2

0.3

0.5

0.3

0.3

0.2

0.1

0.3

0.3

0.2

0.2

0.3

0.5

0.3

0.3

0.2

0.1

0.3

0.3

0.2

0.2

0.3

0.5

0.3

0.3

0.2

0.1

Page 44: KYRON + ACTYON_LTG(060303)-1

1F (DSL) - ENGINE CONTROLS

44

DSLFUEL TANK171

1

2

3

4

5*

6

7

8

9

AIR BLEEDING, FUEL

NECK, FUEL TANK FILLER - REPLACE

TANK, FUEL - REPLACE

TANK, FUEL - OVERHAUL

UNIT - GASKET

HOSE, AIR BLEEDER - REPLACE

PROTECTOR, FUEL TANK - REPLACE

HOSE, AIR VENT - REPLACE

CAP, FUEL TANK - REPLACE

GROMMET - FUEL FILLER - REPLACE

1710400

1710500

1710900

1710910

1711700

1712000

1712200

1713500

1713600

1713610

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.6

0.6

1.1

1.5

0.4

0.6

0.3

0.6

0.1

0.2

0.6

0.6

1.1

1.5

0.4

0.6

0.3

0.6

0.1

0.2

0.6

0.6

1.1

1.5

0.4

0.6

0.3

0.6

0.1

0.2

Page 45: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

45

1B1D

1E1F

1G

DSLFUEL LINE172

1

2

3

4

5

6

7

8

9

HOUSING, OIL FILTER - REPLACE

COVER, OIL FILTER HOUSING - REPLACE

FILTER AND/OR O-RING, OIL - REPLACE

GASKET, OIL FILTER HOUSING - REPLACE

PIPE, FUEL RETURN - REPLACE

PIPE, FUEL SUPPLY - REPLACE

COOLER ASSY, OIL - REPLACE

COOLER GASKET, OIL - REPLACE

HOSE, COIL COOLER - REPLACE

1720200

1720230

1720240

1720250

1720700

1720760

1720950

1720960

1720970

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

1.0

0.3

0.3

1.1

0.7

0.7

1.0

0.8

0.6

1.1

0.3

0.3

1.1

0.7

0.7

0.9

0.8

0.5

1.0

0.3

0.3

1.1

0.7

0.7

1.0

0.8

0.6

Page 46: KYRON + ACTYON_LTG(060303)-1

1F (DSL) - ENGINE CONTROLS

46

DSLACCELERATOR CONTROL182

18206001

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

MODULE, ACCELERATOR PEDAL - REPLACE

D20DT

KYRON

0.3 0.3 0.3

Page 47: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

47

1B1D

1E1F

1G

DSLCOMMON RAIL SYSTEM190

1G - ENGINE INTAKE & EXHAUST

1

2

3

4

5

6

7

8

9

10

11

12

13

PIPE ASSY, FUEL - REPLACE

A - Replace each additional

PIPE, HIGH PRESSURE PUMP - REPLACE

HOSE, FUEL RETURN - REPLACE

PUMP ASSY, FUEL - REPLACE

BRACKET, FUEL PUMP - REPLACE

HOLDER, INJECTOR - REPLACE

A - Replace each additional

SPROCKET, PUMP - REPLACE

BEARING HOUSING, PUMP - REPLACE

BEARING SHAFT, PUMP - REPLACE

GASKET, FUEL PUMP - REPLACE

HOUSING BOLT - REPLACE

COMMON RAIL - REPLACE

INJECTOR ASSY, FUEL - REPLACE

A - Replace each additional

1900100

190010A

1900200

1900300

1900400

1900500

1900600

190060A

1900410

1900420

1900430

1900440

1900450

1900000

1900150

190015A

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.2

0.1

0.2

0.3

2.8

0.8

0.3

0.2

1.5

1.5

-

2.8

3.0

0.5

0.1

0.2

0.2

0.1

0.2

0.3

3.8

0.7

0.3

0.2

2.5

2.7

2.9

3.8

3.0

0.5

0.1

0.2

0.2

0.1

0.2

0.3

2.8

0.8

0.3

0.2

1.5

1.5

-

2.8

3.0

0.4

0.1

0.2

Page 48: KYRON + ACTYON_LTG(060303)-1

1G (DSL) - ENGINE INTAKE & EXHAUST

48

DSLAIR INTAKE SYSTEM191

1

2

3

4

5

6

7

AIR CLEANER - REPLACE

FILTER, AIR CLEANER - REPLACE

METER, AIR METER - REPLACE

SNORKEL ASSY - REPLACE

HOUSING, AIR CLEANER UPR - REPLACE

HOUSING, AIR CLEANER LWR - REPLACE

HOSE, TURBO CHARGER- REPLACE

1910300

1910500

1911320

1910400

1910410

1910420

1910430

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

0.4

0.2

0.2

0.2

0.2

0.3

0.2

0.4

0.2

0.2

0.2

0.2

0.3

0.2

0.4

0.2

0.2

0.2

0.2

0.3

0.2

Page 49: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

49

1B1D

1E1F

1G

DSLINTAKE MANIFOLD193

Operation Description

1

2

3

4

5

6

7

8

9

10

11

MANIFOLD, INTAKE DIESEL - REPLACE

VALVE AND/OR GASKET, EGR - REPLACE

ELECTRIC SWITCH VALVE - REPLACE

HOSE, EGR VACUUM OUTLET - REPLACE

GASKET, INTAKE MANIFOLD - REPLACE

BRACKET, INTAKE MANIFOLD - REPLACE

PIPE ASSY, EGR - REPLACE

GASKET, EGR PIPE - REPLACE

PIPE ASSY, EGR (LH) - REPLACE

PIPE ASSY, EGR (RH) - REPLACE

MODULATOR, VACUUM M - REPLACE

1930250

1930700

1930710

1930730

1933100

1935000

1935100

1935200

1935300

1935400

1935500

NO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

1.7

0.4

0.5

0.2

1.7

0.5

0.4

0.3

0.3

0.3

0.3

2.0

0.3

0.5

0.2

2.0

0.5

0.4

0.3

0.3

0.3

0.3

1.7

0.4

0.5

0.2

1.7

0.5

0.4

0.3

0.3

0.3

0.3

Page 50: KYRON + ACTYON_LTG(060303)-1

1G (DSL) - ENGINE INTAKE & EXHAUST

50

DSLEXHAUST MANIFOLD194

1

2

MANIFOLD AND/OR GASKET, EXHAUST - REPLACE

NUT, EXHAUST MANIFOLD - REPLACE

1940400

1940900

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

D20DT

KYRON

1.1

0.3

1.1

0.3

1.1

0.3

Page 51: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

51

1B1D

1E1F

1G

DSLEXHAUST PIPE LINE196

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

1

2

3

4

5

6

7

8

9

HANGER AND/OR CLAMP, EXHAUST SYSTEM-REPLACE

PIPE, FRONT EXHAUST - REPLACE

HEAT SHIELD, CENTER MUFFLER - REPLACE

MUFFLER - REPLACE

EXHAUST SYSTEM (COMPLETE) - REPLACE

PIPE, TAIL - REPLACE

CONVERTER - REPLACE

EXHAUST PIPE GASKET - REPLACE

SHIELD - FRONT HEAT, REPLACE

1960300

1960900

1961420

1962100

1962500

1962600

1961500

1961510

1961520

KYRON

D20DT

0.2

-

0.4

0.5

1.2

0.3

0.3

0.2

0.4

0.2

0.2

0.4

0.5

1.2

0.3

0.3

0.2

0.4

0.2

-

0.4

0.5

1.2

0.3

0.3

0.2

0.4

Page 52: KYRON + ACTYON_LTG(060303)-1

1G (DSL) - ENGINE INTAKE & EXHAUST

52

DSLTURBO CHARGER ASSEMBLY197

1

2

3

4

5

6

TURBO CHARGER ASSEMBLY - REPLACE

TUBE-OIL SUPPLY - REPLACE

TUSE-OIL RETURN - REPLACE

INTERCOOLER - TURBO

HOSE AND DUCT 1, 2 - REPLACE

A - Replace each additional

GASKET, OIL RETURN - REPLACE

1970100

1970110

1970120

1970510

1970520

197052A

1970130

Operation DescriptionNO.Operation

Code

ACTYON

D27DT D20DTREMARK

D20DT

KYRON

0.9

0.5

0.7

1.0

0.2

0.2

0.3

0.8

0.5

0.7

0.9

0.2

0.2

0.3

0.9

0.5

0.7

1.0

0.2

0.2

0.3

Page 53: KYRON + ACTYON_LTG(060303)-1

DIESEL ENGINE MECHANICAL - 1D

53

1B1D

1E1F

1G

DSLSENSORS198

1

2

3

4

5

6

SENSOR, CRANKSHAFT POSITION - REPLACE

SENSOR ASSY - CAM POSITION

SENSOR, KNOCK - REPLACE

A - Replace each additional

SENSOR ASSY - COOLANT

A - Replace each additional

SENSOR, 8P - REPLACE

ECU, ENGINE - REPLACE

1980100

1980200

1980300

198030A

1980400

198050A

1980700

1980600

Operation DescriptionNO.Operation

Code

ACTYON

D20DTD27DTREMARK

KYRON

D20DT

0.4

0.3

0.7

0.1

0.9

0.2

0.3

0.6

0.4

0.3

0.7

0.1

0.9

0.2

0.3

0.6

0.4

0.3

0.7

0.1

0.9

0.2

0.3

0.6

Page 54: KYRON + ACTYON_LTG(060303)-1

MEMO

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

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...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

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Page 55: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE

1C (GSL) - GASOLINE ENGINE MECHANICAL .................................... 56111. ENGINE UNIT .................................................................................................. 56113. BELT SYSTEM ................................................................................................ 57121. ENGINE BLOCK .............................................................................................. 58122. CRANKSHAFT & PISTON ............................................................................... 60123. OIL PAN & PUMP ........................................................................................... 62131. CYLINDER HEAD ............................................................................................ 64132. CAM SUPPORT & SHAFT .............................................................................. 66133. TIMING COVER & CHAIN DRIVE ................................................................... 68138. ENGINE & TRANSAXLE MOUNT .................................................................... 70139. VACUUM SYSTEM ......................................................................................... 71

1D (GSL) - ENGINE COOLING .............................................................. 72141. RADIATOR ....................................................................................................... 72143. COOLING FAN ................................................................................................ 73144. OIL COOLER ................................................................................................... 74145. RADIATOR HOSE & PIPE .............................................................................. 75148. THERMOSTAT & WATER PUMP ................................................................... 76

1E (GSL) - ENGINE ELECTRICAL ......................................................... 77151. IGNITION CABLE ............................................................................................. 77154. ALTERNATOR UNIT ........................................................................................ 78156. STARTER ........................................................................................................ 79157. BATTERY ........................................................................................................ 80158. FUSE & RELAY .............................................................................................. 81

1F (GSL) - ENGINE CONTROLS ........................................................... 82171. FUEL TANK ..................................................................................................... 82172. FUEL LINE & OIL LINE ................................................................................... 83173. CANISTER & FUEL VACUUM ........................................................................ 84181. FUEL INJECTION ............................................................................................ 85182. ACCELERATOR CONTROL ............................................................................ 86186. EMISSION CONTROL ..................................................................................... 88

1G (GSL) - ENGINE INTAKE & EXHAUST ............................................ 89191. AIR INTAKE SYSTEM ..................................................................................... 89193. INTAKE MANIFOLD ........................................................................................ 90194. EXHAUST MANIFOLD ..................................................................................... 91196. EXHAUST PIPE LINE ...................................................................................... 92

SECTION 1

Page 56: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

56

GSLENGINE UNIT111

1C (GSL) - GASOLINE ENGINE MECHANICAL

1

2

ENGINE ASSEMBLY (M/T) - OVERHAUL

ENGINE ASSEMBLY (A/T) - OVERHAUL

ENGINE ASSEMBLY (M/T) - REPLACE

ENGINE ASSEMBLY (A/T) - REPLACE

Operation DescriptionNO.

1110100

1110300

1110800

1110900

OperationCode

REMARKKYRON

G23DG32D

ACTYON

26.0

26.0

8.0

8.7

24.2

23.2

7.7

8.7

Page 57: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

57

1B1D

1E1F

1G

GSL113 BELT SYSTEM

1

2

3

4

POLY-BELT - REPLACE

PULLEY, AUTO TENSIONER - REPLACE

TIGHTENER ASSEMBLY, BELT - REPLACE

SHOCK ABSORBER, TENSIONER - REPLACE

Operation DescriptionNO.

1132210

1132410

1132550

1132560

REMARKOperation

Code

KYRON

G23DG32D

ACTYON

0.5

0.5

1.2

-

0.5

0.5

1.2

0.5

Page 58: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

58

GSLENGINE BLOCK121

Page 59: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

59

1B1D

1E1F

1G

1

2

3

4

5

6

7

1210200

1210300

1210700

121070A

1210800

1210900

1211100

1211110

OIL LEVEL INDICATOR AND/OR O-RING - REPLACE

TUBE, OIL LEVEL INDICATOR - REPLACE

PLUG, EXPANSION - REPLACE

A - Replace each additional

PLUG, CYLINDER BLOCK DRAIN - REPLACE

PLUG, OIL GALLERY - REPLACE

BLOCK, CYLINDER - REPLACE

SEMI BLOCK (SHORT BLOCK), CYLINDER - REPLACE

Operation DescriptionNO.Operation

Code REMARKKYRON

G23DG32D

ACTYON

0.2

0.3

4.4

0.1

0.5

-

26.0

21.5

0.2

0.3

4.1

0.1

0.5

-

23.2

19.2

Page 60: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

60

GSLCRANKSHAFT & PISTON122

Page 61: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

61

1B1D

1E1F

1G

SEAL (S), CRANKSHAFT REAR MAIN (A/T) - REPLACE

SEAL (S), CRANKSHAFT REAR MAIN (M/T) - REPLACE

COVER, CRANKSHAFT SEALING (A/T) - REPLACE

COVER, CRANKSHAFT SEALING (M/T) - REPLACE

DAMPER, CRANKSHAFT VIBRATION - REPLACE

BEARING, CRANKSHAFT MAIN (ONE) - REPLACE

A - Replace each additional

BEARING, CRANKSHAFT THRUST - REPLACE

BEARING, CONNECTING ROD (ONE) - REPLACE

A - Replace each additional

CRANKSHAFT (M/T) - REPLACE

D - Replace one piston ring

E - Replace all piston rings

F - Replace one connecting rod

G - Replace all connecting rods

CRANKSHAFT (A/T) - REPLACE

D - Replace one piston ring

E - Replace all piston rings

F - Replace one connecting rod

G - Replace all connecting rods

PISTON, ROD AND/OR RINGS (ONE) - REPLACE

A - Replace each additional

BUSHING, CONNECTING ROD - REPLACE

A - Replace each additional

FLYWHEEL (M/T) - REPLACE

A - Flywheel ring gear

FLYWHEEL (A/T) - REPLACE

A - Flywheel ring gear

BEARING, PILOT - REPLACE

BEARING, GROOVED BALL(M/T)-REPLACE

1220200

1220400

1220410

1220420

1220500

1220600

122060A

1220610

1220800

122080A

1221100

122110D

122110E

122110F

122110G

1221200

122120D

122120E

122120F

122120G

1221500

122150A

1221540

122154A

1221700

122170A

1221900

122190A

1222100

1222110

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Operation DescriptionNO.Operation

CodeREMARKOperation DescriptionNO.

OperationCode

REMARKKYRON

G23DG32D

ACTYON

6.3

5.4

6.3

5.4

2.8

9.7

0.1

10.3

10.8

0.1

13.8

0.4

1.2

0.5

1.2

18.0

0.4

1.2

0.6

1.2

19.5

0.1

19.5

0.1

5.3

0.8

6.3

0.8

5.6

5.6

6.3

5.4

6.3

5.4

2.8

9.7

0.1

10.3

10.8

0.1

13.8

0.4

1.2

0.5

1.2

17.0

0.4

1.2

0.6

1.2

19.5

0.1

19.5

0.1

5.3

0.8

6.3

0.8

5.6

5.6

Page 62: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

62

GSLOIL PAN & PUMP123

Page 63: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

63

1B1D

1E1F

1G

1231300

1231500

1231510

1231600

1231700

1231710

1231900

1232300

1232600

1232610

1232670

1232690

1232700

1232800

1234100

1

2

3

4

5

6

7

8

9

10

11

12

13

PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE

PAN AND/OR GASKET, OIL - REPLACE

PAN AND/OR GASKET, OIL (AUTO) - REPLACE

SWITCH AND/OR GASKET, OIL LEVEL - REPLACE

PUMP, ENGINE OIL - REPLACE

PUMP, ENGINE OIL - OVERHAUL

SWITCH, OIL PRESSURE GAUGE - REPLACE

OIL SEAL, CRANKSHAFT (FRONT) - REPLACE

SPROCKET, OIL PUMP - REPLACE

STRAINER ASSEMBLY, OIL - REPLACE

CHAIN, OIL PUMP ROLLER - REPLACE

TENSIONER, OIL PUMP ROLLER CHAIN - REPLACE

VALVE, OIL PRESSURE RELIEF - REPLACE

SHAFT, OIL PUMP DRIVE - REPLACE

PLATE, OIL BAFFLE - REPLACE

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.2

5.0

5.0

0.3

4.0

5.7

0.4

3.9

5.6

5.6

5.6

5.6

5.6

5.6

5.6

0.2

5.0

5.0

0.3

4.0

5.7

0.4

3.7

5.6

5.6

5.6

5.6

5.6

5.6

5.6

Page 64: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

64

GSLCYLINDER HEAD131

Page 65: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

65

1B1D

1E1F

1G

Operation DescriptionNO.Operation

CodeREMARKOperation DescriptionNO.

OperationCode

REMARK

1

2

3

4

5

6

7

8

9

10

GASKET, CYLINDER HEAD - REPLACE

HEAD, CYLINDER - REPLACE

HEAD, CYLINDER - OVERHAUL

VALVE (ONE CYLINDER) - REPLACE

A - Valves (each additional)

GUIDE, VALVE - REPLACE

A - Valves (each additional)

SEAL, VALVE GUIDE - REPLACE

A - Replace each additional

SPRING CAP AND/OR SEAL, VALVE - REPLACE

LIFTER, VALVE - REPLACE

A - Valves (each additional)

PLUG, CYLINDER HEAD CORE HOLE - REPLACE

A - Replace each additional

BOLT, CYLINDER HEAD (ONE) - REPLACE

A - Replace each additional

CAP, CAMSHAFT BEARING - REPLACE

1312300

1312500

1312600

1312700

131270A

1312800

131280A

1312810

131281A

1312900

1313600

131380A

1314700

131470A

1313800

131380A

1315600

KYRON

G23DG32D

ACTYON

6.0

6.3

8.6

8.6

0.1

6.3

0.3

6.6

0.1

6.6

2.0

0.1

1.4

0.1

1.2

0.1

1.2

5.6

6.3

8.4

8.4

0.1

6.3

0.3

6.6

0.1

6.6

2.0

0.1

0.9

0.1

1.2

0.1

1.2

Page 66: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

66

GSLCAM SUPPORT & SHAFT132

Page 67: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

67

1B1D

1E1F

1G

1

2

3

4

5

6

7

COVER AND/OR GASKET, CYLINDER HEAD - REPLACE

COVER, CYLINDER HEAD FRONT - REPLACE

CAMSHAFT - REPLACE

PIN, CAMSHAFT - REPLACE

CAP OR SEAL, OIL FILLER - REPLACE

SEALING, SPARK PLUG HOLE - REPLACE

SEALING, VENTILATION - REPLACE

1322110

1322210

1322300

1322610

1322700

1322710

1322720

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.5

4.1

2.2

0.7

0.2

0.3

0.3

0.5

4.1

2.2

0.7

0.2

0.3

0.3

Page 68: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

68

GSLTIMING COVER & CHAIN DRIVE133

Page 69: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

69

1B1D

1E1F

1G

PULLEY, CRANKSHAFT - REPLACE

COVER AND/OR GASKET, TIMING - REPLACE

BELT OR CHAIN, TIMING - REPLACE

SPROCKET, CRANKSHAFT TIMING - REPLACE

HUB OR VIBRATION DAMPER - REPLACE

SPROCKET, CAMSHAFT TIMING - REPLACE

ADJUST ASSEMBLY - REPLACE

MAGNET, CAMSHAFT ADJUST - REPLACE

SENSOR, CRANKSHAFT POSITION - REPLACE

SENSOR, CAMSHAFT POSITION - REPLACE

RAIL, CLAMPING SLIDING - REPLACE

RAIL, SLIDING - REPLACE

RAIL, UPPER SLIDING - REPLACE

CHAIN TIGHTENER - REPLACE

WASHER, CHAIN TIGHTENER - REPLACE

1332100

1332200

1332500

1333100

1333140

1333300

1333400

1333430

1333700

1333800

1336500

1336700

1336900

1337300

1337500

Operation DescriptionNO.Operation

CodeREMARK

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

KYRON

G23DG32D

ACTYON

4.0

5.8

5.6

16.0

3.4

2.7

3.0

0.2

0.6

0.4

1.5

5.6

1.2

0.5

0.5

2.0

5.8

5.2

14.0

3.4

2.7

3.0

0.2

0.6

0.4

1.5

5.2

1.2

0.5

0.5

Page 70: KYRON + ACTYON_LTG(060303)-1

1C (GSL) - GASOLINE ENGINE MECHANICAL

70

GSLENGINE & TRANSAXLE MOUNT138

1

2

3

4

5

6

MOUNT, ENGINE (FRONT) - REPLACE One

Two

BRACKET, ENGINE MOUNT (FRONT) - REPLACE One

Two

STOPPER ENGINE MOUNTING - REPLACE

CROSS MEMBER, ENGINE MOUNTING REAR - REPLACE

CROSS MEMBER, FRONT AXLE MOUNTING - REPLACE

INSULATOR, HEAT SHIELD - REPLACE

1380200

1380210

1380400

1380410

1380420

1380440

1380600

1384500

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.5

1.0

0.5

0.8

0.5

0.6

0.6

0.3

0.5

0.8

0.5

0.8

0.5

0.6

0.6

0.3

Page 71: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

71

1B1D

1E1F

1G

GSLVACUUM SYSTEM139

1391300

1391310

1

2

Operation DescriptionNO.Operation

CodeREMARK

VALVE, PURGE CONTROL - REPLACE

VACUUM HOSE AND/OR TUBE - REPLACE

KYRON

G23DG32D

ACTYON

0.5

0.5

0.5

0.5

Page 72: KYRON + ACTYON_LTG(060303)-1

1D (GSL) - ENGINE COOLING

72

GSLRADIATOR141

1D (GSL) - ENGINE COOLING

1

2

3

4

COOLANT - REPLACE

COCK OR PLUG, RADIATOR DRAIN - REPLACE

RADIATOR ASSEMBLY - REPLACE

COOLING SYSTEM - FLUSH

1410100

1410300

1410500

1411700

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.5

1.0

1.6

0.6

0.5

1.0

1.6

0.6

Page 73: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

73

1B1D

1E1F

1G

GSLCOOLING FAN143

1

2

3

4

5

6

DEFLECTOR AND/OR SEAL (LOWER) - REPLACE

SHROUD, RADIATOR FAN (ONE PIECE) - REPLACE

BLADE, FAN - REPLACE

CLUTCH, FAN - REPLACE

PULLEY, FAN BELT IDLE - REPLACE

BRACKET, COOLING FAN - REPLACE

1430500

1430700

1431600

1431700

1431900

1431910

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.8

0.5

0.7

0.7

0.5

4.1

0.8

0.5

0.7

0.7

0.5

-

Page 74: KYRON + ACTYON_LTG(060303)-1

1D (GSL) - ENGINE COOLING

74

GSLOIL COOLER144

1

2

3

4

5

6

OIL COOLER REINFORCEMENT

OIL COOLER ASSEMBLY - REPLACE

OIL COOLER GASKET - REPLACE

PIPE, OIL COOLANT - REPLACE

RING, OIL COOLANT - REPLACE

OUTLET HOSE OIL COOLANT - REPLACE

1443010

1443020

1443030

1443040

1443050

1443060

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

3.6

3.8

3.9

0.7

0.7

0.7

-

-

-

0.7

0.7

0.7

Page 75: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

75

1B1D

1E1F

1G

GSLRADIATOR HOSE & PIPE145

1

2

3

4

5

6

7

8

9

10

HOSE, OVERFLOW - REPLACE

RESERVOIR, RADIATOR COOLANT - REPLACE

BRACKET, RADIATOR COOLANT, RESERVOIR - REPLACE

HOSE, MAKE UP - REPLACE

HOSE, UPPER ENGINE COOLANT - REPLACE

HOSE, LOWER ENGINE COOLANT - REPLACE

CHOSE AND/OR TUBE, DEAERATION - REPLACE

A - Replace each additional

HOSE, INLET HEATER - REPLACE

HOSE, OUTLET HEATER - REPLACE

CAP ASSY - RESERVOIR TANK - REPLACE

1450300

1450400

1450410

1450600

1450700

1450800

1451400

145140A

1453100

1453200

1450420

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.3

0.4

0.5

0.6

0.4

0.6

0.3

0.1

1.0

1.0

0.1

0.3

0.4

0.5

0.6

0.4

0.6

0.3

0.1

1.0

1.0

0.1

Page 76: KYRON + ACTYON_LTG(060303)-1

1D (GSL) - ENGINE COOLING

76

GSLTHERMOSTAT & WATER PUMP148

1

2

3

4

5

6

7

8

9

10

THERMOSTAT AND/OR GASKET - REPLACE

PORT AND/OR GASKET, COOLANT OUTLET - REPLACE

FLANGE, WATER PUMP - REPLACE

PULLEY, WATER PUMP - REPLACE

IMPELLER, WATER PUMP - REPLACE

SEAL, WATER PUMP MECHANICAL - REPLACE

WATER PUMP - REPLACE

SENSOR, WATER PUMP TEMPERATURE - REPLACE

PORT, COOLING WATER DUTLET - REPLACE

PIPE, HOT WATER INLET - REPLACE

1480500

1480600

1481250

1481270

1481280

1481700

1482100

1482200

1482210

1482220

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.5

1.0

0.5

0.3

4.2

3.2

4.2

0.2

0.8

0.9

0.5

1.0

0.5

0.3

4.2

3.2

4.2

0.2

0.8

0.9

Page 77: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

77

1B1D

1E1F

1G

GSLIGNITION CABLE151

1E (GSL) - ENGINE ELECTRICAL

WIRES, SPARK PLUG(ONE OR TWO) DOHC - REPLACE

WIRES, SPARK PLUG(ALL) DOHC - REPLACE

PLUGS, SPARK(ONE OR TWO) DOHC - REPLACE

PLUGS, SPARK(ALL) DOHC - REPLACE

COIL, IGNITION CONTROL DOHC - REPLACE

A - Replace each additional

PLUG, COUPLING - REPLACE

A - Replace each additional

COVER, PROTECTION - REPLACE

1510200

1510500

1510900

1511200

1511400

151140A

1511600

151160A

1512000

1

2

3

4

5

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.2

0.3

0.5

0.7

0.3

0.1

0.3

0.1

-

0.2

0.3

0.4

0.5

0.3

0.1

0.3

0.1

0.2

Page 78: KYRON + ACTYON_LTG(060303)-1

1E (GSL) - ENGINE ELECTRICAL

78

GSL

PULLEY AND/OR FAN, ALTERNATOR - REPLACE

BEARING, ALTERNATOR-REPLACE Front

Rear

ALTERNATOR ASSEMBLY - REPLACE

ALTERNATOR ASSEMBLY - OVERHAUL

BRACKET, ALTERNATOR MOUNTING - REPLACE

1540100

1540300

1540500

1541700

1541900

1544100

1

2

3

4

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.5

0.8

0.8

0.8

1.5

1.2

0.5

0.8

0.8

0.8

1.5

1.2

ALTERNATOR UNIT154

Page 79: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

79

1B1D

1E1F

1G

GSLSTARTER156

1

2

MOTOR ASSEMBLY, STARTER DOHC - REPLACE

SWITCH, STARTER MOTOR MAGNETIC - REPLACE

1560900

1562700

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

1.0

1.2

1.0

1.2

Page 80: KYRON + ACTYON_LTG(060303)-1

1E (GSL) - ENGINE ELECTRICAL

80

GSLBATTERY157

1

2

3

4

BATTERY - REPLACE

RETAINER AND/OR BOLTS, BATTERY - REPLACE

CARRIER, BATTERY - REPLACE

CABLE - BATTERY GROUND

1570300

1570500

1571100

1571200

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.2

0.2

0.3

0.2

0.2

0.2

0.3

0.2

Page 81: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

81

1B1D

1E1F

1G

GSLFUSE & RELAY158

1

2

3

4

5

RELAY - REPLACE

Fog Lamp

Enable (ABS)

Window Wiper Motor

Head Lamp

Other Relays

Turn Signal

COVER, FUSE BOX - REPLACE

BOX, RELAY & FUSE - REPLACE

FUSE - REPLACE

CONTROL UNIT P/WINDOW AUTO DOWN - REPLACE

1580200

1580500

1580900

1581100

1581500

1582100

1582300

1582700

1583700

1584700

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.6

0.2

0.4

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.6

0.2

0.4

Page 82: KYRON + ACTYON_LTG(060303)-1

1F (GSL) - ENGINE CONTROLS

82

GSLFUEL TANK171

1

2

3

4

5

6

7

8

9

PUMP, FUEL AND/OR GAUGE, ORING - REPLACE

AIR BLEEDING, FUEL

NECK, FUEL TANK FILLER - REPLACE

TANK, FUEL - REPLACE

GROMMET, FUEL FILLER - REPLACE

PROTECTOR, FUEL TANK - REPLACE

VALAE, ROLLOVER - REPLACE

HOSE, AIR VENT - REPLACE

CAP, FUEL TANK - REPLACE

1710300

1710400

1710500

1710900

1711300

1712200

1712410

1713500

1713600

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

1F (GSL) - ENGINE CONTROLS

0.7

0.5

0.7

1.3

-

0.3

-

0.7

0.2

0.7

0.5

0.7

1.3

-

0.3

-

0.7

0.2

Page 83: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

83

1B1D

1E1F

1G

GSLFUEL LINE & OIL LINE172

1

2

3

4

5

6

7

8

9

10

11

12

13

14

HOUSING, OIL FILTER - REPLACE

COVER, OIL FILTER HOUSING - REPLACE

FILTER, OIL - REPLACE

GASKET, OIL FILTER - REPLACE

FILTER, FUEL ELEMENT - REPLACE

BRACKET, FUEL FILTER - REPLACE

VALVE, 2WAY CHECK - REPLACE

HOSE, FUEL RETURN OR SUPPLY - REPLACE

PIPE, FUEL VAPOR - REPLACE

PIPE, FUEL RETURN - REPLACE

PIPE, FUEL SUPPLY - REPLACE

ANOTHER HOSE, FUEL - REPLACE

A - Additional another hose, fuel

HOSE, FUEL(TANK TO PIPE) - REPLACE

A - Additional hose, fuel (tank to pipe)

HOSE, 2WAY CHECK VALVE INLET - REPLACE

1720200

1720230

1720240

1720250

1720300

1720310

1720330

1720340

1720600

1720700

1720760

1720870

172087A

1721300

172130A

1723400

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

2.7

0.2

0.5

2.7

0.2

-

0.5

0.3

1.0

0.7

0.7

0.3

0.3

0.3

0.3

-

2.7

0.2

0.5

2.7

0.2

-

0.5

0.3

1.0

0.7

0.7

0.3

0.3

0.3

0.3

-

Page 84: KYRON + ACTYON_LTG(060303)-1

1F (GSL) - ENGINE CONTROLS

84

GSLCANISTER & FUEL VACUUM173

1731410

1731500

1731910

1732700

1

2

3

4

Operation DescriptionNO.Operation

CodeREMARK

HOSE OR PIPE,2WAY CHECK VALVE TO CANISTER - REPLACE

CANISTER, FUEL VAPOR - REPLACE

PIPE,CANISTER TO PURGE CONTROL VALVE - REPLACE

SOLENOID,EVAP EMISSION PURGE - REPLACE

KYRON

G23DG32D

ACTYON

0.3

0.4

0.3

0.3

0.3

0.4

0.3

0.3

Page 85: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

85

1B1D

1E1F

1G

GSLFUEL INJECTION181

1810300

1810900

1811200

1811400

1811500

1811600

1811700

1

2

3

4

5

6

7

Operation DescriptionNO.Operation

CodeREMARK

BODY, THROTTLE DOHC - REPLACE

REGULATOR AND/OR GASKETS DOHC - REPLACE

INJECTOR, FUEL (ONE OR ALL) DOHC - REPLACE

RAIL, FUEL DOHC - REPLACE

RING SEAL, CONNETOR ASSY FUEL SUPPLY

PIPE ASSY, FUEL RETURN - REPLACE

CONNECTOR ASSY, FUEL PRESSURE- REPLACE

KYRON

G23DG32D

ACTYON

0.8

0.3

1.1

1.0

0.3

0.5

0.3

0.8

0.3

1.1

1.0

0.3

0.5

0.3

Page 86: KYRON + ACTYON_LTG(060303)-1

1F (GSL) - ENGINE CONTROLS

86

GSLACCELERATOR CONTROL182

Page 87: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

87

1B1D

1E1F

1G

1820300

1820500

1820600

1820700

1821100

1821230

1822310

1822330

1822340

1822350

1822380

1822400

1

2

3

4

5

6

7

8

9

10

11

12

Operation DescriptionNO.Operation

CodeREMARK

CABLE, ACCELERATOR CONTROL - REPLACE

PEDAL, ACCELERATOR - REPLACE

MODULE, ACCELERATOR PEDAL - REPLACE

SPRING, THROTTLE RETURN - REPLACE

PAD, ACCELERATOR PEDAL - REPLACE

BRACKET, ACCELERATOR PEDAL MOUNT - REPLACE

LEVER, ACCELERATOR CONTROL - REPLACE

SPRING, ACCELERATOR CONTROL - REPLACE

BRACKET, ACCELERATOR CONTROL LEVER BEARING -REPLACE

ROD, CONNECTING - REPLACE

LEVER, REVERSING - REPLACE

LEVER, SLOTTED GATE - REPLACE

KYRON

G23DG32D

ACTYON

0.4

0.4

0.3

0.2

0.2

0.4

0.3

0.2

0.5

0.3

0.4

0.4

0.4

0.4

0.3

0.2

0.2

0.4

0.3

0.2

0.5

0.3

0.4

0.4

Page 88: KYRON + ACTYON_LTG(060303)-1

1F (GSL) - ENGINE CONTROLS

88

GSLEMISSION CONTROL186

1861300

186130A

1862110

1862120

1

2

3

Operation DescriptionNO.Operation

CodeREMARK

SENSOR, KNOCK - REPLACE

A - Additional sensor, knock

ECU (ENGINE) - REPLACE

SENSOR, AIR TEMPERATURE - REPLACE

KYRON

G23DG32D

ACTYON

0.8

0.8

0.8

0.8

0.8

0.8

0.8

0.8

Page 89: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

89

1B1D

1E1F

1G

GSL191

1G (GSL) - ENGINE INTAKE & EXHAUST

AIR INTAKE SYSTEM

1910300

1910350

1910500

1910700

1910900

1911310

1911320

1910800

1

2

3

4

5

6

7

8

Operation DescriptionNO.Operation

CodeREMARK

AIR CLEANER - REPLACE

BRACKET, AIR CLEANER HOUSING MOUNTING-REPLACE

FILTER, AIR CLEANER - REPLACE

DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE

SENSOR, MAP - REPLACE

HOUSING, INLET AIR - REPLACE

METER, AIR MASS - REPLACE

DUCT INT AIR - REPLACE

KYRON

G23DG32D

ACTYON

0.5

0.7

0.2

0.3

0.4

0.5

0.2

0.3

0.5

0.7

0.2

0.3

0.4

0.5

0.2

0.3

Page 90: KYRON + ACTYON_LTG(060303)-1

1G (GSL) - ENGINE INTAKE & EXHAUST

90

GSLINTAKE MANIFOLD193

Operation Description

1

2

3

4

5

6

7

MANIFOLD, INTAKE LOWER - REPLACE

GASKET, UPPER INTAKE MANIFOLD - REPLACE

MANIFOLD, INTAKE UPPER - REPLACE

FLAP, RESONANCE - REPLACE

PACKING - REPLACE

SENSOR ASSY, MAP - REPLACE

ADAPTOR, MAP SENSOR - REPLACE

1930220

1930210

1930230

1932200

1932400

1932700

1932800

NO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

1.3

0.7

2.3

1.6

1.6

-

-

1.3

0.7

2.3

-

-

0.2

0.3

Page 91: KYRON + ACTYON_LTG(060303)-1

GASOLINE ENGINE MECHANICAL - 1G

91

1B1D

1E1F

1G

GSLEXHAUST MANIFOLD194

1

2

3

4

MANIFOLD AND/OR GASKET EXHAUST DOHC-REPLACE

SENSOR, OXYGEN DOHC - REPLACE

COVER, EXHAUST MANIFOLD UPPER - REPLACE

COVER, EXHAUST MANIFOLD LOWER - REPLACE

1940300

1940600

1940810

1940830

Operation DescriptionNO.Operation

CodeREMARK

KYRON

G23DG32D

ACTYON

1.4

0.2

0.6

0.4

0.8

0.2

0.5

0.4

Page 92: KYRON + ACTYON_LTG(060303)-1

1G (GSL) - ENGINE INTAKE & EXHAUST

92

GSL

Operation DescriptionNO.Operation

CodeREMARK

1

2

3

4

5

6

7

8

9

10

HANGER AND/OR CLAMP, EXHAUST SYSTEM - REPLACE

PIPE, FRONT EXHAUST - REPLACE

SHIELD, CONVERTER - REPLACE

HEAT SHIELD, FRONT - REPLACE

HEAT SHIELD, CENTER MUFFLER - REPLACE

CONVERTER - REPLACE

MUFFLER - REPLACE

EXHAUST SYSTEM (COMPLETE) - REPLACE

PIPE, TAIL - REPLACE

GASKET

A - Additional - Gasket

1960300

1960900

1961300

1961400

1961420

1961500

1962100

1962500

1962600

1962700

196270A

KYRON

G23DG32D

ACTYON

0.2

0.6

0.5

0.5

0.5

0.6

0.5

1.5

0.5

0.2

0.2

0.2

0.6

0.5

0.5

0.5

0.6

0.5

1.5

0.5

0.2

0.2

EXHAUST PIPE LINE196

Page 93: KYRON + ACTYON_LTG(060303)-1

SUSPENSION

2C. FRONT SUSPENSION ................................................................. 94213. KNUCKLE & HUB ............................................................................................ 94214. FRONT SHOCK ABSORBER ........................................................................... 96215. CONTROL ARM ............................................................................................... 98

2D. REAR SUSPENSION ................................................................. 100231. REAR AXLE & STABILIZER ........................................................................... 100232. REAR SHOCK ABSORBER ........................................................................... 104

2E. TIRES & WHEEL ....................................................................... 106241. WHEELS ........................................................................................................ 106

SECTION 2

Page 94: KYRON + ACTYON_LTG(060303)-1

2C - FRONT SUSPENSION

94

KNUCKLE & HUB213

2C - FRONT SUSPENSION

REAR KNUCKLE & HUB MULI LINKS

Page 95: KYRON + ACTYON_LTG(060303)-1

FRONT SUSPENSION - 2C

95

2C2D

2E

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

WHEEL ALIGNMENT

HUB AND RBRAKE DISC - REPLACE

Right

Left

Both

BEARING, FRONT HUB INNER AND/OR OUTER - REPLACE

Right

Left

Both

VALVE, LOCKING HUB SOLENOID - REPLACE

KNUCKLE ASSEMBLY, STEERING - REPLACE

Right

Left

Both

SEAL, KNUCKLE OIL - REPLACE

Right

Left

Both

SHIELD, DISC BRAKE - REPLACE

Right

Left

Both

HOSE, VACUUM, LOCKING HUB - REPLACE

O-RING, WHEEL END HUB - REPLACE

Additional

Opposite

HUB ACTUATOR, FRT LOCKING - REPLACE

Additional

Opposite

HOSE, LOCKING HUB AOTUATOR - REPLACE

HOSE, LOCKING HUB AOTUATOR - REPLACE

HOSE, LOCKING HUB AOTUATOR - REPLACE

2130300

2130470

2130480

2130490

2130710

2130720

2130730

2130950

2131100

2131200

2131300

2131400

2131410

2131420

2132100

2132200

2132300

2133750

2136100

2136200

2136300

2137100

2137200

2137300

2138100

2138200

2138300

Operation DescriptionNO.Operation

CodeKYRON REMARKACTYON

1.0

0.5

0.5

1.0

0.8

0.8

1.6

0.2

0.8

0.8

1.6

1.2

1.2

2.0

0.6

0.6

1.2

0.3

0.5

0.1

0.4

0.8

0.2

0.7

0.3

0.3

0.2

1.0

0.5

0.5

1.0

0.8

0.8

1.6

0.2

0.8

0.8

1.6

1.2

1.2

2.0

0.6

0.6

1.2

0.3

0.5

0.1

0.4

0.8

0.2

0.7

0.3

0.3

0.2

Page 96: KYRON + ACTYON_LTG(060303)-1

2C - FRONT SUSPENSION

96

FRONT SHOCK ABSORBER214

Page 97: KYRON + ACTYON_LTG(060303)-1

FRONT SUSPENSION - 2C

97

2C2D

2E

1

2

3

4

5

6

7

SPRING, FRONT COIL - REPLACE

Right

Left

Both

SEAT AND/OR INSULATOR - REPLACE

Right

Left

Both

BUMPER, STOPPER - REPLACE

Right

Left

Both

BOOT, DAMPER STRUT - REPLACE

Right

Left

Both

SHOCK ABSORBER - REPLACE

Right

Left

Both

SHOCK ABSORBER & SPING ASSEMBLY - REPLACE

Right

Left

Both

YOKE, FRT SHOCK ABSORBER - REPLACE

Right

Left

Both

Operation DescriptionNO.

2140100

2140200

2140300

2141500

2141600

2141700

2142330

2142340

2142350

2142360

2142370

2142380

2143100

2143200

2143300

2140600

2140610

2140620

2145100

2145200

2145300

OperationCode

KYRON REMARKACTYON

0.8

0.8

1.5

0.8

0.8

1.5

0.8

0.8

1.5

0.8

0.8

1.5

0.8

0.8

1.5

0.6

0.6

1.0

0.7

0.7

1.4

0.8

0.8

1.5

0.8

0.8

1.5

0.8

0.8

1.5

0.8

0.8

1.5

0.8

0.8

1.5

0.6

0.6

1.0

0.6

0.6

1.2

Page 98: KYRON + ACTYON_LTG(060303)-1

2C - FRONT SUSPENSION

98

CONTROL ARM215

Page 99: KYRON + ACTYON_LTG(060303)-1

FRONT SUSPENSION - 2C

99

2C2D

2E

1

2

3

4

5

6

7

8

9

10

11

LINK AND/OR BUSHING, FRONT STABILIZER - REPLACE

Right

Left

Both

STABILIZER, FRONT - REPLACE

CAM BOLT, FRONT LOWER ARM MOUNTING - REPLACE

Right

Left

Both

ARM ASSEMBLY, FRONT UPPER CONTROL - REPLACE

Right

Left

Both

BUSHING, FRONT UPPER CONTROL ARM - REPLACE

Right

Left

Both

BUSHING, FRONT LOWER CONTROL ARM - REPLACE

Right

Left

Both

ARM ASSEMBLY, FRONT LOWER CONTROL - REPLACE

Right

Left

Both

OIL, FRONT AXLE - REPLACE

BUSHING, STABILIZER SUPPORT

CLAMP, STABILIZER BUSHING

BUSHING, STABILIZER - REPLACE

Right

Left

Both

Operation DescriptionNO.

2150100

2150200

2150300

2150500

2151800

2151810

2151820

2154000

2154100

2154200

2154230

2154240

2154250

2154260

2154270

2154280

2154500

2154600

2154700

2154900

2155100

2156100

2157100

2157200

2157300

OperationCode

KYRON REMARKACTYON

0.3

0.3

0.5

0.5

0.3

0.3

0.5

0.4

0.4

0.8

0.5

0.5

1.0

1.0

0.9

0.9

1.0

1.0

2.0

0.3

0.3

0.3

0.1

0.3

0.4

0.3

0.3

0.5

0.5

0.3

0.3

0.5

0.4

0.4

0.8

0.5

0.5

1.0

1.0

0.9

0.9

1.0

1.0

2.0

0.3

0.3

0.3

0.1

0.3

0.4

Page 100: KYRON + ACTYON_LTG(060303)-1

2D - REAR SUSPENSION

100

REAR AXLE & STABILIZER231-1

5 - LINK SYSTEM

2D - REAR SUSPENSION

Page 101: KYRON + ACTYON_LTG(060303)-1

REAR SUSPENSION - 2D

101

2C2D

2E

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

STABILIZER, REAR - REPLACE

DAMPER, STABILIZER - REPLACE

Right

Left

Both

AXLE ASSEMBLY, REAR - REPLACE

AXLE ASSEMBLY, REAR - OVERHAUL

BREATHER AIR - REPLACE

CAP, HUB - REPLACE

Right

Left

Both

LINK AND/OR BUSHING, REAR STABILIZER - REPLACE

Right

Left

Both

KNUCKLE, REAR (DISC) - REPLACE

ZRight

Left

Both

COVER, DIFFERENTIAL BEARING - REPLACE

HOUSING, REAR AXLE - REPLACE

SHAFT, REAR AXLE - REPLACE

Right

Left

Both

GASKET, REAR DIFFERENTIAL CARRIER - REPLACE

NUT, LOCK - REPLACE

FLANGE, PINION - REPLACE

BEARING, PINION - REPLACE

BEARING, REAR AXLE SHAFT - REPLACE

Right

Left

Both

SEAL, DRIVE PINION GEAR OIL - REPLACE

RING, DIFFERENTIAL BEARING COVER - REPLACE

Operation DescriptionNO.

2310100

2310300

2310310

2310320

2310900

2310910

2310930

2312100

2312200

2312300

2314100

2314200

2314300

2315100

2315200

2315300

2315310

2316300

2316410

2316420

2316430

2316630

2316710

2316720

2316730

2316810

2316820

2316830

2316850

2316860

OperationCode

KYRON REMARKACTYON

0.7

0.3

0.3

0.5

2.4

5.9

0.3

0.2

0.2

0.3

0.3

0.3

0.6

1.1

1.1

2.2

3.0

2.9

0.7

0.7

1.4

0.8

0.6

0.4

3.0

1.3

1.3

2.6

3.0

0.8

0.7

0.3

0.3

0.5

2.4

5.9

0.3

0.2

0.2

0.3

0.3

0.3

0.6

1.1

1.1

2.2

3.0

2.9

0.7

0.7

1.4

0.8

0.6

0.4

3.0

1.3

1.3

2.6

3.0

0.8

Page 102: KYRON + ACTYON_LTG(060303)-1

2D - REAR SUSPENSION

102

REAR AXLE & STABILIZER231-2IRS

Page 103: KYRON + ACTYON_LTG(060303)-1

REAR SUSPENSION - 2D

103

2C2D

2E

18

19

20

21

22

23

24

25

26

SEAL, REAR AXLE OIL - REPLACE

Right

Left

Both

SEAL, REAR AXLE OIL INNER - REPLACE

Right

Left

Both

SEAL, REAR AXLE OIL OUTER - REPLACE

Right

Left

Both

SHIM, BEARING COVER - REPLACE

COVER, REAR AXLE CASE - REPLACE

CASE, DIFFERENTIAL - REPLACE

GEAR SET - REPLACE

OIL, REAR AXLE - REPLACE

SHAFT, REAR DRIVE AXLE

Operation DescriptionNO.

1.0

1.0

2.0

3.2

3.2

5.9

3.2

3.2

5.9

2.9

0.5

4.0

0.4

0.4

0.6

OperationCode

KYRON REMARKACTYON

2316900

2317000

2317100

2317110

2317120

2317130

2317140

2317150

2317160

2317210

2317700

2317760

2317780

2310920

2318100

1.0

1.0

2.0

3.2

3.2

5.9

3.2

3.2

5.9

2.9

0.5

4.0

0.4

0.4

-

Page 104: KYRON + ACTYON_LTG(060303)-1

2D - REAR SUSPENSION

104

REAR SHOCK ABSORBER232IRS

5 - LINK SYSTEM

Page 105: KYRON + ACTYON_LTG(060303)-1

REAR SUSPENSION - 2D

105

2C2D

2E

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

SPRINGS, REAR COIL - REPLACE

Right

Left

Both

SEAT AND/OR INSULATOR - REPLACE

Right

Left

Both

SHOCK ABSORBER, REAR - REPLACE

Right

Left

Both

BUMPER, SHOCK - REPLACE

Right

Left

Both

RUBBER RING, REAR S/ABS - REPLACE

Right

Left

Both

ROD AND/OR BUSH, LATERAL - REPLACE

ARM & BUSH ASSEMBLY, REAR UPPER - REPLACE

Right

Left

Both

ARM & BUSH ASSEMBLY, REAR ROWER - REPLACE

Right

Left

Both

BUMPER, REAR SUSPENSION - REPLACE

Right

Left

Both

REAR SPRING SEAT

REAR UPPER ARM

COVER, LATERAL LOD - REPLACE

BUSHING, LATERAL LOD - REPLACE

BUSHING, LOWER ARM - REPLACE

BUSHING, UPPER ARM - REPLACE

Operation DescriptionNO.

2320100

2320300

2320400

2320700

2320800

2320900

2321100

2321200

2321300

2321410

2321510

2321610

2321630

2321640

2321650

2323500

2323510

2323511

2323512

2323530

2323531

2323532

2324100

2324200

2324300

2327100

2328100

2329100

2329200

2329300

2329400

OperationCode

KYRONREMARKACTYON

0.8

0.8

1.6

0.8

0.8

1.6

0.3

0.3

0.6

1.1

1.1

2.0

1.1

1.1

2.0

0.2

0.4

0.4

0.6

0.4

0.4

0.6

0.2

0.2

0.3

0.3

0.5

-

-

0.5

0.5

0.8

0.8

1.6

0.8

0.8

1.6

0.3

0.3

0.6

1.1

1.1

2.0

1.1

1.1

2.0

0.2

0.4

0.4

0.6

0.4

0.4

0.6

0.2

0.2

0.3

0.3

0.5

0.2

0.4

0.5

0.5

5-LINK

0.8

0.8

1.6

0.8

0.8

1.6

0.3

0.3

0.6

1.1

1.1

2.0

1.1

1.1

2.0

0.2

0.4

0.4

0.6

0.4

0.4

0.6

0.2

0.2

0.3

0.3

0.5

-

-

0.5

0.5

IRS

Page 106: KYRON + ACTYON_LTG(060303)-1

2E - TIRES & WHEEL

106

WHEELS241

2E - TIRES & WHEEL

Page 107: KYRON + ACTYON_LTG(060303)-1

TIRES & WHEEL - 2E

107

2C2D

2E

1

2

3

4

5

6

7

WHEEL - BALANCE

A - Each additional

WHEEL (ONE) - REPLACE

A - Replace each additional

TIRE (ONE) - REPLACE

A - Replace each additional

STEM, VALVE (ONE) - REPLACE

BOLT, WHEEL - REPLACE

A - Replace each additional

CAP, WHEEL - REPLACE

A - Replace each additional

WINCH ASSY - SPARE TIRE - REPLACE

Operation DescriptionNO.

2410700

241070A

2411100

241110A

2411300

241130A

2411500

2411700

241170A

2411900

241190A

2411800

OperationCode

KYRON REMARKACTYON

0.3

0.2

0.4

0.3

0.3

0.2

0.5

0.2

0.1

0.2

0.1

0.4

0.3

0.2

0.4

0.3

0.3

0.2

0.5

0.2

0.1

0.2

0.1

0.4

Page 108: KYRON + ACTYON_LTG(060303)-1

MEMO

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

...................................................................................................................................................................................................................................................................................................................................................................................................................................................................

Page 109: KYRON + ACTYON_LTG(060303)-1

DRIVE LINE & AXLE

SECTION 3

3A. DRIVE LINE & AXLE .................................................................. 110321. AXLE SHAFT PARTS ..................................................................................... 110323. PROPELLER SHAFT ..................................................................................... 112

Page 110: KYRON + ACTYON_LTG(060303)-1

3A - DRIVE LINE & AXLE

110

AXLE SHAFT PARTS321

3A - DRIVE LINE & AXLE

Page 111: KYRON + ACTYON_LTG(060303)-1

DRIVE LINE & AXLE - 3A

111

3A

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

AXLE ASSEMBLY, FRONT DRIVE - REPLACE

AXLE ASSEMBLY, FRONT - OVERHAUL

SHAFT ASSY, FRONT AXLE - REPLACE

Right

Left

Both

BEARING, OUTER PINION - REPLACE

BEARING, INNER PINION - REPLACE

GEAR SET (PINION, RING, SIDE), FRONT AXLE - REPLACE

COVER, FRONT AXLE HOUSING - REPLACE

BRACKET, FRONT AXLE MOUNTING - REPLACE

Right

Left

Both

BEARING BALL AND/OR SEAL, SHAFT OIL - REPLACE

Right

Left

Both

SHAFT, INNER - REPLACE

Right

Left

Both

HOSE, AIR BENT - REPLACE

PINION GEAR, FRONT AXLE - REPLACE

OIL, FRONT AXLE - REPLACE

BOOT SET, OUTER - REPLACE

Right

Left

Both

OIL SEAL (PINION), FRONT AXLE - REPLACE

RING GEAR, FRONT AXLE - REPLACE

Operation DescriptionNO.

3211100

3211310

3211510

3211520

3211530

3211730

3211740

3211750

3211760

3211770

3211780

3211790

3211830

3211840

3211850

3211860

3211870

3211880

3212100

3211320

3211610

3211620

3211630

3211640

3211650

OperationCode

KYRON REMARKACTYON

2.1

5.0

0.8

0.8

1.6

2.0

5.0

5.0

2.2

0.9

0.9

1.8

0.7

0.7

1.2

0.7

0.7

1.2

0.3

5.0

0.6

1.9

1.9

3.8

0.4

5.0

2.1

5.0

0.8

0.8

1.6

2.0

5.0

5.0

2.2

0.9

0.9

1.8

0.7

0.7

1.2

0.7

0.7

1.2

0.3

5.0

0.6

1.9

1.9

3.8

0.4

5.0

Page 112: KYRON + ACTYON_LTG(060303)-1

3A - DRIVE LINE & AXLE

112

PROPELLER SHAFT323

1

2

3

4

5

SHAFT, PROPELLER - REPLACE

Front

Rear

JOINT, UNIV, PROPELLER FRONT - REPLACE

One

Two

JOINT, UNIV, PROPELLER REAR - REPLACE

One

Two

YOKE, JOINT, FRONT - REPLACE

One

Two

YOKE, JOINT, REAR - REPLACE

One

Two

Operation DescriptionNO.

3230110

3230120

3230310

3230320

3230330

3230340

3230510

3230520

3230530

3230540

OperationCode

KYRON REMARKACTYON

0.3

0.4

0.7

1.0

0.7

1.0

0.7

1.2

0.7

1.2

0.3

0.4

0.7

1.0

0.7

1.0

0.7

1.2

0.7

1.2

KYRON ACTYON

Page 113: KYRON + ACTYON_LTG(060303)-1

BRAKES

SECTION 4

4A. HYDRAURIC BRAKE ............................................................... 114425. BRAKE PIPE ................................................................................................ 114428. BRAKE PEDAL & MOUNT .......................................................................... 115

4B. MASTER CYLINDER & BOOSTER ........................................ 116431. MASTER CYLINDER & BOOSTER ............................................................ 116

4D. FRONT BRAKE ........................................................................ 117445. FRONT BRAKE ............................................................................................ 117

4E. REAR BRAKE .......................................................................... 118456. REAR BRAKE .............................................................................................. 118

4F. ANTI-LOCK BRAKE SYSTEM................................................. 120462. REAR BRAKE .............................................................................................. 120

4G. PARKING BRAKE .................................................................... 122478. PARKING BRAKE ........................................................................................ 122

Page 114: KYRON + ACTYON_LTG(060303)-1

4A - HYDRAURIC BRAKES

114

BRAKE PIPE425NON - ABS

ABS/ESP

4A - HYDRAURIC BRAKE

1

2

3

4

HOSE, BRAKE - REPLACE

Right Front

Lef Front

Both Front

Right Rear

Left Rear

Both Rear

PIPE, REAR BRAKE - REPLACE

Right

Left

PIPE, MASTER CYLINDER TO MODULATOR VALVE FRONT

-REPLACE

PIPE, FRONT BRAKE - REPLACE

Right

Left

Both

Operation DescriptionNO.

4250100

4250200

4250300

4250400

4250500

4250600

4250800

4251100

4251500

4253800

4253810

4253820

OperationCode

KYRON REMARKACTYON

0.5

0.5

0.9

0.4

0.4

0.7

0.5

0.5

0.5

0.7

0.7

1.2

0.5

0.5

0.9

0.4

0.4

0.7

0.5

0.5

0.5

0.7

0.7

1.2

Page 115: KYRON + ACTYON_LTG(060303)-1

HYDRAURIC BRAKES - 4A

115

4A4B

4D4E

4F4G

BRAKE PEDAL & MOUNT428

1

2

3

4

5

PEDAL AND/OR BUSHING, BRAKE - REPLACE

SPRING, BRAKE PDEAL RETURN - REPLACE

PAD, BRAKE PEDAL - REPLACE

SWITCH, STOP LAMP - REPLACE

BRACKET, BRAKE PEDAL - REPLACE

Operation DescriptionNO.

4280100

4280300

4280500

4280700

4281300

OperationCode

KYRON REMARKACTYON

0.5

0.5

0.2

0.2

0.5

0.5

0.5

0.2

0.2

0.5

Page 116: KYRON + ACTYON_LTG(060303)-1

4B - MASTER CYLINDER & BOOSTER

MASTER CYLINDER & BOOSTER431

1

2

3

4

5

6

7

CYLINDER, BRAKE MASTER - OVERHAUL

CYLINDER, BRAKE MASTER - REPLACE

VALVE, BOOSTER CHECK - REPLACE

SEAL, BOOSTER MOUNTING - REPLACE

BRAKE SYSTEM - BLEED

BOOSTER, VACUUM POWER BRAKE - REPLACE

RESERVOIR, BRAKE MASTER CYLINDER - REPLACE

HOSE, BRAKE BOOSTER VACUUM - REPLACE

Operation DescriptionNO.

4310100

4310200

4310210

4310220

4310230

4310600

4310800

4312100

OperationCode

KYRON REMARK

4B - MASTER CYLINDER & BOOSTER

ACTYON

1.4

0.6

0.2

0.3

1.2

0.8

0.4

0.2

1.4

0.6

0.2

0.3

1.2

0.8

0.4

0.2

Page 117: KYRON + ACTYON_LTG(060303)-1

MASTER CYLINDER & BOOSTER - 4B

117

4A4B

4D4E

4F4G

FRONT BRAKE445

4D - FRONT BRAKE

1

2

PADS, DISC BRAKE (FRONT) - REPLACE

Both

Right

Left

CALIPER ASSEMBLY, FRONT - REPLACE

Right

Left

Both

Operation DescriptionNO.

4450100

4450110

4450120

4450300

4450400

4450500

OperationCode

KYRON REMARKACTYON

0.6

0.4

0.4

0.6

0.6

1.2

0.6

0.4

0.4

0.6

0.6

1.2

Page 118: KYRON + ACTYON_LTG(060303)-1

4E - REAR BRAKES

118

REAR BRAKE456

4E - REAR BRAKE

KYRON / ACTYON

KYRON

Page 119: KYRON + ACTYON_LTG(060303)-1

REAR BRAKES - 4E

119

4A4B

4D4E

4F4G

1

2

3

4

5

6

7

PLATE, BRAKE BACKING - REPLACE

Right

Left

Both

SLIDING CALIPER, REAR - REPLACE

Right

Left

Both

DISC, REAR BRAKE - REPLACE

Right

Left

Both

PAD, REAR BRAKE - REPLACE

Right

Left

Both

HUB, REAR - REPLACE

Right

Left

Both

BACK PLATE (IRS), RR BRAKE - REPLACE

ABS IMPULSERING (REAR) - REPLACE

Operation DescriptionNO.

4563800

4563900

4564100

4564300

4564400

4564500

4565100

4565200

4565300

4566300

4566400

4566500

4566700

4566800

4566900

4566910

4566920

OperationCode

KYRON REMARKACTYON

0.8

0.8

1.4

0.6

0.6

1.2

0.5

0.5

1.0

0.6

0.6

1.2

1.3

1.3

2.3

1.9

0.8

0.8

0.8

1.4

0.6

0.6

1.2

0.5

0.8

1.0

0.6

0.6

1.2

1.3

1.3

2.3

-

0.8

Page 120: KYRON + ACTYON_LTG(060303)-1

4F - ANTI-LOCK BRAKE SYSTEM

120

ABS SYSTEM462

4F - ANTI-LOCK BRAKE SYSTEM

Page 121: KYRON + ACTYON_LTG(060303)-1

ANTI-LOCK BRAKE SYSTEM - 4F

121

4A4B

4D4E

4F4G

1

2

3

4

5

6

SENSOR, WHEEL SPEED, FRONT AND/OR REAR - REPLACE

Right Front

Left Front

Both Front

Right Rear

Left Rear

Both Rear

HYDRAULIC MODULATOR ASSEMBLY (ABS, ABD) - REPLACE

ECU (ABS) - REPLACE

ABS IMPULSERING - REPLACE

Right Front

Left Front

Both Front

Right Rear

Left Rear

Both Rear

SENSOR, ACCEL - REPLACE

ESP SENSOR CLUSTER - REPLACE

Operation DescriptionNO.

4620100

4620200

4620300

4620400

4620500

4620600

4620800

4620900

4620910

4620920

4620930

4620940

4620950

4620960

4620970

4620980

OperationCode

KYRON REMARKACTYON

0.5

0.4

0.9

0.4

0.3

0.7

0.8

0.9

1.0

1.0

1.9

1.5

1.5

2.8

0.8

0.4

0.5

0.4

0.9

0.4

0.3

0.7

0.8

0.9

1.0

1.0

1.9

1.5

1.5

2.8

0.8

0.4

Page 122: KYRON + ACTYON_LTG(060303)-1

4G - PARKING BRAKES

122

PARKING BRAKE478

4G - PARKING BRAKE

KYRON

KYRON / ACTYON

Page 123: KYRON + ACTYON_LTG(060303)-1

PARKING BRAKES - 4G

123

4A4B

4D4E

4F4G

1

2

3

4

5

6

7

8

9

10

11

12

13

14

PARKING BRAKE - ADJUST

GRIP, PARKING BRAKE HANDLE - REPLACE

CABLE, PARKING BRAKE - REPLACE

Front

Rear Both

SPRING, TENSION - REPLACE

BODY, PARKING BRAKE - REPLACE

PEDAL, PARKING BRAKE - REPLACE

DAMPER, PARKING BRAKE - REPLACE

CABLE, RELEASE - REPLACE

CONTROL UNIT, PARKING AID - REPLACE

SENSOR, PARKING BRAKE AID - REPLACE

SHOE ASSY, PARKING BRAKE - REPLACE

Rear Both

Right

Left

EQUALIZER, PARKING BRAKE - REPLACE

HANDLE, PARKING BRAKE - REPLACE

SWITCH, PARKING BRAKE - REPLACE

Operation DescriptionNO.

4780100

4780200

4780500

4780600

4780700

4781600

4780810

4780830

4780890

4781000

4781010

4781320

4781300

4781310

4781400

4781410

4782000

OperationCode

KYRON REMARKACTYON

0.3

0.4

0.6

0.7

0.4

0.6

0.5

0.4

0.6

0.7

1.0

1.5

0.9

0.9

0.3

0.3

0.5

0.3

0.4

0.6

0.7

0.4

-

-

-

-

0.6

1.0

1.5

0.9

0.9

0.3

-

0.5

Page 124: KYRON + ACTYON_LTG(060303)-1

MEMO

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