Kyron Actyon LTG 060303 1 PDF

SECTION INDEX
Labor Time Guide A. GENERAL INFORMATION
1. ENGINE (Diesel)
ENGINE (Gasoline)
2. SUSPENSION
FOREWORD
3. DRIVE LINE & AXLE
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 4. BRAKES
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 5. TRANSMISSION & TRANSFER CASE
warranty, policy and campaign adjustment and other
work authorized and performed for the account of
SsangYong Motor Co., Ltd.
6. STEERING
This use of this guide for any other purpose is neither
intended not authorized by SsangYong Motor Co., 7. H.V.A.C (Heating, Ventilation &
Ltd.
Air Conditioning)
Please read the introduction of this guide thoroughly
to acquaint with SsangYong warranty system.
8. RESTRAINTS
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 9. BODY & ACCESSORIES
methods, techniques or equipment or other advances
in the industry.
10. PAINT
11. OTHERS
PYUNGTAEK, KOREA
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
GENERAL INFORMATION - A
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 technicians 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 dealers qualified service staff to assist technicians in customer problem
analysis and symtom diagnosis.
5
A - GENERAL INFORMATION
2. HOW TO READ THIS MANUAL
1B - DIESEL ENGINE MECHANICAL
131
7 6
Operation KYRON ACTYON

NO. Operation Description REMARK
Code D27DT D20DT
1 GASKET, CYLINDER HEAD - REPLACE 1312300 5.0 3.0 -
2 HEAD, CYLINDER - REPLACE 1312500 5.0 5.0 -
HEAD, CYLINDER - OVERHAUL 1312600 7.6 7.5 -
3 VALVE (ONE CYLINDER) - REPLACE 1312700 7.6 7.0 -
C - Valves (each additional) 131270C 0.1 0.1 -
2 3B 3A 4 5
6
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, and
describes what kind of operation is to be performed.
3B. Supplementary Operation

The description corresponding to each operation number names the parts or component concerned, and
describes 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 was
performed.
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 :
Auxiliary Code Description

0 Major operation
A
B
.
Supplementary operation
.
.
R
7
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 the
incidental 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 and
6 minutes).
Enter the operation time on the warranty claim in the same manner.
6) Model Code
This code represents the vehicle model.
Vehicle model
KYRON
ACTYON
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
8
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)
1312700 VALVE - REPLACE 7.0

131270C VALVES (EACH ADDITIONAL) 0.1
Operation Time Total 7.1

Code D27DT D20DT
1 GASKET, CYLINDER HEAD - REPLACE 1312300 5.0 3.0 -
2 HEAD, CYLINDER - REPLACE 1312500 5.0 5.0 -
HEAD, CYLINDER - OVERHAUL 1312600 7.6 7.5 -
3 VALVE (ONE CYLINDER) - REPLACE 1312700 7.6 7.0 -
C - Valves (each additional) 131270C 0.1 0.1 -
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
9
4. PAINT REPAIR
4-1. INSTRUCTION
The time allowances herein for painting operations are established on the basis of techniques and
material 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 to
their neutral shape.
2. Welding and soldering joints, overlapping seams formed by partial replacement and surfaces
smoothed 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 working
process, and material allowances, which are necessary for a proper and professional paint job. It shall
be 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 the
material will be varied in the course of paint.
The material allowances consist of mixed paint and additional material such as masking tape, sanding
paper, cleaning solvent and etc. needed for the operation of each step.
INCLUDES ; moving the vehicle / mixing all materials / color blending / equipment cleaning / color spray
sample / repainting time on clear coat / masking / sanding / cleaning / spraying / removing
of the masking and polishing.
EXCLUDES ; removal and reinstallation of body attaching parts.
4-3. REPAIR TYPE
Type Description
COLOR COAT PAINT EXPOSED SURFACES
Top-coat entire surface, including small dents that have been straightened(without filling in). Its
operation should be used when correcting painting conditions such as thin paint, color mismatch
or surface scratches not extending beyond the prime coat.
REFINISH PAINT NEW PART
This operation involves sanding out a defect to expose a local area of bare metal, prime locally and
then apply color coat.
This applies to those paint repairs that require a repair to the prime coat before the color coat is applied.
POLISHING 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 HOUR

P 9836080 3.1
10
5. DEFECT CODE
5-1. NATURE CODE
N01 Hard start, no start N41 Sponge pedal

N02 Poor idle N42 Unstable steering
N03 Surge, hesitate, stumble N43 Excessive shock
N04 Engine noise, engine knoking noise N44 Poor release
N05 Choke malfunction N45 Unusual tire wear
N06 Engine stalled (general) N46 Misaligned or mismatched
N07 Excessive fuel consumption N47 Weak
N08 Excessive oil consumption N48 Hard to turn
N09 Overheated N49 Impossible to turn
N10 Shift shock N50 Vehicle bouncing
N11 Engine run-on N51 Deteriorated
N12 Flooded, overflowing N52 Distorsion, rainbow, waving
N13 Poor acceleration, uneven acceleration N53 Color mismatched
N14 Abnormal combustion N54 Defective chrom plate, defective painting
N15 Lack of engine power N55 Rust, corrosion, perforation
N16 Percolation N56 Glazed
N17 Improper exhaust gas (black smoke, white smoke) N57 Loose, poor fit
N18 Backfire, afterfire N58 Bubbles
N19 Vapor lock N59 Vehicle vibration
N20 Blocked N60 Excessive vibration
N21 Shuddering, pulsation, vibration, chattering N61 Dead battery
N22 Slippage (slipping) N62 Inaccurate (meter, gauge, etc.)
N23 Difficult engagement N63 Poor sound (horn, radio, etc.)
N24 Difficult disengagement N64 Overcharged, discharged
N25 Abnormal shifts N65 Electrical failures
N26 Impossible shifts N66 Blown fuse
N27 Squeaking, squealing, abnormal(wind)noise N67 Warning light on
N28 Dragging N68 Intermittent operation
N29 Pulls N69 Pulls to left or right
N30 Stalled while driving N70 Poor AM reception / interference
N31 Stalled while idling N71 Oil leak, oil entering
N32 Stalled between shifts N72 Water leak, water entering
N33 Stalling during sudden braking N73 Leaks-other (air, fuel, refrigerant, vacuum)
N34 Fails to reach normal operating temperature N74 Poor FM reception / interference
N35 RPM too low N75 Radio / CD does not operate properly
N36 RPM too high N76 Tape deck does not operate properly
N37 Jumping-out N77 Improper memory
N38 Improper synchronizing N78 Improper volume control
N39 Oil diluted N80 Head lamp improperly aimed
N40 Misfire N82 Loosening, failing-off, sagged
11
N83 Gas leak, gas entering N92 Inoperative

N84 Improper opening and/or closing N93 High/low operating effort
N85 Grabbed N94 Special policy
N86 Poor maneuverability N95 Glass cracked
N87 Insufficient brake N96 Glass broken
N88 Brake judder N97 Glass chipped
N90 Color rainbow, color waving N98 Glass scratched
N91 Interference or hitting N99 Undefined
5-2. CAUSE CODE
R01 Scored, scratched or chipped R19 Improperly machined

R02 Frozen (temperature) R20 Faulty casting
R03 Peeling, comimg-off R21 Improper clearance, back lash, free play
R04 Rusty, corroded R22 Lack of lubricants
R05 Split, cut or torn R23 Improper welding or soldering, welding or solder-
ing omitted
R06 Broken or cracked R24 Improper tightening, fit or assembly
R07 Porous, pin holes, cavity R25 Sticks, binds, seized
R08 Bent, kinky, twisted, distorted, wraped or wrinkled R26 Foreign material, clogged
R09 Stripped - bolts, holes, nuts R27 Improper sealing, sealer omitted or skipped
R10 Soiled R28 Improper adjustment
R11 Weakened, loss of tension or resilience R31 Incorrect part
(spring, cushion, etc.)
R12 Abnormal wear R32 Improperly installed
R13 Out of balance R33 Improperly routed
R14 Out of round R34 Missing part
R15 Loose or improper connection R35 Flaw in material
R16 Open circuit or short circuit R36 Contaminants
R17 Burnt or burned - out R99 Undefined
R18 Grounded or shorted
12
5-3. PAINT CODE
P01 Oversprayed, drip P19 Atmospheric fallout

P02 Undersprayed, bare P20 Polishing mark, sanding mark
P03 Color mismatched P21 Touch up
P04 Low Gloss P22 Dust, dirt
P05 Mottled, cloudy P23 Poor welding
P06 Sags or runs P24 Rust
P07 Pin hole P25 Blistered
P11 Peeling, scaling P26 Chipped
P12 Orange peel P27 Cracked
P13 Slow drying P30 Surface scratch
P14 Thin no paint P31 Scab corrosion
P15 Wavy P32 Dent
P16 Tape mark, touch mark P33 Rust perforation
P17 Chemical damage P34 Discolored, faded
P18 Acid rain P99 Undefined
6. ABBREVIATION
A/C Air conditioning MAP Manifold absolute pressure
ABD Antilock brake differential MAT Manifold air temperature
ADJ Adjust M/T Manual transaxle
ASSY Assembly OH Overhaul
A/T Auto transaxle PLA Plating
CC Color coat print POL Polishing
CHK Check RAD Radiator
CLN Clean REF Refinish paint
DOHC Double overhead camshaft REKES Remote keyless entry system
ECS Electrical control system RI Reinstall
EGR Exhaust gas recirculation RP Replacement
IAC Idle air control TPS Throttle position sensor
I/P Instrument panel T/C Transfer case
L.C.R.V Load conscious reducing valve T.O.D Torque on demand
13
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 1B -DSL Diesel Engine Mechanical 111 Engine Unit (20p)
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
1D -DSL Engine Cooling 141 Radiator (35p)
143 Cooling Fan
145 Radiator Hose & Pipe
148 Thermostat & Water Pump
1E -DSL Engine Electrical 154 Alternator Unit (39p)
156 Starter
157 Battery
158 Fuse & Relay
1F -DSL Engine Controls 170 Fuel Filter & Line (43p)
171 Fuel Tank
172 Fuel Line
182 Accelerator Control
1G -DSL Engine Intake & Exhaust 190 Common Rail System (47p)
191 Air Intake System
193 Intake Manifold
194 Exhaust Manifold
196 Exhaust Pipe Line
197 Turbo Charger Assembly
198 Sensors
14

1. GASOLINE 1C -GSL Gasoline Engine 111 Engine Unit (56p)
ENGINE Mechanical 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
1D -GSL Engine Cooling 141 Radiator (72p)
143 Cooling Fan
144 Oil Cooler
145 Radiator Hose & Pipe
148 Thermostat & Water Pump
1E -GSL Engine Electrical 151 Ignition Cable (77p)
154 Alternator Unit
156 Starter
157 Battery
158 Fuse & Relay
1F -GSL Engine Controls 171 Fuel Tank (82p)
172 Fuel Line & Oil Line
173 Canister & Fuel Vacuum
181 Fuel Injection
182 Accelerator Control
186 Emission Control
1G -GSL Engine Intake & Exhaust 191 Air Intake System (89p)
193 Intake Manifold
194 Exhaust Manifold
196 Exhaust Pipe Line
15

2. SUSPENSION 2C Front Suspension 213 Knuckle & Hub (94p)
214 Front Shock Absorber
215 Control Arm
2D Rear Suspension 231 Rear Axle & Stabilizer (100p)
232 Rear Shock Absorber
2E Tires & Wheel 241 Wheels (106p)
3. DRIVE LINE & 3A Drive Line & Axle 321 Axle Shaft Parts (110p)
AXLE
323 Propeller Shaft
4. BRAKES 4A Hydraulic Brake 425 Brake Pipe (114p)
428 Brake Pedal & Mount
4B Master Cylinder & Booster 431 Master Cylinder & Booster (116p)
4D Front Brake 445 Front Brake (117p)
4E Rear Brake 456 Rear Brake (118p)
4F Anti-Lock Brake System 462 Rear Brake (120p)
4G Parking Brake 478 Parking Brake (122p)
5. TRANSMISSION 5A Auto Transmission Controls 519 Auto Transmission Controls (127p)
& TRANSFER
CASE 5B BTR M74 Auto Transmission 541 BTR M74 I (128p)
542 BTR M74 II
543 BTR M74 III
544 BTR M74 IV
5D Auto Transmission 551 Auto Transmisson I (134p)
556 Auto Transmisson II
557 Auto Transmisson III
558 Auto Transmisson IV
559 Auto Transmisson V
5E Manual Transmission 561 Manual Transmission (141p)
563 Transmission Gear
566 Gear Shift Cover & Fork
569 Shift Control
5F Clutch 581 Clutch Parts (147p)
582 Hydraulic Clutch
583 Clutch Pedal
5G Transmission Case 591 Transfer Case (Part Time) (150p)
6. STEERING 6A Power Streering Gear 621 Power Steering Gear (155p)
623 Power Steering Pipe Line
6E Streering Wheel & Column 641 Steering Wheel (157p)
643 Steering Column
647 Tie Rod
16

7. H.V.A. C 7A H.V.A.C (Air Distribution) 711. Air Distribution (162p)
(Heating,
Ventilation & 713. Evaporator
Air Conditioning) 714. Blower
7B H.V.A.C (Control) 732. Compressor (166p)
733. Compressor Mount
734. A/C Hose & Pipe Line
735. A/C Control Switch & Sensor
8. RESTRAINTS 8A Seat Belts 812. Rear Seat Belt (173p)
822. Rear Seat Belt
8B S.R.S (Supplemental Inflatable 832. Air Bag System (175p)
Restraints)
833. Immobilizer
9. BODY & 9A Body Wiring System 911. Wiring Harness (178p)
ACCESSORIES
9B Lighting System 916. Front Lamp (180p)
918. Rear Lamp
9D Wiper & Washer System 921. Washer System (184p)
923. Wiper System
9E Inst. Driver System 925. Instrument Cluster (186p)
9F Audio & Anti-theft System 928. Electrical Parts (188p)
929. STICS & Auto Cruise
9G Interior Trim 931. Instrument Panel (192p)
932. Switch
933. Instrument Parts
934. Console
935. Front Door Trim
936. Rear Door Trim
938. Pillar Trim
939. Floor Carpet & Panel
9H Seats 941. Front Seat (206p)
942. Rear Seat
9L Glass & Mirrors 946. Glass & Out Side Mirrors (208p)
9M Exterior Parts 951. Emblem & Lettering (210p)
952. Mud Guard
9O Bumpers & Fascias 956. Front Bumper (212p)
957. Rear Bumper
17

9. BODY & 9P Doors 961a Front Door & Lock (214p)
ACCESSORIES
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
9Q Roof 968 Car Lock (226p)
971 Headlining & Roof Panel
972a Sunshade & Inside Mirror
9R Body Front End 972b Sun Roof (230p)
973. Hood Panel
974 Front Panel
975 Fender Panel
976 Dash Panel & Cowl
977 Grille
9S Body Rear End 978 Trunk Lid Panel & Spoiler (236p)
979 Side Trim
10. PAINT 10A Paint Exterior 10a KYRON (240p)
10a ACTYON (241p)
11. OTHERS 11 Others 11 Others (245p)
18
SECTION 1
DIESEL ENGINE
1B. (DSL) DIESEL ENGINE MECHANICAL ........................................20
111. ENGINE UNIT ................................................................................................. 20
113. BELT SYSTEM ............................................................................................... 21
121. ENGINE BLOCK ............................................................................................. 22
122. CRANKSHAFT & PISTON ............................................................................. 24
123. OIL PAN & PUMP .......................................................................................... 26
131. CYLINDER HEAD ........................................................................................... 28
132. CAM SUPPORT & SHAFT ............................................................................ 30
133. TIMING COVER & CHAIN DRIVE ................................................................. 31
136. INJECEION PIPE ............................................................................................ 32
138. ENGINE & TRANSAXLE MOUNT .................................................................. 33
139. VACUUM SYSTEM ........................................................................................ 34
1D. (DSL) ENGINE COOLING..............................................................35

141. RADIATOR ...................................................................................................... 35
143. COOLING FAN ............................................................................................... 36
145. RADIATOR HOSE & PIPE ............................................................................. 37
148. THERMOSTAT & WATER PUMP ................................................................. 38
1E. (DSL) ENGINE ELECTRICAL ........................................................39

154. ALTERNATOR UNIT ....................................................................................... 39
156. STARTER ........................................................................................................ 40
157. BATTERY ........................................................................................................ 41
158. FUSE & RELAY .............................................................................................. 42
1F. (DSL) ENGINE CONTROLS ..........................................................43

170. FUEL FILTER & LINE .................................................................................... 43
171. FUEL TANK .................................................................................................... 44
172. FUEL LINE ...................................................................................................... 45
182. ACCELERATOR CONTROL .......................................................................... 46
1G. (DSL) ENGINE INTAKE & EXHAUST ...........................................47

190. COMMON RAIL SYSTEM .............................................................................. 47
191. AIR INTAKE SYSTEM .................................................................................... 48
193. INTAKE MANIFOLD ....................................................................................... 49
194. EXHAUST MANIFOLD .................................................................................... 50
196. EXHAUST PIPE LINE ..................................................................................... 51
197. TURBO CHARGER ASSEMBLY ................................................................... 52
198. SENSORS ....................................................................................................... 53
1B (DSL) - DIESEL ENGINE MECHANICAL
1B - DIESEL ENGINE MECHANICAL

111 ENGINE UNIT DSL

Code D20DT D27DT D20DT
1 ENGINE ASSEMBLY (M/T) - OVERHAUL 1110100 16.3 16.4 16.3
ENGINE ASSEMBLY (A/T) - OVERHAUL 1110300 17.3 17.3 17.3
2 ENGINE ASSEMBLY (M/T) - REPLACE 1110800 7.6 7.6 7.6
ENGINE ASSEMBLY (A/T) - REPLACE 1110900 8.5 8.5 8.5
20
DIESEL ENGINE MECHANICAL - 1D
1B
113 BELT SYSTEM DSL
1D
1E
1F
1G
1 BELT, PULLEY - REPLACE 1132210 0.4 0.4 0.4
2 PULLEY ASSEMBLY, IDLER - REPLACE 1132500 0.4 0.5 0.4
3 BELT TENSIONER, ABSORBER ASSEMBLY - REPLACE 1132530 0.5 0.6 0.5
4 PULLEY, COOLING FAN - REPLACE 1132600 0.4 0.4 0.4
5 SEALING, CRANKSHAFT (FRONT) - REPLACE 1132700 1.3 1.3 1.3
6 TENSIONER ASSY, BELT - REPLACE 1132800 0.6 0.6 0.6
7 TIMING CASE - REPLACE 1132900 11.3 11.3 11.3
8 TIMING GASKET - REPLACE 1132910 14.3 11.3 14.3
21
121 ENGINE BLOCK DSL
22
1B
1 OIL LEVEL INDICATOR AND/OR O-RING - REPLACE 1210200 0.2 0.2 0.2
1D
2 TUBE, OIL LEVEL INDICATOR - REPLACE 1210300 0.4 0.4 0.4
3 PLUG, EXPANSION - REPLACE 1210700 4.1 4.1 4.1
A - Replace each additional 121070A 0.1 0.1 0.1
1E
4 PLUG, CYLINDER BLOCK DRAIN - REPLACE 1210800 0.3 0.3 0.3
5 BLOCK, CYLINDER - REPLACE 1211100 15.4 15.2 15.4
6 BALL, PLUG OIL CHANNEL - REPLACE 1211200 1.0 1.0 1.0
7 SEMI BLOCK (SHORT BLOCK), CYLINDER - REPLACE 1211110 16.8 16.8 16.8
1F
8 SEALING, CRANKSHAFT (REAR) - REPLACE M/T 1211300 3.1 3.1 3.1
A/T 1211310 3.5 3.6 3.5
1G
23
122 CRANKSHAFT & PISTON DSL
24
1B
1 BEARING, CRANKSHAFT MAIN (ONE) - REPLACE 1220600 15.4 14.8 15.4
1D
2 BEARING, CRANKSHAFT THRUST - REPLACE 1220610 15.4 14.8 15.4
3 BEARING, GROOVED BALL (M/T) - REPLACE 1220900 5.4 5.4 5.4
1E
4 FLYWHEEL (M/T) - REPLACE 1221700 3.5 3.3 3.5
A - Flywheel ring gear (M/T) 122170A 3.7 3.8 3.7
5 FLYWHEEL (A/T) - REPLACE 1221900 6.6 6.8 6.6
A - Flywheel ring gear (AT) 122190A 0.8 0.8 0.8
1F
6 RING, PISTION REPLACE 1222200 15.0 14.7 15.0
7 PIN, PISTON - REPLACE 1222300 15.0 14.6 15.0
1G
8 SNAP RING, PISTON - REPLACE 1222400 14.6 14.6 14.6
9 PISTON - REPLACE 1222500 14.6 15.0 14.6
10 BUSHING, CONNECTING ROD - REPLACE 1222600 14.6 14.6 14.6
11 CONNECTING, ROD - REPLACE 1222700 14.6 15.0 14.6
12 BEARING, CONNECTING ROD - REPLACE 1222800 14.6 14.6 14.6
13 CRANKSHAFT - REPLACE A/T 1222900 15.4 14.4 15.4
M/T 1222910 14.5 13.8 14.5
25
123 OIL PAN & PUMP DSL
26
1B
1 PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE 1231300 0.3 0.3 0.3
1D
2 PAN AND/OR GASKET, OIL (A/T) - REPLACE 1231510 4.2 4.2 2.1
3 PUMP, ENGINE OIL - REPLACE 1231700 2.4 3.5 2.4
4 SPROCKET, OIL PUMP - REPLACE 1232600 2.9 3.8 2.9
1E
5 CHAIN, OIL PUMP ROLLER - REPLACE 1232670 6.5 6.5 6.5
6 OIL JET - REPLACE 1232680 2.1 3.6 2.1
7 TENSIONER, OIL PUMP ROLLER CHAIN - REPLACE 1232690 11.8 11.8 11.8
8 PLATE, OIL BUFFLE - REPLACE 1234100 - 3.8 -
1F
9* GUIDE TUBE, OIL LEVEL - REPLACE 1235000 0.4 0.4 0.4
10* GAUGE, OIL LEVEL - REPLACE 1235100 0.2 0.2 0.2
1G
27
131 CYLINDER HEAD DSL
28
1B
1 GASKET, CYLINDER HEAD - REPLACE 1312300 5.3 4.9 5.3
1D
GASKET, CYLINDER HEAD - OVERHAUL 1312310 7.0 7.0 7.0
2 HEAD, CYLINDER - REPLACE 1312500 5.3 4.9 5.3
HEAD, CYLINDER - OVERHAUL 1312600 7.8 7.9 7.8
1E
3 VALVE (ONE CYLINDER) - REPLACE 1312700 5.2 5.7 5.2
A - Valves (each additional) 131270A 0.1 0.1 0.1
4 VALVE GUIDE - REPLACE 1312810 3.0 2.8 3.0
1F
5 SPRING CAP AND/OR SEAL, VALVE - REPLACE 1312900 2.8 3.0 2.8
6 BOLT, CYLINDER HEAD (ONE) - REPLACE 1313800 1.3 1.2 1.3
1G
7 CAP, CAMSHAFT BEARING - REPLACE 1315600 2.6 2.6 2.6
8 FINGER FOLLOWER 1314000 3.2 3.2 3.2
9 ADJUSTER, CAMSHAFT - REPLACE 1314100 2.2 3.3 2.2
10 VALVE COTTER - REPLACE 1314200 2.8 3.0 2.8
11 RETAINER, VALVE SPRING - REPLACE 1314300 2.8 3.0 2.8
12 SEAL, VALVE GUIDE - REPLACE 1314400 6.7 6.3 6.7
13 BOLT WASHER, CYLINDER HEAD - REPLACE 1314500 - 1.2 -
29
132 CAM SUPPORT & SHAFT DSL

1 COVER, CYLINDER HEAD - REPLACE 1322110 1.3 1.6 1.3
2 CAMSHAFT - REPLACE 1322300 2.9 2.9 2.9
3 CAP AND/OR GASKET, OIL FILLER - REPLACE 1322700 0.2 0.2 0.2
4 OIL, SEPERATOR ASSY - REPLACE 1322800 0.2 0.2 0.2
5 BRACKET, OIL SEPERATOR - REPLACE 1322900 0.2 0.2 0.2
6 HOSE, BLOW BY INLET - REPLACE 1323000 0.2 0.2 0.2
HOSE, BLOW BY INLET - RECLAMPING 1323001 0.2 0.2 0.2
7 HOSE, BLOW BY OUTLET - REPLACE 1323100 0.2 0.2 0.2
8 HOSE, OIL RETURN - REPLACE 1323200 0.2 0.2 0.2
30
1B
133 TIMING COVER & CHAIN DRIVE DSL
Operation KYRON ACTYON 1D

1E
1F
1G
1 BELT OR CHAIN, TIMING - REPLACE 1332500 6.5 6.5 6.5
2 SPROCKET, CAMSHAFT TIMING - REPLACE 1333300 2.4 2.4 2.4
3 CHAIN TIGHTENER - REPLACE 1337300 0.4 0.4 0.4
4 RAIL ASSY, SLIDING - REPLACE 1332600 5.4 5.4 5.4
5 RAIL ASSY, GUIDE UPER - REPLACE 1332700 2.4 2.4 2.4
31
136 INJECEION PIPE DSL

1 PLUG, PRE - HEATING - REPLACE 1365800 0.1 0.1 0.1
32
1B
138 ENGINE & TRANSAXLE MOUNT DSL
1D
1E
1F
1G
1 MOUNT, ENGINE (FRONT) - REPLACE One 1380200 0.5 0.5 0.5
Two 1380210 1.0 1.0 1.0
2 BRACKET, ENGINE MOUNT (FRONT) - REPLACE One 1380400 0.6 0.6 0.6
Two 1380410 0.9 0.9 0.9
3 STOPPER, ENGINE MOUNTING - REPLACE 1380420 0.3 0.3 0.3
4 CROSS MEMBER, REAR ENGINE MOUNTING - REPLACE 1380440 0.3 0.3 0.3
5 CROSS MEMBER, FRONT AXLE MOUNTING - REPLACE 1380600 0.3 0.3 0.3
33
139 VACUUM SYSTEM DSL

1 VACUUM PUMP ASSEMBLY - REPLACE 1390100 1.9 1.9 1.9
2 O-RING, VACUUM PUMP ASSY 1390110 0.7 0.7 0.7
34
1D - ENGINE COOLING
1B
141 RADIATOR DSL

1E
1F
1G
1 COOLANT - REPLACE 1410100 0.5 0.5 0.5

2 COCK OR PLUG, RADIATOR DRAIN - REPLACE 1410300 1.0 1.0 1.0
3 RADIATOR ASSEMBLY - REPLACE 1410500 1.3 1.3 1.3
4 COOLING SYSTEM - FLUSH 1411700 0.5 0.5 0.5
35
1D (DSL) - ENGINE COOLING
143 COOLING FAN DSL

1 SHROUD, RADIATOR FAN - REPLACE 1430700 0.5 0.5 0.5
2 COOLING FAN-SHROUD 1431710 0.3 0.3 0.3
3 BLADE, FAN - REPLACE 1431600 0.5 0.5 0.5
4 CLUTCH, FAN - REPLACE 1431700 0.5 0.5 0.5
5 COOLING FAN PULLEY 1431730 0.7 0.7 0.7
36
1B
145 RADIATOR HOSE & PIPE DSL

1E
1F
1G
1 RESERVOIR, RADIATOR COOLANT - REPLACE 1450400 0.3 0.3 0.3
2 HOSE, MAKE UP - REPLACE 1450600 0.3 0.3 0.3
3 HOSE, UPPER ENGINE COOLANT - REPLACE 1450700 0.3 0.3 0.3
4 HOSE, LOWER ENGINE COOLANT - REPLACE 1450800 0.5 0.5 0.5
5 HOSE AND/OR TUBE, DEAERATION - REPLACE 1451400 0.3 0.3 0.3
6 CAP ASSY - RESERVOIR TANK - REPLACE 1450420 0.2 0.2 0.2
37
1D (DSL) - ENGINE COOLING
148 THERMOSTAT & WATER PUMP DSL

1 THERMOSTAT AND/OR GASKET DIESEL - REPLACE 1480400 0.8 0.8 0.8
2 PORT AND/OR GASKET, COOLANT OUTLET - REPLACE 1480600 1.2 1.4 1.2
3 WATER PUMP AND/OR GASKET - REPLACE 1481200 1.5 1.9 1.5
4 WATER PUMP ASSY- REPLACE 1481250 1.5 1.5 1.5
5 WATER PUMP ASSY- REPLACE 1481260 1.5 1.5 1.5
6 PULLEY, WATER PUMP - REPLACE 1481270 0.4 0.4 0.4
38
1E - ENGINE ELECTRICAL
1B
154 ALTERNATOR UNIT DSL

1E
1F
1G
1 PULLEY AND/OR FAN, ALTERNATOR - REPLACE 1540100 0.6 0.8 0.6
2 ALTERNATOR ASSEMBLY - REPLACE 1541700 0.7 0.7 0.7
3 ALTERNATOR ASSEMBLY - OVERHAUL 1541900 1.5 1.5 1.5
4 BRACKET, ALTERNATOR MOUNTING - REPLACE 1544100 0.9 0.9 0.9
39
1E (DSL) - ENGINE ELECTRICAL
156 STARTER DSL

1 MOTOR ASSEMBLY, STARTER DIESEL - REPLACE 1561000 0.5 0.5 0.5
2 SWITCH, STARTER MOTOR MAGNETIC - REPLACE 1562700 0.8 0.8 0.8
40
1B
157 BATTERY DSL
1D
1E
1F
1G
1 BATTERY - REPLACE 1570300 0.2 0.2 0.2
2 RETAINER AND/OR BOLTS, BATTERY - REPLACE 1570500 0.2 0.2 0.2
3 CARRIER, BATTERY - REPLACE 1571100 0.3 0.3 0.3
4 CABLE - BATTERY GROUND 1571200 0.3 0.3 0.3
41
1E (DSL) - ENGINE ELECTRICAL
158 FUSE & RELAY DSL

1 RELAY - REPLACE
Fog Lamp 1580200 0.2 0.2 0.2
Enable (ABS) 1580500 0.2 0.2 0.2
Window Wiper Motor 1580900 0.2 0.2 0.2
Head Lamp 1581100 0.2 0.2 0.2
Other Relays 1581500 0.2 0.2 0.2
Turn Signal 1582100 0.2 0.2 0.2
Preheating Time 1582200 0.2 0.2 0.2
2 COVER, FUSE BOX - REPLACE 1582300 0.1 0.1 0.1
3 BOX, REALY & FUSE - REPLACE 1582700 0.4 0.4 0.4
4 FUSE - REPLACE 1583700 0.2 0.2 0.2
5 CONTROL UNIT - P/WINDOW AUTO DOWN - REPLACE 1584700 0.5 0.5 0.5
6 BOX, IP FUSE - REPLACE 1585700 0.5 0.5 0.5
42
1F - ENGINE CONTROLS
1B
170 FUEL FILTER & LINE DSL
1D
1E
1F
1G
1 FILTER ASSY, FUEL - REPLACE 1700100 0.3 0.3 0.3
2 BRACKET, FUEL FILTER - REPLACE 1700200 0.3 0.3 0.3
3 PUMP, FUEL PRIMING - REPLACE 1700300 0.2 0.2 0.2
4 HOSE, PRIMING PUMP TO FILTER - REPLACE 1700400 0.2 0.2 0.2
5 HOSE, FUEL RETURN - REPLACE 1700500 0.3 0.3 0.3
6 HOSE, SUPPLY PIPE TO PRIMING PUMP - REPLACE 1700600 0.5 0.5 0.5
7 TUBE ASSY, FUEL FILTER TO PUMP - REPLACE 1700700 0.3 0.3 0.3
8 TUBE ASSY, FUEL FILTER - REPLACE 1700800 0.3 0.3 0.3
9 WATER SEPERATOR - REPLACE 1700910 0.2 0.2 0.2
10 WATER SEPERATOR - HOSE 1700920 0.1 0.1 0.1
43
1F (DSL) - ENGINE CONTROLS
171 FUEL TANK DSL

1 AIR BLEEDING, FUEL 1710400 0.6 0.6 0.6
2 NECK, FUEL TANK FILLER - REPLACE 1710500 0.6 0.6 0.6
3 TANK, FUEL - REPLACE 1710900 1.1 1.1 1.1
TANK, FUEL - OVERHAUL 1710910 1.5 1.5 1.5
4 UNIT - GASKET 1711700 0.4 0.4 0.4
5* HOSE, AIR BLEEDER - REPLACE 1712000 0.6 0.6 0.6
6 PROTECTOR, FUEL TANK - REPLACE 1712200 0.3 0.3 0.3
7 HOSE, AIR VENT - REPLACE 1713500 0.6 0.6 0.6
8 CAP, FUEL TANK - REPLACE 1713600 0.1 0.1 0.1
9 GROMMET - FUEL FILLER - REPLACE 1713610 0.2 0.2 0.2
44
1B
172 FUEL LINE DSL
1D
1E
1F
1G
1 HOUSING, OIL FILTER - REPLACE 1720200 1.0 1.1 1.0
2 COVER, OIL FILTER HOUSING - REPLACE 1720230 0.3 0.3 0.3
3 FILTER AND/OR O-RING, OIL - REPLACE 1720240 0.3 0.3 0.3
4 GASKET, OIL FILTER HOUSING - REPLACE 1720250 1.1 1.1 1.1
5 PIPE, FUEL RETURN - REPLACE 1720700 0.7 0.7 0.7
6 PIPE, FUEL SUPPLY - REPLACE 1720760 0.7 0.7 0.7
7 COOLER ASSY, OIL - REPLACE 1720950 1.0 0.9 1.0
8 COOLER GASKET, OIL - REPLACE 1720960 0.8 0.8 0.8
9 HOSE, COIL COOLER - REPLACE 1720970 0.6 0.5 0.6
45
1F (DSL) - ENGINE CONTROLS
182 ACCELERATOR CONTROL DSL

1 MODULE, ACCELERATOR PEDAL - REPLACE 1820600 0.3 0.3 0.3
46
1G - ENGINE INTAKE & EXHAUST
1B
190 COMMON RAIL SYSTEM DSL
1D
1E
1F
1G
1 PIPE ASSY, FUEL - REPLACE 1900100 0.2 0.2 0.2
2 PIPE, HIGH PRESSURE PUMP - REPLACE 1900200 0.2 0.2 0.2
3 HOSE, FUEL RETURN - REPLACE 1900300 0.3 0.3 0.3
4 PUMP ASSY, FUEL - REPLACE 1900400 2.8 3.8 2.8
5 BRACKET, FUEL PUMP - REPLACE 1900500 0.8 0.7 0.8
6 HOLDER, INJECTOR - REPLACE 1900600 0.3 0.3 0.3
7 SPROCKET, PUMP - REPLACE 1900410 1.5 2.5 1.5
8 BEARING HOUSING, PUMP - REPLACE 1900420 1.5 2.7 1.5
9 BEARING SHAFT, PUMP - REPLACE 1900430 - 2.9 -
10 GASKET, FUEL PUMP - REPLACE 1900440 2.8 3.8 2.8
11 HOUSING BOLT - REPLACE 1900450 3.0 3.0 3.0
12 COMMON RAIL - REPLACE 1900000 0.5 0.5 0.4
13 INJECTOR ASSY, FUEL - REPLACE 1900150 0.1 0.1 0.1
47
1G (DSL) - ENGINE INTAKE & EXHAUST
191 AIR INTAKE SYSTEM DSL

1 AIR CLEANER - REPLACE 1910300 0.4 0.4 0.4
2 FILTER, AIR CLEANER - REPLACE 1910500 0.2 0.2 0.2
3 METER, AIR METER - REPLACE 1911320 0.2 0.2 0.2
4 SNORKEL ASSY - REPLACE 1910400 0.2 0.2 0.2
5 HOUSING, AIR CLEANER UPR - REPLACE 1910410 0.2 0.2 0.2
6 HOUSING, AIR CLEANER LWR - REPLACE 1910420 0.3 0.3 0.3
7 HOSE, TURBO CHARGER- REPLACE 1910430 0.2 0.2 0.2
48
1B
193 INTAKE MANIFOLD DSL
1D
1E
1F
1G
1 MANIFOLD, INTAKE DIESEL - REPLACE 1930250 1.7 2.0 1.7
2 VALVE AND/OR GASKET, EGR - REPLACE 1930700 0.4 0.3 0.4
3 ELECTRIC SWITCH VALVE - REPLACE 1930710 0.5 0.5 0.5
4 HOSE, EGR VACUUM OUTLET - REPLACE 1930730 0.2 0.2 0.2
5 GASKET, INTAKE MANIFOLD - REPLACE 1933100 1.7 2.0 1.7
6 BRACKET, INTAKE MANIFOLD - REPLACE 1935000 0.5 0.5 0.5
7 PIPE ASSY, EGR - REPLACE 1935100 0.4 0.4 0.4
8 GASKET, EGR PIPE - REPLACE 1935200 0.3 0.3 0.3
9 PIPE ASSY, EGR (LH) - REPLACE 1935300 0.3 0.3 0.3
10 PIPE ASSY, EGR (RH) - REPLACE 1935400 0.3 0.3 0.3
11 MODULATOR, VACUUM M - REPLACE 1935500 0.3 0.3 0.3
49
194 EXHAUST MANIFOLD DSL

1 MANIFOLD AND/OR GASKET, EXHAUST - REPLACE 1940400 1.1 1.1 1.1
2 NUT, EXHAUST MANIFOLD - REPLACE 1940900 0.3 0.3 0.3
50
1B
196 EXHAUST PIPE LINE DSL
1D
1E
1F
1G
1 HANGER AND/OR CLAMP, EXHAUST SYSTEM-REPLACE 1960300 0.2 0.2 0.2
2 PIPE, FRONT EXHAUST - REPLACE 1960900 - 0.2 -
3 HEAT SHIELD, CENTER MUFFLER - REPLACE 1961420 0.4 0.4 0.4
4 MUFFLER - REPLACE 1962100 0.5 0.5 0.5
5 EXHAUST SYSTEM (COMPLETE) - REPLACE 1962500 1.2 1.2 1.2
6 PIPE, TAIL - REPLACE 1962600 0.3 0.3 0.3
7 CONVERTER - REPLACE 1961500 0.3 0.3 0.3
8 EXHAUST PIPE GASKET - REPLACE 1961510 0.2 0.2 0.2
9 SHIELD - FRONT HEAT, REPLACE 1961520 0.4 0.4 0.4
51
197 TURBO CHARGER ASSEMBLY DSL

1 TURBO CHARGER ASSEMBLY - REPLACE 1970100 0.9 0.8 0.9
2 TUBE-OIL SUPPLY - REPLACE 1970110 0.5 0.5 0.5
3 TUSE-OIL RETURN - REPLACE 1970120 0.7 0.7 0.7
4 INTERCOOLER - TURBO 1970510 1.0 0.9 1.0
5 HOSE AND DUCT 1, 2 - REPLACE 1970520 0.2 0.2 0.2
6 GASKET, OIL RETURN - REPLACE 1970130 0.3 0.3 0.3
52
1B
198 SENSORS DSL

1E
1F
1G
1 SENSOR, CRANKSHAFT POSITION - REPLACE 1980100 0.4 0.4 0.4
2 SENSOR ASSY - CAM POSITION 1980200 0.3 0.3 0.3
3 SENSOR, KNOCK - REPLACE 1980300 0.7 0.7 0.7
4 SENSOR ASSY - COOLANT 1980400 0.9 0.9 0.9
5 SENSOR, 8P - REPLACE 1980700 0.3 0.3 0.3
6 ECU, ENGINE - REPLACE 1980600 0.6 0.6 0.6
53
MEMO
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SECTION 1
GASOLINE ENGINE
1C (GSL) - GASOLINE ENGINE MECHANICAL .................................... 56
111. ENGINE UNIT .................................................................................................. 56
113. BELT SYSTEM ................................................................................................ 57
121. ENGINE BLOCK .............................................................................................. 58
122. CRANKSHAFT & PISTON ............................................................................... 60
123. OIL PAN & PUMP ........................................................................................... 62
131. CYLINDER HEAD ............................................................................................ 64
132. CAM SUPPORT & SHAFT .............................................................................. 66
133. TIMING COVER & CHAIN DRIVE ................................................................... 68
138. ENGINE & TRANSAXLE MOUNT .................................................................... 70
139. VACUUM SYSTEM ......................................................................................... 71
1D (GSL) - ENGINE COOLING .............................................................. 72

141. RADIATOR ....................................................................................................... 72
143. COOLING FAN ................................................................................................ 73
144. OIL COOLER ................................................................................................... 74
145. RADIATOR HOSE & PIPE .............................................................................. 75
148. THERMOSTAT & WATER PUMP ................................................................... 76
1E (GSL) - ENGINE ELECTRICAL ......................................................... 77

151. IGNITION CABLE ............................................................................................. 77
154. ALTERNATOR UNIT ........................................................................................ 78
156. STARTER ........................................................................................................ 79
157. BATTERY ........................................................................................................ 80
158. FUSE & RELAY .............................................................................................. 81
1F (GSL) - ENGINE CONTROLS ........................................................... 82

171. FUEL TANK ..................................................................................................... 82
172. FUEL LINE & OIL LINE ................................................................................... 83
173. CANISTER & FUEL VACUUM ........................................................................ 84
181. FUEL INJECTION ............................................................................................ 85
182. ACCELERATOR CONTROL ............................................................................ 86
186. EMISSION CONTROL ..................................................................................... 88
1G (GSL) - ENGINE INTAKE & EXHAUST ............................................ 89

191. AIR INTAKE SYSTEM ..................................................................................... 89
193. INTAKE MANIFOLD ........................................................................................ 90
194. EXHAUST MANIFOLD ..................................................................................... 91
196. EXHAUST PIPE LINE ...................................................................................... 92
1C (GSL) - GASOLINE ENGINE MECHANICAL

111 ENGINE UNIT GSL

Code G32D G23D
1 ENGINE ASSEMBLY (M/T) - OVERHAUL 1110100 26.0 24.2
ENGINE ASSEMBLY (A/T) - OVERHAUL 1110300 26.0 23.2
2 ENGINE ASSEMBLY (M/T) - REPLACE 1110800 8.0 7.7
ENGINE ASSEMBLY (A/T) - REPLACE 1110900 8.7 8.7
56
GASOLINE ENGINE MECHANICAL - 1G
1B
113 BELT SYSTEM GSL
1D
1E
1F
1G

Code G32D G23D
1 POLY-BELT - REPLACE 1132210 0.5 0.5
2 PULLEY, AUTO TENSIONER - REPLACE 1132410 0.5 0.5
3 TIGHTENER ASSEMBLY, BELT - REPLACE 1132550 1.2 1.2
4 SHOCK ABSORBER, TENSIONER - REPLACE 1132560 - 0.5
57
121 ENGINE BLOCK GSL
58
1B
Code G32D G23D
1 OIL LEVEL INDICATOR AND/OR O-RING - REPLACE 1210200 0.2 0.2
1D
2 TUBE, OIL LEVEL INDICATOR - REPLACE 1210300 0.3 0.3
3 PLUG, EXPANSION - REPLACE 1210700 4.4 4.1
A - Replace each additional 121070A 0.1 0.1
1E
4 PLUG, CYLINDER BLOCK DRAIN - REPLACE 1210800 0.5 0.5
5 PLUG, OIL GALLERY - REPLACE 1210900 - -
6 BLOCK, CYLINDER - REPLACE 1211100 26.0 23.2
7 SEMI BLOCK (SHORT BLOCK), CYLINDER - REPLACE 1211110 21.5 19.2
1F
1G
59
122 CRANKSHAFT & PISTON GSL
60
1B
Code G32D G23D
1 SEAL (S), CRANKSHAFT REAR MAIN (A/T) - REPLACE 1220200 6.3 6.3
1D
SEAL (S), CRANKSHAFT REAR MAIN (M/T) - REPLACE 1220400 5.4 5.4
2 COVER, CRANKSHAFT SEALING (A/T) - REPLACE 1220410 6.3 6.3
COVER, CRANKSHAFT SEALING (M/T) - REPLACE 1220420 5.4 5.4
1E
3 DAMPER, CRANKSHAFT VIBRATION - REPLACE 1220500 2.8 2.8
4 BEARING, CRANKSHAFT MAIN (ONE) - REPLACE 1220600 9.7 9.7
5 BEARING, CRANKSHAFT THRUST - REPLACE 1220610 10.3 10.3
1F
6 BEARING, CONNECTING ROD (ONE) - REPLACE 1220800 10.8 10.8
7 CRANKSHAFT (M/T) - REPLACE 1221100 13.8 13.8
1G
D - Replace one piston ring 122110D 0.4 0.4
E - Replace all piston rings 122110E 1.2 1.2
F - Replace one connecting rod 122110F 0.5 0.5
G - Replace all connecting rods 122110G 1.2 1.2
8 CRANKSHAFT (A/T) - REPLACE 1221200 18.0 17.0
D - Replace one piston ring 122120D 0.4 0.4
E - Replace all piston rings 122120E 1.2 1.2
F - Replace one connecting rod 122120F 0.6 0.6
G - Replace all connecting rods 122120G 1.2 1.2
9 PISTON, ROD AND/OR RINGS (ONE) - REPLACE 1221500 19.5 19.5
10 BUSHING, CONNECTING ROD - REPLACE 1221540 19.5 19.5
11 FLYWHEEL (M/T) - REPLACE 1221700 5.3 5.3
A - Flywheel ring gear 122170A 0.8 0.8
12 FLYWHEEL (A/T) - REPLACE 1221900 6.3 6.3
A - Flywheel ring gear 122190A 0.8 0.8
13 BEARING, PILOT - REPLACE 1222100 5.6 5.6
14 BEARING, GROOVED BALL(M/T)-REPLACE 1222110 5.6 5.6
61
123 OIL PAN & PUMP GSL
62
1B
Code G32D G23D
1 PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE 1231300 0.2 0.2
1D
2 PAN AND/OR GASKET, OIL - REPLACE 1231500 5.0 5.0
PAN AND/OR GASKET, OIL (AUTO) - REPLACE 1231510 5.0 5.0
3 SWITCH AND/OR GASKET, OIL LEVEL - REPLACE 1231600 0.3 0.3
1E
4 PUMP, ENGINE OIL - REPLACE 1231700 4.0 4.0
PUMP, ENGINE OIL - OVERHAUL 1231710 5.7 5.7
5 SWITCH, OIL PRESSURE GAUGE - REPLACE 1231900 0.4 0.4
6 OIL SEAL, CRANKSHAFT (FRONT) - REPLACE 1232300 3.9 3.7
1F
7 SPROCKET, OIL PUMP - REPLACE 1232600 5.6 5.6
8 STRAINER ASSEMBLY, OIL - REPLACE 1232610 5.6 5.6
9 CHAIN, OIL PUMP ROLLER - REPLACE 1232670 5.6 5.6
1G
10 TENSIONER, OIL PUMP ROLLER CHAIN - REPLACE 1232690 5.6 5.6
11 VALVE, OIL PRESSURE RELIEF - REPLACE 1232700 5.6 5.6
12 SHAFT, OIL PUMP DRIVE - REPLACE 1232800 5.6 5.6
13 PLATE, OIL BAFFLE - REPLACE 1234100 5.6 5.6
63
131 CYLINDER HEAD GSL
64
1B
Code G32D G23D
1 GASKET, CYLINDER HEAD - REPLACE 1312300 6.0 5.6
1D
2 HEAD, CYLINDER - REPLACE 1312500 6.3 6.3
HEAD, CYLINDER - OVERHAUL 1312600 8.6 8.4
3 VALVE (ONE CYLINDER) - REPLACE 1312700 8.6 8.4
1E
A - Valves (each additional) 131270A 0.1 0.1
4 GUIDE, VALVE - REPLACE 1312800 6.3 6.3
5 SEAL, VALVE GUIDE - REPLACE 1312810 6.6 6.6
1F
6 SPRING CAP AND/OR SEAL, VALVE - REPLACE 1312900 6.6 6.6
7 LIFTER, VALVE - REPLACE 1313600 2.0 2.0
1G
8 PLUG, CYLINDER HEAD CORE HOLE - REPLACE 1314700 1.4 0.9
9 BOLT, CYLINDER HEAD (ONE) - REPLACE 1313800 1.2 1.2
10 CAP, CAMSHAFT BEARING - REPLACE 1315600 1.2 1.2
65
132 CAM SUPPORT & SHAFT GSL
66
1B
Code G32D G23D
1 COVER AND/OR GASKET, CYLINDER HEAD - REPLACE 1322110 0.5 0.5
1D
2 COVER, CYLINDER HEAD FRONT - REPLACE 1322210 4.1 4.1
3 CAMSHAFT - REPLACE 1322300 2.2 2.2
4 PIN, CAMSHAFT - REPLACE 1322610 0.7 0.7
1E
5 CAP OR SEAL, OIL FILLER - REPLACE 1322700 0.2 0.2
6 SEALING, SPARK PLUG HOLE - REPLACE 1322710 0.3 0.3
7 SEALING, VENTILATION - REPLACE 1322720 0.3 0.3
1F
1G
67
133 TIMING COVER & CHAIN DRIVE GSL
68
1B
Code G32D G23D
1 PULLEY, CRANKSHAFT - REPLACE 1332100 4.0 2.0
1D
2 COVER AND/OR GASKET, TIMING - REPLACE 1332200 5.8 5.8
3 BELT OR CHAIN, TIMING - REPLACE 1332500 5.6 5.2
4 SPROCKET, CRANKSHAFT TIMING - REPLACE 1333100 16.0 14.0
1E
5 HUB OR VIBRATION DAMPER - REPLACE 1333140 3.4 3.4
6 SPROCKET, CAMSHAFT TIMING - REPLACE 1333300 2.7 2.7
7 ADJUST ASSEMBLY - REPLACE 1333400 3.0 3.0
8 MAGNET, CAMSHAFT ADJUST - REPLACE 1333430 0.2 0.2
1F
9 SENSOR, CRANKSHAFT POSITION - REPLACE 1333700 0.6 0.6
10 SENSOR, CAMSHAFT POSITION - REPLACE 1333800 0.4 0.4
11 RAIL, CLAMPING SLIDING - REPLACE 1336500 1.5 1.5
1G
12 RAIL, SLIDING - REPLACE 1336700 5.6 5.2
13 RAIL, UPPER SLIDING - REPLACE 1336900 1.2 1.2
14 CHAIN TIGHTENER - REPLACE 1337300 0.5 0.5
15 WASHER, CHAIN TIGHTENER - REPLACE 1337500 0.5 0.5
69
138 ENGINE & TRANSAXLE MOUNT GSL

Code G32D G23D
1 MOUNT, ENGINE (FRONT) - REPLACE One 1380200 0.5 0.5
Two 1380210 1.0 0.8
2 BRACKET, ENGINE MOUNT (FRONT) - REPLACE One 1380400 0.5 0.5
Two 1380410 0.8 0.8
3 STOPPER ENGINE MOUNTING - REPLACE 1380420 0.5 0.5
4 CROSS MEMBER, ENGINE MOUNTING REAR - REPLACE 1380440 0.6 0.6
5 CROSS MEMBER, FRONT AXLE MOUNTING - REPLACE 1380600 0.6 0.6
6 INSULATOR, HEAT SHIELD - REPLACE 1384500 0.3 0.3
70
1B
139 VACUUM SYSTEM GSL

1E
1F
1G
Code G32D G23D
1 VALVE, PURGE CONTROL - REPLACE 1391300 0.5 0.5
2 VACUUM HOSE AND/OR TUBE - REPLACE 1391310 0.5 0.5
71
1D (GSL) - ENGINE COOLING

141 RADIATOR GSL

Code G32D G23D
1 COOLANT - REPLACE 1410100 0.5 0.5

2 COCK OR PLUG, RADIATOR DRAIN - REPLACE 1410300 1.0 1.0
3 RADIATOR ASSEMBLY - REPLACE 1410500 1.6 1.6
4 COOLING SYSTEM - FLUSH 1411700 0.6 0.6
72
1B
143 COOLING FAN GSL
1D
1E
1F
1G

Code G32D G23D
1 DEFLECTOR AND/OR SEAL (LOWER) - REPLACE 1430500 0.8 0.8
2 SHROUD, RADIATOR FAN (ONE PIECE) - REPLACE 1430700 0.5 0.5
3 BLADE, FAN - REPLACE 1431600 0.7 0.7
4 CLUTCH, FAN - REPLACE 1431700 0.7 0.7
5 PULLEY, FAN BELT IDLE - REPLACE 1431900 0.5 0.5
6 BRACKET, COOLING FAN - REPLACE 1431910 4.1 -
73
144 OIL COOLER GSL

Code G32D G23D
1 OIL COOLER REINFORCEMENT 1443010 3.6 -
2 OIL COOLER ASSEMBLY - REPLACE 1443020 3.8 -
3 OIL COOLER GASKET - REPLACE 1443030 3.9 -
4 PIPE, OIL COOLANT - REPLACE 1443040 0.7 0.7
5 RING, OIL COOLANT - REPLACE 1443050 0.7 0.7
6 OUTLET HOSE OIL COOLANT - REPLACE 1443060 0.7 0.7
74
1B
145 RADIATOR HOSE & PIPE GSL
1D
1E
1F
1G
Code G32D G23D
1 HOSE, OVERFLOW - REPLACE 1450300 0.3 0.3
2 RESERVOIR, RADIATOR COOLANT - REPLACE 1450400 0.4 0.4
3 BRACKET, RADIATOR COOLANT, RESERVOIR - REPLACE 1450410 0.5 0.5
4 HOSE, MAKE UP - REPLACE 1450600 0.6 0.6
5 HOSE, UPPER ENGINE COOLANT - REPLACE 1450700 0.4 0.4
6 HOSE, LOWER ENGINE COOLANT - REPLACE 1450800 0.6 0.6
7 CHOSE AND/OR TUBE, DEAERATION - REPLACE 1451400 0.3 0.3
8 HOSE, INLET HEATER - REPLACE 1453100 1.0 1.0
9 HOSE, OUTLET HEATER - REPLACE 1453200 1.0 1.0
10 CAP ASSY - RESERVOIR TANK - REPLACE 1450420 0.1 0.1
75
148 THERMOSTAT & WATER PUMP GSL

Code G32D G23D
1 THERMOSTAT AND/OR GASKET - REPLACE 1480500 0.5 0.5
2 PORT AND/OR GASKET, COOLANT OUTLET - REPLACE 1480600 1.0 1.0
3 FLANGE, WATER PUMP - REPLACE 1481250 0.5 0.5
4 PULLEY, WATER PUMP - REPLACE 1481270 0.3 0.3
5 IMPELLER, WATER PUMP - REPLACE 1481280 4.2 4.2
6 SEAL, WATER PUMP MECHANICAL - REPLACE 1481700 3.2 3.2
7 WATER PUMP - REPLACE 1482100 4.2 4.2
8 SENSOR, WATER PUMP TEMPERATURE - REPLACE 1482200 0.2 0.2
9 PORT, COOLING WATER DUTLET - REPLACE 1482210 0.8 0.8
10 PIPE, HOT WATER INLET - REPLACE 1482220 0.9 0.9
76
1E (GSL) - ENGINE ELECTRICAL
1B
151 IGNITION CABLE GSL
1D
1E
1F
1G
Code G32D G23D
1 WIRES, SPARK PLUG(ONE OR TWO) DOHC - REPLACE 1510200 0.2 0.2
WIRES, SPARK PLUG(ALL) DOHC - REPLACE 1510500 0.3 0.3
2 PLUGS, SPARK(ONE OR TWO) DOHC - REPLACE 1510900 0.5 0.4
PLUGS, SPARK(ALL) DOHC - REPLACE 1511200 0.7 0.5
3 COIL, IGNITION CONTROL DOHC - REPLACE 1511400 0.3 0.3
4 PLUG, COUPLING - REPLACE 1511600 0.3 0.3
5 COVER, PROTECTION - REPLACE 1512000 - 0.2
77
154 ALTERNATOR UNIT GSL

Code G32D G23D
1 PULLEY AND/OR FAN, ALTERNATOR - REPLACE 1540100 0.5 0.5
2 BEARING, ALTERNATOR-REPLACE Front 1540300 0.8 0.8
Rear 1540500 0.8 0.8
3 ALTERNATOR ASSEMBLY - REPLACE 1541700 0.8 0.8
ALTERNATOR ASSEMBLY - OVERHAUL 1541900 1.5 1.5
4 BRACKET, ALTERNATOR MOUNTING - REPLACE 1544100 1.2 1.2
78
1B
156 STARTER GSL
1D
1E
1F
1G

Code G32D G23D
1 MOTOR ASSEMBLY, STARTER DOHC - REPLACE 1560900 1.0 1.0
2 SWITCH, STARTER MOTOR MAGNETIC - REPLACE 1562700 1.2 1.2
79
157 BATTERY GSL

Code G32D G23D
1 BATTERY - REPLACE 1570300 0.2 0.2
2 RETAINER AND/OR BOLTS, BATTERY - REPLACE 1570500 0.2 0.2
3 CARRIER, BATTERY - REPLACE 1571100 0.3 0.3
4 CABLE - BATTERY GROUND 1571200 0.2 0.2
80
1B
158 FUSE & RELAY GSL
1D
1E
1F
1G
Code G32D G23D
1 RELAY - REPLACE
Fog Lamp 1580200 0.2 0.2
Enable (ABS) 1580500 0.2 0.2
Window Wiper Motor 1580900 0.2 0.2
Head Lamp 1581100 0.2 0.2
Other Relays 1581500 0.2 0.2
Turn Signal 1582100 0.2 0.2
2 COVER, FUSE BOX - REPLACE 1582300 0.2 0.2
3 BOX, RELAY & FUSE - REPLACE 1582700 0.6 0.6
4 FUSE - REPLACE 1583700 0.2 0.2
5 CONTROL UNIT P/WINDOW AUTO DOWN - REPLACE 1584700 0.4 0.4
81
1F (GSL) - ENGINE CONTROLS

171 FUEL TANK GSL

Code G32D G23D
1 PUMP, FUEL AND/OR GAUGE, ORING - REPLACE 1710300 0.7 0.7
2 AIR BLEEDING, FUEL 1710400 0.5 0.5
3 NECK, FUEL TANK FILLER - REPLACE 1710500 0.7 0.7
4 TANK, FUEL - REPLACE 1710900 1.3 1.3
5 GROMMET, FUEL FILLER - REPLACE 1711300 - -
6 PROTECTOR, FUEL TANK - REPLACE 1712200 0.3 0.3
7 VALAE, ROLLOVER - REPLACE 1712410 - -
8 HOSE, AIR VENT - REPLACE 1713500 0.7 0.7
9 CAP, FUEL TANK - REPLACE 1713600 0.2 0.2
82
1B
172 FUEL LINE & OIL LINE GSL
1D
1E
1F
1G
Code G32D G23D
1 HOUSING, OIL FILTER - REPLACE 1720200 2.7 2.7
2 COVER, OIL FILTER HOUSING - REPLACE 1720230 0.2 0.2
3 FILTER, OIL - REPLACE 1720240 0.5 0.5
4 GASKET, OIL FILTER - REPLACE 1720250 2.7 2.7
5 FILTER, FUEL ELEMENT - REPLACE 1720300 0.2 0.2
6 BRACKET, FUEL FILTER - REPLACE 1720310 - -
7 VALVE, 2WAY CHECK - REPLACE 1720330 0.5 0.5
8 HOSE, FUEL RETURN OR SUPPLY - REPLACE 1720340 0.3 0.3
9 PIPE, FUEL VAPOR - REPLACE 1720600 1.0 1.0
10 PIPE, FUEL RETURN - REPLACE 1720700 0.7 0.7
11 PIPE, FUEL SUPPLY - REPLACE 1720760 0.7 0.7
12 ANOTHER HOSE, FUEL - REPLACE 1720870 0.3 0.3
A - Additional another hose, fuel 172087A 0.3 0.3
13 HOSE, FUEL(TANK TO PIPE) - REPLACE 1721300 0.3 0.3
A - Additional hose, fuel (tank to pipe) 172130A 0.3 0.3
14 HOSE, 2WAY CHECK VALVE INLET - REPLACE 1723400 - -
83
173 CANISTER & FUEL VACUUM GSL

Code G32D G23D
1 HOSE OR PIPE,2WAY CHECK VALVE TO CANISTER - REPLACE 1731410 0.3 0.3
2 CANISTER, FUEL VAPOR - REPLACE 1731500 0.4 0.4
3 PIPE,CANISTER TO PURGE CONTROL VALVE - REPLACE 1731910 0.3 0.3
4 SOLENOID,EVAP EMISSION PURGE - REPLACE 1732700 0.3 0.3
84
1B
181 FUEL INJECTION GSL
1D
1E
1F
1G
Code G32D G23D
1 BODY, THROTTLE DOHC - REPLACE 1810300 0.8 0.8
2 REGULATOR AND/OR GASKETS DOHC - REPLACE 1810900 0.3 0.3
3 INJECTOR, FUEL (ONE OR ALL) DOHC - REPLACE 1811200 1.1 1.1
4 RAIL, FUEL DOHC - REPLACE 1811400 1.0 1.0
5 RING SEAL, CONNETOR ASSY FUEL SUPPLY 1811500 0.3 0.3
6 PIPE ASSY, FUEL RETURN - REPLACE 1811600 0.5 0.5
7 CONNECTOR ASSY, FUEL PRESSURE- REPLACE 1811700 0.3 0.3
85
182 ACCELERATOR CONTROL GSL
86
1B
Code G32D G23D
1 CABLE, ACCELERATOR CONTROL - REPLACE 1820300 0.4 0.4
1D
2 PEDAL, ACCELERATOR - REPLACE 1820500 0.4 0.4
3 MODULE, ACCELERATOR PEDAL - REPLACE 1820600 0.3 0.3
4 SPRING, THROTTLE RETURN - REPLACE 1820700 0.2 0.2
1E
5 PAD, ACCELERATOR PEDAL - REPLACE 1821100 0.2 0.2
6 BRACKET, ACCELERATOR PEDAL MOUNT - REPLACE 1821230 0.4 0.4
7 LEVER, ACCELERATOR CONTROL - REPLACE 1822310 0.3 0.3
8 SPRING, ACCELERATOR CONTROL - REPLACE 1822330 0.2 0.2
1F
9 BRACKET, ACCELERATOR CONTROL LEVER BEARING - 1822340 0.5 0.5
REPLACE
10 ROD, CONNECTING - REPLACE 1822350 0.3 0.3
1G
11 LEVER, REVERSING - REPLACE 1822380 0.4 0.4
12 LEVER, SLOTTED GATE - REPLACE 1822400 0.4 0.4
87
186 EMISSION CONTROL GSL

Code G32D G23D
1 SENSOR, KNOCK - REPLACE 1861300 0.8 0.8
A - Additional sensor, knock 186130A 0.8 0.8
2 ECU (ENGINE) - REPLACE 1862110 0.8 0.8
3 SENSOR, AIR TEMPERATURE - REPLACE 1862120 0.8 0.8
88
1G (GSL) - ENGINE INTAKE & EXHAUST
1B
191 AIR INTAKE SYSTEM GSL

1E
1F
1G
Code G32D G23D
1 AIR CLEANER - REPLACE 1910300 0.5 0.5
2 BRACKET, AIR CLEANER HOUSING MOUNTING-REPLACE 1910350 0.7 0.7
3 FILTER, AIR CLEANER - REPLACE 1910500 0.2 0.2
4 DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE 1910700 0.3 0.3
5 SENSOR, MAP - REPLACE 1910900 0.4 0.4
6 HOUSING, INLET AIR - REPLACE 1911310 0.5 0.5
7 METER, AIR MASS - REPLACE 1911320 0.2 0.2
8 DUCT INT AIR - REPLACE 1910800 0.3 0.3
89
193 INTAKE MANIFOLD GSL

Code G32D G23D
1 MANIFOLD, INTAKE LOWER - REPLACE 1930220 1.3 1.3
2 GASKET, UPPER INTAKE MANIFOLD - REPLACE 1930210 0.7 0.7
3 MANIFOLD, INTAKE UPPER - REPLACE 1930230 2.3 2.3
4 FLAP, RESONANCE - REPLACE 1932200 1.6 -
5 PACKING - REPLACE 1932400 1.6 -
6 SENSOR ASSY, MAP - REPLACE 1932700 - 0.2
7 ADAPTOR, MAP SENSOR - REPLACE 1932800 - 0.3
90
1B
194 EXHAUST MANIFOLD GSL
1D
1E
1F
1G
Code G32D G23D
1 MANIFOLD AND/OR GASKET EXHAUST DOHC-REPLACE 1940300 1.4 0.8
2 SENSOR, OXYGEN DOHC - REPLACE 1940600 0.2 0.2
3 COVER, EXHAUST MANIFOLD UPPER - REPLACE 1940810 0.6 0.5
4 COVER, EXHAUST MANIFOLD LOWER - REPLACE 1940830 0.4 0.4
91
196 EXHAUST PIPE LINE GSL

Code G32D G23D
1 HANGER AND/OR CLAMP, EXHAUST SYSTEM - REPLACE 1960300 0.2 0.2
2 PIPE, FRONT EXHAUST - REPLACE 1960900 0.6 0.6
3 SHIELD, CONVERTER - REPLACE 1961300 0.5 0.5
4 HEAT SHIELD, FRONT - REPLACE 1961400 0.5 0.5
5 HEAT SHIELD, CENTER MUFFLER - REPLACE 1961420 0.5 0.5
6 CONVERTER - REPLACE 1961500 0.6 0.6
7 MUFFLER - REPLACE 1962100 0.5 0.5
8 EXHAUST SYSTEM (COMPLETE) - REPLACE 1962500 1.5 1.5
9 PIPE, TAIL - REPLACE 1962600 0.5 0.5
10 GASKET 1962700 0.2 0.2
A - Additional - Gasket 196270A 0.2 0.2
92
SECTION 2
SUSPENSION
2C. FRONT SUSPENSION ................................................................. 94
213. KNUCKLE & HUB ............................................................................................ 94
214. FRONT SHOCK ABSORBER ........................................................................... 96
215. CONTROL ARM ............................................................................................... 98
2D. REAR SUSPENSION ................................................................. 100

231. REAR AXLE & STABILIZER ........................................................................... 100
232. REAR SHOCK ABSORBER ........................................................................... 104
2E. TIRES & WHEEL ....................................................................... 106

241. WHEELS ........................................................................................................ 106
2C - FRONT SUSPENSION
213 KNUCKLE & HUB
REAR KNUCKLE & HUB MULI LINKS
94
FRONT SUSPENSION - 2C
2C
Operation
NO. Operation Description KYRON ACTYON REMARK
Code
1 WHEEL ALIGNMENT 2130300 1.0 1.0
2D
2 HUB AND RBRAKE DISC - REPLACE
Right 2130470 0.5 0.5
Left 2130480 0.5 0.5
2E
Both 2130490 1.0 1.0
3 BEARING, FRONT HUB INNER AND/OR OUTER - REPLACE
Right 2130710 0.8 0.8
Left 2130720 0.8 0.8
Both 2130730 1.6 1.6
4 VALVE, LOCKING HUB SOLENOID - REPLACE 2130950 0.2 0.2
5 KNUCKLE ASSEMBLY, STEERING - REPLACE
Right 2131100 0.8 0.8
Left 2131200 0.8 0.8
Both 2131300 1.6 1.6
6 SEAL, KNUCKLE OIL - REPLACE
Right 2131400 1.2 1.2
Left 2131410 1.2 1.2
Both 2131420 2.0 2.0
7 SHIELD, DISC BRAKE - REPLACE
Right 2132100 0.6 0.6
Left 2132200 0.6 0.6
Both 2132300 1.2 1.2
8 HOSE, VACUUM, LOCKING HUB - REPLACE 2133750 0.3 0.3
9 O-RING, WHEEL END HUB - REPLACE 2136100 0.5 0.5
10 Additional 2136200 0.1 0.1
11 Opposite 2136300 0.4 0.4
12 HUB ACTUATOR, FRT LOCKING - REPLACE 2137100 0.8 0.8
13 Additional 2137200 0.2 0.2
14 Opposite 2137300 0.7 0.7
15 HOSE, LOCKING HUB AOTUATOR - REPLACE 2138100 0.3 0.3
95
214 FRONT SHOCK ABSORBER
96
2C
Operation
Code
1 SPRING, FRONT COIL - REPLACE
2D
Right 2140100 0.8 0.8
Left 2140200 0.8 0.8
Both 2140300 1.5 1.5
2E
2 SEAT AND/OR INSULATOR - REPLACE
Right 2141500 0.8 0.8
Left 2141600 0.8 0.8
Both 2141700 1.5 1.5
3 BUMPER, STOPPER - REPLACE
Right 2142330 0.8 0.8
Left 2142340 0.8 0.8
Both 2142350 1.5 1.5
4 BOOT, DAMPER STRUT - REPLACE
Right 2142360 0.8 0.8
Left 2142370 0.8 0.8
Both 2142380 1.5 1.5
5 SHOCK ABSORBER - REPLACE
Right 2143100 0.8 0.8
Left 2143200 0.8 0.8
Both 2143300 1.5 1.5
6 SHOCK ABSORBER & SPING ASSEMBLY - REPLACE
Right 2140600 0.6 0.6
Left 2140610 0.6 0.6
Both 2140620 1.0 1.0
7 YOKE, FRT SHOCK ABSORBER - REPLACE
Right 2145100 0.7 0.6
Left 2145200 0.7 0.6
Both 2145300 1.4 1.2
97
215 CONTROL ARM
98
2C
Operation
Code
1 LINK AND/OR BUSHING, FRONT STABILIZER - REPLACE
2D
Right 2150100 0.3 0.3
Left 2150200 0.3 0.3
Both 2150300 0.5 0.5
2E
2 STABILIZER, FRONT - REPLACE 2150500 0.5 0.5
3 CAM BOLT, FRONT LOWER ARM MOUNTING - REPLACE
Right 2151800 0.3 0.3
Left 2151810 0.3 0.3
Both 2151820 0.5 0.5
4 ARM ASSEMBLY, FRONT UPPER CONTROL - REPLACE
Right 2154000 0.4 0.4
Left 2154100 0.4 0.4
Both 2154200 0.8 0.8
5 BUSHING, FRONT UPPER CONTROL ARM - REPLACE
Right 2154230 0.5 0.5
Left 2154240 0.5 0.5
Both 2154250 1.0 1.0
6 BUSHING, FRONT LOWER CONTROL ARM - REPLACE
Right 2154260 1.0 1.0
Left 2154270 0.9 0.9
Both 2154280 0.9 0.9
7 ARM ASSEMBLY, FRONT LOWER CONTROL - REPLACE
Right 2154500 1.0 1.0
Left 2154600 1.0 1.0
Both 2154700 2.0 2.0
8 OIL, FRONT AXLE - REPLACE 2154900 0.3 0.3
9 BUSHING, STABILIZER SUPPORT 2155100 0.3 0.3
10 CLAMP, STABILIZER BUSHING 2156100 0.3 0.3
11 BUSHING, STABILIZER - REPLACE
Right 2157100 0.1 0.1
Left 2157200 0.3 0.3
Both 2157300 0.4 0.4
99
2D - REAR SUSPENSION
231-1 REAR AXLE & STABILIZER
5 - LINK SYSTEM
100
REAR SUSPENSION - 2D
2C
Operation
Code
1 STABILIZER, REAR - REPLACE 2310100 0.7 0.7
2D
2 DAMPER, STABILIZER - REPLACE
Right 2310300 0.3 0.3
Left 2310310 0.3 0.3
2E
Both 2310320 0.5 0.5
3 AXLE ASSEMBLY, REAR - REPLACE 2310900 2.4 2.4
AXLE ASSEMBLY, REAR - OVERHAUL 2310910 5.9 5.9
4 BREATHER AIR - REPLACE 2310930 0.3 0.3
5 CAP, HUB - REPLACE
Right 2312100 0.2 0.2
Left 2312200 0.2 0.2
Both 2312300 0.3 0.3
6 LINK AND/OR BUSHING, REAR STABILIZER - REPLACE
Right 2314100 0.3 0.3
Left 2314200 0.3 0.3
Both 2314300 0.6 0.6
7 KNUCKLE, REAR (DISC) - REPLACE
ZRight 2315100 1.1 1.1
Left 2315200 1.1 1.1
Both 2315300 2.2 2.2
8 COVER, DIFFERENTIAL BEARING - REPLACE 2315310 3.0 3.0
9 HOUSING, REAR AXLE - REPLACE 2316300 2.9 2.9
10 SHAFT, REAR AXLE - REPLACE
Right 2316410 0.7 0.7
Left 2316420 0.7 0.7
Both 2316430 1.4 1.4
11 GASKET, REAR DIFFERENTIAL CARRIER - REPLACE 2316630 0.8 0.8
12 NUT, LOCK - REPLACE 2316710 0.6 0.6
13 FLANGE, PINION - REPLACE 2316720 0.4 0.4
14 BEARING, PINION - REPLACE 2316730 3.0 3.0
15 BEARING, REAR AXLE SHAFT - REPLACE
Right 2316810 1.3 1.3
Left 2316820 1.3 1.3
Both 2316830 2.6 2.6
16 SEAL, DRIVE PINION GEAR OIL - REPLACE 2316850 3.0 3.0
17 RING, DIFFERENTIAL BEARING COVER - REPLACE 2316860 0.8 0.8
101
231-2 REAR AXLE & STABILIZER

IRS
102
2C
Operation
Code
18 SEAL, REAR AXLE OIL - REPLACE
2D
Right 2316900 1.0 1.0
Left 2317000 1.0 1.0
Both 2317100 2.0 2.0
2E
19 SEAL, REAR AXLE OIL INNER - REPLACE
Right 2317110 3.2 3.2
Left 2317120 3.2 3.2
Both 2317130 5.9 5.9
20 SEAL, REAR AXLE OIL OUTER - REPLACE
Right 2317140 3.2 3.2
Left 2317150 3.2 3.2
Both 2317160 5.9 5.9
21 SHIM, BEARING COVER - REPLACE 2317210 2.9 2.9
22 COVER, REAR AXLE CASE - REPLACE 2317700 0.5 0.5
23 CASE, DIFFERENTIAL - REPLACE 2317760 4.0 4.0
24 GEAR SET - REPLACE 2317780 0.4 0.4
25 OIL, REAR AXLE - REPLACE 2310920 0.4 0.4
26 SHAFT, REAR DRIVE AXLE 2318100 0.6 -
103
232 REAR SHOCK ABSORBER

IRS
5 - LINK SYSTEM
104
2C
Operation KYRON
NO. Operation Description ACTYON REMARK
Code IRS 5-LINK
1 SPRINGS, REAR COIL - REPLACE
2D
Right 2320100 0.8 0.8 0.8
Left 2320300 0.8 0.8 0.8
Both 2320400 1.6 1.6 1.6
2E
2 SEAT AND/OR INSULATOR - REPLACE
Right 2320700 0.8 0.8 0.8
Left 2320800 0.8 0.8 0.8
Both 2320900 1.6 1.6 1.6
3 SHOCK ABSORBER, REAR - REPLACE
Right 2321100 0.3 0.3 0.3
Left 2321200 0.3 0.3 0.3
Both 2321300 0.6 0.6 0.6
4 BUMPER, SHOCK - REPLACE
Right 2321410 1.1 1.1 1.1
Left 2321510 1.1 1.1 1.1
Both 2321610 2.0 2.0 2.0
5 RUBBER RING, REAR S/ABS - REPLACE
Right 2321630 1.1 1.1 1.1
Left 2321640 1.1 1.1 1.1
Both 2321650 2.0 2.0 2.0
6 ROD AND/OR BUSH, LATERAL - REPLACE 2323500 0.2 0.2 0.2
7 ARM & BUSH ASSEMBLY, REAR UPPER - REPLACE
Right 2323510 0.4 0.4 0.4
Left 2323511 0.4 0.4 0.4
Both 2323512 0.6 0.6 0.6
8 ARM & BUSH ASSEMBLY, REAR ROWER - REPLACE
Right 2323530 0.4 0.4 0.4
Left 2323531 0.4 0.4 0.4
Both 2323532 0.6 0.6 0.6
9 BUMPER, REAR SUSPENSION - REPLACE
Right 2324100 0.2 0.2 0.2
Left 2324200 0.2 0.2 0.2
Both 2324300 0.3 0.3 0.3
10 REAR SPRING SEAT 2327100 0.3 0.3 0.3
11 REAR UPPER ARM 2328100 0.5 0.5 0.5
12 COVER, LATERAL LOD - REPLACE 2329100 - - 0.2
13 BUSHING, LATERAL LOD - REPLACE 2329200 - - 0.4
14 BUSHING, LOWER ARM - REPLACE 2329300 0.5 0.5 0.5
15 BUSHING, UPPER ARM - REPLACE 2329400 0.5 0.5 0.5
105
2E - TIRES & WHEEL
2E - TIRES & WHEEL

241 WHEELS
106
TIRES & WHEEL - 2E
2C
Operation
Code
1 WHEEL - BALANCE 2410700 0.3 0.3
2D
A - Each additional 241070A 0.2 0.2
2 WHEEL (ONE) - REPLACE 2411100 0.4 0.4
2E
3 TIRE (ONE) - REPLACE 2411300 0.3 0.3
4 STEM, VALVE (ONE) - REPLACE 2411500 0.5 0.5
5 BOLT, WHEEL - REPLACE 2411700 0.2 0.2
6 CAP, WHEEL - REPLACE 2411900 0.2 0.2
7 WINCH ASSY - SPARE TIRE - REPLACE 2411800 0.4 0.4
107
MEMO
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SECTION 3
DRIVE LINE & AXLE

3A. DRIVE LINE & AXLE .................................................................. 110
321. AXLE SHAFT PARTS ..................................................................................... 110
323. PROPELLER SHAFT ..................................................................................... 112
3A - DRIVE LINE & AXLE

321 AXLE SHAFT PARTS
110
DRIVE LINE & AXLE - 3A
3A
Operation
Code
1 AXLE ASSEMBLY, FRONT DRIVE - REPLACE 3211100 2.1 2.1

AXLE ASSEMBLY, FRONT - OVERHAUL 3211310 5.0 5.0
2 SHAFT ASSY, FRONT AXLE - REPLACE
Right 3211510 0.8 0.8
Left 3211520 0.8 0.8
Both 3211530 1.6 1.6
3 BEARING, OUTER PINION - REPLACE 3211730 2.0 2.0
4 BEARING, INNER PINION - REPLACE 3211740 5.0 5.0
5 GEAR SET (PINION, RING, SIDE), FRONT AXLE - REPLACE 3211750 5.0 5.0
6 COVER, FRONT AXLE HOUSING - REPLACE 3211760 2.2 2.2
7 BRACKET, FRONT AXLE MOUNTING - REPLACE
Right 3211770 0.9 0.9
Left 3211780 0.9 0.9
Both 3211790 1.8 1.8
8 BEARING BALL AND/OR SEAL, SHAFT OIL - REPLACE
Right 3211830 0.7 0.7
Left 3211840 0.7 0.7
Both 3211850 1.2 1.2
9 SHAFT, INNER - REPLACE
Right 3211860 0.7 0.7
Left 3211870 0.7 0.7
Both 3211880 1.2 1.2
10 HOSE, AIR BENT - REPLACE 3212100 0.3 0.3
11 PINION GEAR, FRONT AXLE - REPLACE 5.0 5.0
12 OIL, FRONT AXLE - REPLACE 3211320 0.6 0.6
13 BOOT SET, OUTER - REPLACE
Right 3211610 1.9 1.9
Left 3211620 1.9 1.9
Both 3211630 3.8 3.8
14 OIL SEAL (PINION), FRONT AXLE - REPLACE 3211640 0.4 0.4
15 RING GEAR, FRONT AXLE - REPLACE 3211650 5.0 5.0
111
323 PROPELLER SHAFT
KYRON ACTYON
Operation
Code
1 SHAFT, PROPELLER - REPLACE

Front 3230110 0.3 0.3
Rear 3230120 0.4 0.4
2 JOINT, UNIV, PROPELLER FRONT - REPLACE
One 3230310 0.7 0.7
Two 3230320 1.0 1.0
3 JOINT, UNIV, PROPELLER REAR - REPLACE
One 3230330 0.7 0.7
Two 3230340 1.0 1.0
4 YOKE, JOINT, FRONT - REPLACE
One 3230510 0.7 0.7
Two 3230520 1.2 1.2
5 YOKE, JOINT, REAR - REPLACE
One 3230530 0.7 0.7
Two 3230540 1.2 1.2
112
SECTION 4
BRAKES
4A. HYDRAURIC BRAKE ............................................................... 114
425. BRAKE PIPE ................................................................................................ 114
428. BRAKE PEDAL & MOUNT .......................................................................... 115
4B. MASTER CYLINDER & BOOSTER ........................................ 116

431. MASTER CYLINDER & BOOSTER ............................................................ 116
4D. FRONT BRAKE ........................................................................ 117

445. FRONT BRAKE ............................................................................................ 117
4E. REAR BRAKE .......................................................................... 118

456. REAR BRAKE .............................................................................................. 118
4F. ANTI-LOCK BRAKE SYSTEM ................................................. 120

462. REAR BRAKE .............................................................................................. 120
4G. PARKING BRAKE .................................................................... 122

478. PARKING BRAKE ........................................................................................ 122
4A - HYDRAURIC BRAKES
4A - HYDRAURIC BRAKE
425 BRAKE PIPE
NON - ABS
ABS/ESP
Operation
Code
1 HOSE, BRAKE - REPLACE

Right Front 4250100 0.5 0.5
Lef Front 4250200 0.5 0.5
Both Front 4250300 0.9 0.9
Right Rear 4250400 0.4 0.4
Left Rear 4250500 0.4 0.4
Both Rear 4250600 0.7 0.7
2 PIPE, REAR BRAKE - REPLACE
Right 4250800 0.5 0.5
Left 4251100 0.5 0.5
3 PIPE, MASTER CYLINDER TO MODULATOR VALVE FRONT 4251500 0.5 0.5
-REPLACE
4 PIPE, FRONT BRAKE - REPLACE
Right 4253800 0.7 0.7
Left 4253810 0.7 0.7
Both 4253820 1.2 1.2
114
HYDRAURIC BRAKES - 4A
4A
428 BRAKE PEDAL & MOUNT
4B
4D
4E
4F
4G
Operation
Code
1 PEDAL AND/OR BUSHING, BRAKE - REPLACE 4280100 0.5 0.5

2 SPRING, BRAKE PDEAL RETURN - REPLACE 4280300 0.5 0.5
3 PAD, BRAKE PEDAL - REPLACE 4280500 0.2 0.2
4 SWITCH, STOP LAMP - REPLACE 4280700 0.2 0.2
5 BRACKET, BRAKE PEDAL - REPLACE 4281300 0.5 0.5
115
4B - MASTER CYLINDER & BOOSTER
4B - MASTER CYLINDER & BOOSTER

431 MASTER CYLINDER & BOOSTER
Operation
Code
1 CYLINDER, BRAKE MASTER - OVERHAUL 4310100 1.4 1.4

CYLINDER, BRAKE MASTER - REPLACE 4310200 0.6 0.6
2 VALVE, BOOSTER CHECK - REPLACE 4310210 0.2 0.2
3 SEAL, BOOSTER MOUNTING - REPLACE 4310220 0.3 0.3
4 BRAKE SYSTEM - BLEED 4310230 1.2 1.2
5 BOOSTER, VACUUM POWER BRAKE - REPLACE 4310600 0.8 0.8
6 RESERVOIR, BRAKE MASTER CYLINDER - REPLACE 4310800 0.4 0.4
7 HOSE, BRAKE BOOSTER VACUUM - REPLACE 4312100 0.2 0.2
MASTER CYLINDER & BOOSTER - 4B
4D - FRONT BRAKE
4A
445 FRONT BRAKE
4B
4D
4E
4F
4G
Operation
Code
1 PADS, DISC BRAKE (FRONT) - REPLACE

Both 4450100 0.6 0.6
Right 4450110 0.4 0.4
Left 4450120 0.4 0.4
2 CALIPER ASSEMBLY, FRONT - REPLACE
Right 4450300 0.6 0.6
Left 4450400 0.6 0.6
Both 4450500 1.2 1.2
117
4E - REAR BRAKES
4E - REAR BRAKE
456 REAR BRAKE
KYRON / ACTYON
KYRON
118
REAR BRAKES - 4E
4A
Operation
Code
1 PLATE, BRAKE BACKING - REPLACE
4B
Right 4563800 0.8 0.8
Left 4563900 0.8 0.8
Both 4564100 1.4 1.4
4D
2 SLIDING CALIPER, REAR - REPLACE
Right 4564300 0.6 0.6
Left 4564400 0.6 0.6
Both 4564500 1.2 1.2
4E
3 DISC, REAR BRAKE - REPLACE
Right 4565100 0.5 0.5
Left 4565200 0.5 0.8
4F
Both 4565300 1.0 1.0
4 PAD, REAR BRAKE - REPLACE
Right 4566300 0.6 0.6
Left 4566400 0.6 0.6
4G
Both 4566500 1.2 1.2
5 HUB, REAR - REPLACE
Right 4566700 1.3 1.3
Left 4566800 1.3 1.3
Both 4566900 2.3 2.3
6 BACK PLATE (IRS), RR BRAKE - REPLACE 4566910 1.9 -
7 ABS IMPULSERING (REAR) - REPLACE 4566920 0.8 0.8
119
4F - ANTI-LOCK BRAKE SYSTEM
4F - ANTI-LOCK BRAKE SYSTEM

462 ABS SYSTEM
120
ANTI-LOCK BRAKE SYSTEM - 4F
4A
Operation
Code
1 SENSOR, WHEEL SPEED, FRONT AND/OR REAR - REPLACE
4B
Right Front 4620100 0.5 0.5
Left Front 4620200 0.4 0.4
Both Front 4620300 0.9 0.9
4D
Right Rear 4620400 0.4 0.4
Left Rear 4620500 0.3 0.3
Both Rear 4620600 0.7 0.7
2 HYDRAULIC MODULATOR ASSEMBLY (ABS, ABD) - REPLACE 4620800 0.8 0.8
4E
3 ECU (ABS) - REPLACE 4620900 0.9 0.9
4 ABS IMPULSERING - REPLACE
Right Front 4620910 1.0 1.0
4F
Left Front 4620920 1.0 1.0
Both Front 4620930 1.9 1.9
Right Rear 4620940 1.5 1.5
Left Rear 4620950 1.5 1.5
4G
Both Rear 4620960 2.8 2.8
5 SENSOR, ACCEL - REPLACE 4620970 0.8 0.8
6 ESP SENSOR CLUSTER - REPLACE 4620980 0.4 0.4
121
4G - PARKING BRAKES
4G - PARKING BRAKE
478 PARKING BRAKE
KYRON
KYRON / ACTYON
122
PARKING BRAKES - 4G
4A
Operation
Code
1 PARKING BRAKE - ADJUST 4780100 0.3 0.3
4B
2 GRIP, PARKING BRAKE HANDLE - REPLACE 4780200 0.4 0.4
3 CABLE, PARKING BRAKE - REPLACE
Front 4780500 0.6 0.6
4D
Rear Both 4780600 0.7 0.7
4 SPRING, TENSION - REPLACE 4780700 0.4 0.4
5 BODY, PARKING BRAKE - REPLACE 4781600 0.6 -
6 PEDAL, PARKING BRAKE - REPLACE 4780810 0.5 -
4E
7 DAMPER, PARKING BRAKE - REPLACE 4780830 0.4 -
8 CABLE, RELEASE - REPLACE 4780890 0.6 -
9 CONTROL UNIT, PARKING AID - REPLACE 4781000 0.7 0.6
4F
10 SENSOR, PARKING BRAKE AID - REPLACE 4781010 1.0 1.0
11 SHOE ASSY, PARKING BRAKE - REPLACE
Rear Both 4781320 1.5 1.5
Right 4781300 0.9 0.9
4G
Left 4781310 0.9 0.9
12 EQUALIZER, PARKING BRAKE - REPLACE 4781400 0.3 0.3
13 HANDLE, PARKING BRAKE - REPLACE 4781410 0.3 -
14 SWITCH, PARKING BRAKE - REPLACE 4782000 0.5 0.5
123
MEMO
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SECTION INDEX

Labor Time Guide A. GENERAL INFORMATION

1-2. TYPES OF OPERATION

Supplementary Operation (Adds)

1-3. TIME ALLOWANCES

2. HOW TO READ THIS MANUAL

1B - DIESEL ENGINE MECHANICAL

Operation KYRON ACTYON

3B. Supplementary Operation

Main group code

Main Group Code

Auxiliary Code Description

Supplementary Operation (ADD)

G23D : M161 Gasoline Engine

3. HOW TO USE THIS MANUAL

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

Model : KYRON & ACTYON

1312700 VALVE - REPLACE 7.0

Operation KYRON ACTYON

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

4-2. LABOR TIME

4-3. REPAIR TYPE

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

PF OPERATION CODE HOUR

N01 Hard start, no start N41 Sponge pedal

N83 Gas leak, gas entering N92 Inoperative

5-2. CAUSE CODE

R01 Scored, scratched or chipped R19 Improperly machined

5-3. PAINT CODE

P01 Oversprayed, drip P19 Atmospheric fallout

7. MAIN GROUP CODE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

1D. (DSL) ENGINE COOLING..............................................................35

1E. (DSL) ENGINE ELECTRICAL ........................................................39

1F. (DSL) ENGINE CONTROLS ..........................................................43

1G. (DSL) ENGINE INTAKE & EXHAUST ...........................................47

1B - DIESEL ENGINE MECHANICAL

Operation KYRON ACTYON

121 ENGINE BLOCK DSL

122 CRANKSHAFT & PISTON DSL

123 OIL PAN & PUMP DSL

131 CYLINDER HEAD DSL

132 CAM SUPPORT & SHAFT DSL

Operation KYRON ACTYON

Operation KYRON ACTYON 1D

136 INJECEION PIPE DSL

Operation KYRON ACTYON

139 VACUUM SYSTEM DSL

Operation KYRON ACTYON

Operation KYRON ACTYON 1D

1 COOLANT - REPLACE 1410100 0.5 0.5 0.5

143 COOLING FAN DSL

Operation KYRON ACTYON

Operation KYRON ACTYON 1D

148 THERMOSTAT & WATER PUMP DSL

Operation KYRON ACTYON