SsangYong Actyon & Actyon Sports 2005–2011 Service Manual Set

The base manual supplies the core SUV repair procedures. The supplement adds pickup-specific changes, Euro IV diesel updates and separate gasoline-engine chapters; these sections need to be matched to the vehicle and engine configuration being serviced.

The dedicated wiring publication is labeled Euro IV - LHD. Buyers working on right-hand-drive or non-Euro IV vehicles should note this configuration limit.

PDF Search, Bookmarks and Page Breakdown

Search and diagram navigation: Main service text is searchable, but some wiring-diagram labels are outside the searchable text layer. Embedded PDF bookmarks organize the engine, body, supplement and wiring sections. Small pin numbers and wire codes in dense diagrams require zooming.

One printable English-language PDF contains 2,172 pages total, including seven section-divider pages, 16 memo pages, 13 blank pages, the supplement’s publication page and the wiring publication’s cover.

Engine Overhaul, Drivetrain Service and Electrical Diagnosis

The following highlights are a selection of the contents, rather than a complete contents list. Additional topics include audio-system service and auto-cruise system information.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head and valve work, camshaft/HLA service, timing-chain installation, crankshaft inspection and piston/connecting-rod repair.

• Fuel and emissions: High-pressure pump and injector service, common-rail diagnosis, VGT turbocharger and EGR repair, plus Euro IV fuel-system changes and injector coding.

• Transmission and 4WD: Automatic-transmission overhaul, manual-transmission disassembly and inspection, clutch service, part-time transfer-case repair and IWE locking-hub procedures.

• Chassis and restraints: Front and rear axle service, suspension and power-steering repair, ABS/ESP diagnosis and airbag-system procedures.

• Body and climate control: FATC air conditioning, FFH/PTC heating, body and deck repair, doors, tailgate, trim, seats, belts and sunroof service.

• Electrical fault finding: SCAN-100 loading and reprogramming, module-specific DTC tables, wiring diagrams, connector views, ground locations and fuse-box circuits.

The assembly-level procedures suit professional technicians, independent repair shops and experienced owners with the diagnostic equipment and special tools required for the work.

Diesel and Gasoline Engine Repair

D20DT mechanical work: Oil-leak diagnosis, compression and cylinder-leakage tests accompany internal disassembly and overhaul. Detailed coverage reaches crankshaft bearings and thrust washers, piston selection, the dual-mass flywheel, timing-chain guides and hydraulic lash adjusters. Cooling, lubrication and preheating systems have their own service material.

Euro IV differences: The diesel supplement documents the E-EGR valve, EGR cooler, throttle body, PCV oil separator, intake manifold, fuel rail and high-pressure pipe changes. It distinguishes C2I/C3I injector coding and the different engine-ECU connector arrangements.

Fuel-pressure and injection-control explanations accompany MDP learning and HFM, temperature, camshaft, crankshaft, knock and boost-sensor information. These variant-specific descriptions help match diagnostic procedures and connector references to the installed system.

G23D gasoline coverage: Separate chapters address engine assembly, mechanical repair, cooling, engine electrical systems and intake/exhaust service. Their procedures remain distinct from the common-rail diesel material.

Transmission Overhaul and Pickup-Specific Changes

The ION (BTRA) material explains electronic and hydraulic control, power flow and valve-body operation. Fluid and leak diagnosis, road and garage-shift tests, on-vehicle service, internal assembly, band adjustment and TCU diagnosis support work beyond transmission removal.

Manual-transmission coverage includes internal inspection, maintenance and special-tool references. The clutch, transfer case and locking hubs are treated separately.

Actyon Sports sections identify solid-axle and LCRV differences, revised TCCU information, deck construction and pickup-specific body and electrical changes.

Wiring, Control Modules and Convenience Systems

Named wiring groups include Starting & Charging, Preheating Circuit, G23 ECU, D20DT ECU 3.2, Diagnosis Circuit, A/T Shift Lock, TCCU and Cluster. Connector identification, ground and splice information, power-distribution circuits and pin views provide the references needed to follow circuits between components.

Diagnostic tables address diesel, gasoline and CDPF engine faults, together with TCU, brake, airbag and transfer-case faults. Other tables cover RK-STICS, FFH, rain sensor, FATC, TGS lever, power-trunk and CCCS systems.

Convenience-system chapters cover immobilizer functions, wipers and washers, parking aid and lamps, alongside the body and climate-control material.

Workshop References, Tools and Repair Cautions

Reference tables provide component-specific torques, fluid capacities, pressure-test specifications, wear and machining limits, electrical test values, alignment data and clearances. Bearing and piston selection information, coding/calibration material, maintenance schedules and recommended-fluid tables support repair planning.

Special-tool references include injector puller Y99220072B, valve remover/installer Y99220082B, compression-pressure adapter and gauge Y99220092B, piston-protrusion measuring jig Y99220122B and HLA remover Y99220152B. Dedicated high-pressure pump and fuel-pipe tools are also identified.

Fuel-system cautions: The manual addresses nonreusable high-pressure pipes and protection of exposed openings; reused connections can leak, while contamination can damage the pump and injectors.

Camshaft and sealant cautions: Uneven bearing-cap release can damage the camshafts. The D20DT material also prohibits Loctite 5900 and warns about sealant blocking the vacuum-pump oil passage.

High-pressure fuel, airbag, brake, refrigerant and vehicle-lifting procedures require the isolation, pressure-release and support methods specified in the manual.

A Preview of Piston and Coolant-Sensor Inspection Data

For D20DT piston inspection, the engine-housing chapter specifies permissible piston protrusion of 0.765–1.055 mm relative to the crankcase mating surface, with the piston at TDC.

Cooling-system electrical references list coolant-temperature sensor resistance of 3.33–3.78 kΩ at 20°C and 0.32–0.35 kΩ at 80°C. These temperature-dependent values illustrate the test data supplied alongside mechanical inspection specifications.