Repair Time Manual PS

Transcription

SECTION CODE INDEX
CODES
SEC.
DESCRIPTION
ASS.
1A
HEATER AND VENTILATION
1A-01 Heating control
1A-02 Heater and ventilator
02
BUMPER, ENGINE HOOD AND FRONTAL
02-01 Bumper
02-02 Engine hood
02-03 Frontal
3
CODES
SEC.
Feeding and emission control
6C-01 Fuel feeding
6C-02 Air overfeeding
6C-03 Sensors, thermistors and engine control
switches
6G
Engine electrical system
6G-01 Generator and battery
6G-02 Starting motor
6G-03 Thermo-starting and E.C.M. control unit
Engine exhaust system
6K-01 Exhaust maninfold
6K-02 Muffler
Engine lubrication
6L-01 Oil pump
6L-02 Oil filter and cooler
6L-03 Turbocharger lubrication
STEERING, SUSPENSION AND WHEELS
Steering
3B-01 Tie rod and rods
3B-02 Power-steering system
6K
3C
Steering wheel
3C-01 Steering wheel and columns
6L
3D
Front suspension
3D-01 Front springs
3D-02 Front shock absorber
3E
Rear suspension
3E-01 Rear springs
3E-02 Rear shock absorber
3F
Wheels
3F-01 Wheels and tyres
Front drive shaft
4A-01 Front shaft assembly
4A-02 Front wheel hub assembly
4A-03 King pin assembly
4B
Rear drive shaft
4B-01 Rear shaft assembly
4B-02 Rear wheel hub assembly
4C
Propeller shafts
4C-01 Propeller shaft
05
7
7A
7C
PROPELLER SHAFTS
4A
DESCRIPTION
6C
3B
4
ASS.
TRANSMISSION
Gear box
7A-01 Transmission case
7A-02 Internal organs
7A-03 Gear shifting control
Clutch
7C-01 Hydraulic components
7C-02 Mechanical components
7D
Transfer
7D-01 Transfer case
7D-02 Internal organs
7D-03 Transfer selector lever
7E
Front and rear differential
7E-01 Front differential gear
7E-02 Rear differential gear
08
BRAKE SYSTEM
05-01 Parking brake and disc brake components
05-02 Hydraulic circuit and servobrake
08-01
08-02
08-03
08-04
08-05
BODY ELECTRICAL SYSTEM
Wiring and relays
Switches
Indicators
Headlamp
Other lamps
09-01
09-02
09-03
09-04
09-05
09-06
09-07
09-08
09-09
BODY AND FRAME
Body panels
Roof and moldings
Doors and locks
Trims and door regulators
Windows glass
Seats and seat belts
Inner garnishes
Rubber and weatherstrip profiles
Chassis frame assembly
ENGINE AND ITS SYSTEMS
6
6A-01
6A-02
6A-03
6A-04
6A-05
6A-06
6A-07
6A-08
6A-09
6A-10
6A-11
6A-12
Engine assembly
Stripped engine
Complete engine
Cylinder block
Oil pan
Cylinder head
Crankshaft
Pistons and connecting rods
Engine flywheel
Camshaft and timing belt
Auxiliary organs group
Engine front mounting
Fuel injection
6B-01
6B-02
6B-03
6B-04
Engine cooling
Water pump, thermostat and heat excharger tubing
Fan and control belts
Water radiator and degasing box
Water hoses
6A
6B
09
FOREWORD
This Flat Rate Manual contains the operations and times assigned to repair SANTANA vehicles related in model code list
in GENERAL section. The times assigned will be employed to calculate the labour cost of those repairs done during the
warranty period of the vehicle.
The use of these time assignments as a guide for those services paid by the customer, is subject to the dealer's criteria.
SANTANA MOTOR, S. A.
ILLUSTRATION INDEX
1A-01-02
02-01-02-03
3B-01-02
3C-01
3D-01-02
3E-01-02
3F-01
4A-01-02-03
4B-01-02
4C-01
05-01
05-02
6A-01-02
6A-03-04
6A-05
6A-06-07-08
6A-09
6A-10-11
6A-12
6C-01
6G-01-02-03
6B-01-02
6B-03-04
6C-02
6C-03
6K-01-02
6L-01-02-03
7A-01-02-03
7E-01-02
09-01-02
7C-01-02
08-01-02-03
09-03
7C-01-02-03
08-04-05
09-04-05
09-06-07
09-08
09-09
CONTENTS
GENERAL
Page 1
HEATER AND VENTILATION
1A
BUMPER, ENGINE HOOD AND FRONTAL
02
STEERING, SUSPENSION AND WHEELS
3
PROPELLER SHAFT
BRAKE SYSTEM
ENGINE AND ITS SYSTEMS
TRANSMISSION
BODY ELECTRICAL SYSTEM
BODY AND FRAME
4
05
6
7
08
09
GENERAL
CONTENTS
1.
2.
3.
4.
5.
PAG
HOW TO READ THIS MANUAL ........................................................................
HOW TO USE THIS MANUAL ...........................................................................
CONDITION FOR ESTABLISHING FLAT RATE TIMES ...................................
REPAIR TIME .....................................................................................................
MODEL CODE LIST ...........................................................................................
-1-
2
5
8
8
8
Page 1
1. HOW TO READ THIS MANUAL
6A-06-07-08 ENGINE
6 ENGINE AND ITS SYSTEMS
1
Section number
Indicates section number and the product it refers to (consult index on back cover).
2
Section code
Indicates section code, referring to a concrete par of the product or to a system (consult index on back cover).
3
Assembly components code
Indicates assembly components code of the product (consult index on back cover).
4
Position
The position number corresponds with illustration.
5
Operation code
The operation code is formed by six characters that indicate:
-2-
1
6
3
8
7
2
5
4
51
52
9
- Basic operation code 51 :
Basic operation code
51
6A 06 18
Section code
Component assembly code
Correlative operation number
- "OTHER" operation code 52 :
"OTHER" operation code
52
6A 06 00
Section code
Components assembly code
The two zeros in this position form the "OTHER" operation code. This code is used in
those operations not contemplated in this manual, adjudicating as real repair time
used and detailing the operation.
6
C/V Code variation
This code indicates additional time conceded to a determined operation because of repair time difference
existence, due to the different model equipment or exclusive time of a model. The C/V code, is represented
by the letters (A) (B) (C) and (D) which indicate the following:
A : Additional time for equipping air conditioner or sliding glass on laterals
B : Additional time for equipping mechanical injection engine or this engine exclusive
C : Additional time for equipping electronic injection engine (Common Rail) or this engine exclusive
D : Additional time for equipping sliding glass on laterals
-3-
7
Repair times
Repair times are expressed in hours or in tenths of an hour
8
Operation denomination
- Describes what the operation consists of in the time given.
- Specific situation, the state of the product and installation level of product, the repair time given corresponds
to the described operation in total.
When situation is specified, the state or installation level of the product, complementary operation time
must be added to the basic operation.
- When removal or installation (D/M) and substituting, the same time is given, except if a different time for each
case is specified.
- Some operations may present doubts as to if repair time given includes certain steps of the operation such as
adjustments, timings, diagnosis, etc. In these cases, doubts are solved with "INCLUDES" , "EXCLUDES"
clarifications, or with (*).
If the "INCLUDE", "EXCLUDE" CLARIFICATIONS or the (*) are not mentioned, it is understood that all the steps
of the operation are included until its final mounting or product functioning.
9
Symbols " " " - "
- When the symbol appears " " in the repair time column, it means there is no established time for this operation.
- When the "-" symbol appears in the repair time column, it means that this operation does not correspond or does
not exist for this model.
*
*
-4-
2. HOW TO USE THIS MANUAL
When you have done a repair, substitution, adjustment, etc..., consult this manual to apply correct operation code
and repair time given; see examples 1, 2 or 3.
When filling in the application form, bear the following in mind:
- Make sure you note down basic operation code, the description and repair time given to each of the operations.
- Reasonably choose the complementary operations which intervene in the reparation, substitution, etc., done.
- When using the "OTHER" code (00), note down "real time"; this will correspond to invested time on repair,
substitution, etc. done. In the "Break down description" space of the form, specify real service done.
Example 1: (When doing a service which contains complementary operation and additional time because of C/V)
Model code: AL01 (mechanical injection)
Basic operation: CONNECTING ROD CRANKPINS DIAMETER MEASURE (FOUR)
Complementary Operations: D / M CONNECTING ROD AND PISTON ASSEMBLY (SET)
Additional time: ADDITIONAL TIME WITH AIR CONDITIONER
ADDITIONAL TIME MECHANICAL INJECTION ENGINE
Step 1. Look for CRANKSHAFT in the SECTION CODES AND ASSEMBLY INDEX, or look for CRANKSHAFT in
the ILLUSTRATIONS INDEX.
Step 2. Open page 6A-06, look for connecting rod crankpin number and the operation that has been done.
Step 3. Look for complementary operations.
Step 4. Look for additional time because of C/V (code variation)
Basic
operation:
CONNECTING ROD CRANKPINS DIAMETER
MEASURE (FOUR)
6A0618
Complementary
operation:
D/M CONNECTING ROD AND PISTON
ASSEMBLY (SET)
6A0710
Additional time:
+
A
B
6A0618
Operation time:
0.3
6A0710
+
11.7
-5-
A
+
+
11.7
+
ADDITIONAL TIME WITH AIR CONDITIONER
Operation code:
0.3
+
B
0.2 + 0.1
=
12.3
+
0.2
0.1
+
Example 2: (When a service is done that does not contain complementary operation and does contain additional
time)
Basic operation: D / M CRANKSHAFT PULLEY
Additional time: ADDITIONAL TIME WITH AIR CONDITIONER
Step 1. Look for CRANKSHAFT in the SECTION AND ASSEMBLY CODES INDEX, or look for CRANKSHAFT
PULLEY directly in the ILLUSTRATIONS INDEX.
Step 2. Open page 6A-06, look for crankshaft pulley position number and the operation which has been
done.
Step 3. Look for additional time operation.
Basic
Operation:
D/M CRANKSHAFT PULLEY
6A0622
Complementary
Operation:
Additional time:
Operation code:
6A0622
Operation Time:
1.3
A
A
+
0.2
-6-
=
1.5
1.3
+
+
+
+
0.2
Example 3: (When the OTHER "00" has to be used)
Basic operation: CRANKSHAFT PULLEY ALIGNMENT CHECK
Step 1. Look for CRANKSHAFT in the SECTION AND ASSEMBLY CODES INDEX, or look for CRANKSHAFT
PULLEY directly in the ILLUSTRATIONS INDEX
Step 2. Open page 6A-06, look for crankshaft pulley position number and the operation which has been
done.
Basic
operation:
CRANKSHAFT PULLEY ALIGNMENT CHECK
?
?
ª
If there is no operation that corresponds to the service done, note down real time using the "00" OTHER
code
Operation code: ................................................................................................................................ 6A0600
Operation time: .................................................................................................................................
0.3
u
Full time
When using the "00" OTHER code, describe the break down and the corrective measures in the "Break down
Description" space of the form
-7-
3. CONDITION FOR ESTABLISHING FLAT RATE TIMES
Definition of flat rate time
The flat rate time in this manual refer to the time required to perform warranty related services and repair. It consists
of the following.
Composition:
Flat rate time
Set up time
Net working time
Margin time
Set up time
The time required for set-up, such as:
- Preparing parts, hand tools, special tools, etc.
- Preparing necessary equipment
- Preparing necessary measuring instruments
- Moving the vehicle to and from hoist or wordstall area.
Net working time
The actual time spent on the repair/replacement service. This includes inspection, adjustment and road test as well
as simple diagnosis.
Margin time
The time accompanying the actual working time and time spent for the following:
- Relieving fatigue.
- Cleaning the service shop.
- Others suchas cleaning and toggins of parts.
The specified margin time corresponds to 20% of the net working time.
Working conditions
The following conditions are prerequisites for deternining the net working time:
- The hand tools, special tools and equipment are as specified in Service Manual.
- Tools, equipment, power sources and other supplies are ready to be used.
- The technician is experienced with SANTANA vehicles.
- The work is performed at what is considered to be a normal word pace.
4. TIMES
The flat rate time in this manual for perform warranty releated services and repair, are expressed in hours and tenths
hour.
Examples
0.1 hour
=
6 minutes
0.2 ”
=
12
”
0.3 ”
=
18
”
0.4 ”
=
24
”
0.5 ”
=
30
”
0.6 ”
=
36
”
0.7 ”
=
42
”
0.8 ”
=
48
”
0.9 ”
=
54
”
1.0 ”
=
60
”
To convert minutes to the nearest hour and tenths of an horu devide munutes by 60
Example:
1 hour and 20 minutes (80 minutes)
80 ÷ 60 = 1.333 (1.3 hours)
To convert hours and tenths of hour to minutes multiply hours and tenths by 60
Example:
1 hour and 0.3 (1.3)
1.3 x 60 = 78 minutes (1 hour and 18 minutes)
5. MODEL CODE LIST
MODEL
CODE
AL01
AL02
AL03
MODEL
5 DOORS
LONG
PS-10
HARD ROOF
3 DOORS
LONG
PS-10
CANVAS
AWNING
3 DOORS
LONG VEHICLE
-8-
1A
HEATER AND VENTILATION ......................................................................
1A
HEATING CONTROL ....................................................................................... 1A-01
HEATER AND VENTILATOR ........................................................................ 1A-02
1A-01-02 HEATER AND VENTILATION
HEATING CONTROL
1A-01
HEATER AND VENTILATOR
1A-02
COMPONENTS
POS
COMPONENTS
POS
Heating control panel
1
Air inlet assembly
Heating control lever assembly
2
Fan and protector
5
6
Heater switch
3
Heater assembly
7
Control assembly and heater driving cables
4
Ventilator duct
8
Demister duct
9
Ventilation nozzle
10
COMPONENTS
POS
HEATER AND VENTILATION 1A-01-02
BASIC
POS OPERATION
CODE
C/V
1A-01. HEATING CONTROL
1A-02. HEATER AND VENTILATOR
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
1
1A0101
HEATING CONTROL PANEL SUBSTITUTION
0.2
0.2
0.2
2
1A0102
HEATING CONTROL LEVER ASSEMBLY SUBSTITUTION
3.3
3.3
3.3
0.1
0.1
0.1
0.2
0.2
0.2
0.4
0.4
INCLUDES:
- Control cables adjustment
3
1A0103
HEATING SWITCH SUBSTITUTION
(HEATING CONTROL LEVERS ASSEMBLY DISMOUNTED)
4
1A0104
HEATING DRIVER CABLE SUBSTITUTION (ONE)
(HEATING CONTROL LEVERS ASSEMBLY DISMOUNTED)
4
1A0105
CONTROL ASSEMBLY ADJUSTMENT AND HEATING DRIVER CABLES
0.4
1A0100
OTHER
* * *
5
1A0201
AIR INLET ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
6
1A0202
FAN AND PROTECTOR ASSEMBLY SUBSTITUTION
1.0
1.0
1.0
HEATER ASSEMBLY SUBSTITUTION
2.4
2.4
2.4
VENTILATOR DUCT RH OR LH SUBSTITUTION
0.2
0.2
0.2
0.1
0.1
0.1
0.1
0.1
INCLUDES:
- Control cables adjustment
7
1A0203
8
1A.02.04
(SEPARATED GLOVE BOX)
9
1A0205
DEMISTER DUCT SUBSTITUTION (ONE)
(SEPARATED GLOVE BOX)
10
1A0206
VENTILATION NOZZLE SUBSTITUTION (ONE)
0.1
1A0200
OTHER
* * *
02
BUMPER, GRILLE AND ENGINE HOOD ..............................................
02
BUMPER .............................................................................................................. 02-01
ENGINE HOOD .................................................................................................. 02-02
GRILLE ................................................................................................................. 02-03
02-01-02-03 BUMPER, GRILLE AND ENGINE HOOD
BUMPER
02-01
ENGINE HOOD
02-02
GRILLE
02-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front bumper
1
Hood assembly
7
Front grille
12
Cover outer bumper
2
Hood hinge
8
Fender assy
13
Cover center bumper
3
Opener driver cable
9
Superior profile
14
Rear bumper
4
Lock assembly
10
Front frame assembly
15
Cushion lateral bumper
5
Hood stay
11
Central profile
16
Cushion center bumper
6
Headlamp
17
BUMPER, GRILLE AND ENGINE HOOD 02-01-02-03
BASIC
POS OPERATION
CODE
C/V
02-01. BUMPERS
02-02. ENGINE HOOD
02-03. GRILLE
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
1
020101
FRONT BUMPER ASSEMBLY SUBSTITUTION
1.0
1.0
1.0
2
020102
COVER OUTER BUMPER SUBSTITUTION (ONE)
0.2
0.2
0.2
3
020103
COVER CENTER BUMPER SUBSTITUTION (ONE)
0.2
0.2
0.2
4
020104
REAR BUMPER ASSEMBLY SUBSTITUTION
0.9
0.9
0.9
5
020105
CUSHION LATERAL BUMPER SUBSTITUTION (ONE)
0.2
0.2
0.2
6
020106
CUSHION CENTER BUMPER SUBSTITUTION (ONE)
0.2
0.2
0.2
020100
OTHER
* * *
020201
HOOD ASSEMBLY SUBSTITUTION
1.0
1.0
1.0
0.4
0.4
0.4
0.1
0.1
0.1
7
INCLUDES:
- Element transfer
- Hood lock adjustment
7
020202
D / M HOOD ASSEMBLY
INCLUDES:
8
020203
HOOD HINGE SUBSTITUTION (ONE)
(BONNET ASSEMBLY DISMOUNTED)
9
020204
HOOD OPENER DRIVER CABLE ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
10
020205
HOOD LOCK ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
0.1
0.1
INCLUDES:
020206
HOOD STAY SUBSTITUTION
0.1
020200
OTHER
* * *
12
020301
FRONT GRILLE SUBSTITUTION
0.4
0.4
0.4
13
020302
RIGHT FENDER ASSY SUBSTITUTION
1.8
1.8
1.8
11
INCLUDES:
- Element transfer
02-01-02-03 BUMPER, GRILLE AND ENGINE HOOD
BUMPER
02-01
ENGINE HOOD
02-02
GRILLE
02-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front bumper
1
Hood assembly
7
Front grille
12
Cover outer bumper
2
Hood hinge
8
Fender assy
13
Cover center bumper
3
Opener driver cable
9
Superior profile
14
Rear bumper
4
Lock assembly
10
Front frame assembly
15
Cushion lateral bumper
5
Hood stay
11
Central profile
16
Cushion center bumper
6
Headlamp
17
BUMPER, GRILLE AND ENGINE HOOD 02-03
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
02-03. GRILLE
AL01 AL02 AL03
13
020303
D / M RIGHT FENDER ASSY
1.3
1.3
1.3
13
020304
LEFT FENDER SUBSTITUTION
2.4
2.4
2.4
INCLUDES:
- Element transfer
13
020305
D / M LEFT FENDER ASSEMBLY
1.6
1.6
1.6
14
020306
SUPERIOR PROFILE ASSEMBLY SUBSTITUTION
0.8
0.8
0.8
15
020307
FRONT FRAME WELDERING ASSEMBLY SUBSTITUTION
1.3
1.3
1.3
16
020308
CENTRAL PROFILE ASSEMBLY SUBSTITUTION
0.7
0.7
0.7
17
020309
R/H HEADLAMP PANEL SUBSTITUTION
1.3
1.3
1.3
1.3
1.3
1.3
INCLUDES:
- Headlamp measure
17
020310
L/H HEADLAMP PANEL SUBSTITUTION
INCLUDES:
- Headlamp measure
020300
OTHER
* * *
STEERING, SUSPENSION AND WHEELS ..........................................
3
STEERING ........................................................................................................... 3B
STEERING WHEEL .......................................................................................... 3C
FRONT SUSPENSION .................................................................................... 3D
REAR SUSPENSION ....................................................................................... 3E
WHEELS .............................................................................................................. 3F
3
.
STEERING .................................................................................................................
3B
TIE ROD AND RODS ....................................................................................... 3B-01
POWER-STEERING SYSTEM ...................................................................... 3B-02
3B
3B-01-02 STEERING
3 STEERING, SUSPENSION AND WHEELS
TIE ROD AND RODS
3B.01
POWER-STEERING SYSTEM
3B.02
COMPONENTS
POS
COMPONENTS
POS
Control rod
1
Power-steering oil tank
Union rod
2
Filter
4
5
Tie rod
3
Intake pipe
6
Pressure hose
7
Return hose
8
Power-steering pump
9
Steering gear box
10
Oil tank bracket
11
Suction hose elbow
12
Pitman arm
13
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
3B0101
C/V
STEERING 3B-01-02
MODEL CODES AND
REPAIR TIME
3B-01. TIE ROD AND RODS
3B-02. POWER-STEERING SYSTEM
AL01 AL02 AL03
CONTROL ROD AND TIE ROD SUBSTITUTION (TWO)
0.9
0.9
0.9
1.0
1.0
1.0
INCLUDES:
- Steering measure
2
3B0102
UNION ROD AND TIE ROD SUBSTITUTION (TWO)
INCLUDES:
- Steering measure
2
3B0103
CONVERGENCE MEASURE
0.4
0.4
0.4
3
3B0104
TIE ROD SUBSTITUTION (ONE)
0.3
0.3
0.3
EXCLUDES:
- Convergence adjustment or turning radius
3B0100
OTHER
* * *
4
3B0201
POWER-STEERING OIL TANK SUBSTITUTION (*)
0.4
0.4
0.4
4
3B0202
POWER-STEERING OIL LEVEL INSPECTION
0.1
0.1
0.1
4
3B0203
POWER-STEERING OIL SUBSTITUTION (*)
0.2
0.2
0.2
5
3B0204
POWER-STEERING OIL FILTER SUBSTITUTION
0.1
0.1
0.1
6
3B0205
INTAKE PIPE SUBSTITUTION (*)
0.3
0.3
0.3
7
3B0206
PRESSURE HOSE SUBSTITUTION (*)
0.4
0.4
0.4
8
3B0207
RETURN HOSE SUBSTITUTION (*)
0.3
0.3
0.3
9
3B0208
POWER-STEERING PUMP SUBSTITUTION (*)
1.0
1.0
1.0
9
3B0209
POWER-STEERING PRESSURE CHECK IN THE P/S CIRCUIT
0.4
0.4
0.4
10
3B0210
STEERING GEAR BOX SUBSTITUTION (*)
1.5
1.5
1.5
10
3B0211
TURNING RADIUS MEASURE (RIGHT AND LEFT SIDES)
0.3
0.3
0.3
11
3B0212
OIL TANK BRACKET SUBSTITUTION
0.2
0.2
0.2
12
3B0213
SUCTION HOSE ELBOW SUBSTITUTION (*)
0.3
0.3
0.3
(*) INCLUDES FILLING, DRAINING OR HYDRAULIC SYSTEM LEVEL ADJUSTMENT
3B-01-02 STEERING
TIE ROD AND RODS
3B.01
POWER-STEERING SYSTEM
3B.02
COMPONENTS
POS
COMPONENTS
POS
Control rod
1
Power-steering oil tank
Union rod
2
Filter
4
5
Tie rod
3
Intake pipe
6
Pressure hose
7
Return hose
8
Power-steering pump
9
Steering gear box
10
Oil tank bracket
11
Suction hose elbow
12
Pitman arm
13
COMPONENTS
POS
BASIC
POS OPERATION
CODE
13
3B0214
C/V
STEERING 3B-02
MODEL CODES AND
REPAIR TIME
3B-02. POWER-STEERING SYSTEM
AL01 AL02 AL03
PITMAN ARM SUBSTITUTION
1.0
1.0
1.0
INCLUDES:
- Turning radius measure (left and right sides)
3B0200
OTHER
* * *
STEERING WHEEL ............................................................................................
3C
STEERING WHEEL AND COLUMNS ........................................................ 3C-01
3C
3C-01 STEERING WHEEL
STEERING WHEEL AND COLUMNS
3C.01
COMPONENTS
POS
Steering wheel
1
Upper and lower cover
2
Steering column
3
Column upper bracket
4
Column lower bracket
5
Steering lower column
6
COMPONENTS
POS
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
3C0101
C/V
STEERING WHEEL 3C-01
MODEL CODES AND
REPAIR TIME
3C-01. STEERING WHEEL AND COLUMNS
AL01 AL02 AL03
STEERING WHEEL SUBSTITUTION
0.3
0.3
0.3
INCLUDES:
- Steering wheel repositioning
1
3C0102
STEERING WHEEL OPENWORK
0.2
0.2
0.2
2
3C0103
UPPER AND LOWER COVER SUBSTITUTION (ONE)
0.1
0.1
0.1
3
3C0104
STEERING COLUMN SUBSTITUTION
2.4
2.4
2.4
INCLUDES:
4
3C0105
COLUMN UPPER BRACKET SUBSTITUTION
1.5
1.5
1.5
5
3C0106
COLUMN LOWER BRACKET SUBSTITUTION
0.5
0.5
0.5
6
3C0107
STEERING LOWER COLUMN SUBSTITUTION
0.4
0.4
0.4
INCLUDES:
3C0100
OTHER
* * *
FRONT SUSPENSION .......................................................................................
3D
FRONT SPRINGS ............................................................................................. 3D-01
FRONT SHOCK ABSORBER ....................................................................... 3D-02
3D
3D-01-02 FRONT SUSPENSION
FRONT SPRINGS
3D.01
FRONT SHOCK ABSORBER
3D.02
COMPONENTS
POS
COMPONENTS
POS
Front spring
1
Bush
2
Spring bumper
3
Front shock absorber
4
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
FRONT SUSPENSION 3D-01-02
MODEL CODES AND
REPAIR TIME
3D-01. FRONT SPRINGS
3D-02. FRONT SHOCK ABSORBER
AL01 AL02 AL03
1
3D0101
FRONT SPRING ASSEMBLY SUBSTITUTION (ONE SIDE)
1.2
1.2
1.2
1
3D0102
FRONT SPRING REPAIR
1.8
1.8
1.8
2
3D0103
SPRING BUSH OR CHASSIS SUBSTITUTION (ONE)
0.2
0.2
0.2
0.2
0.2
(REMOVAL SPRING)
3
4
3D0104
SPRING BUMPER SUBSTITUTION (ONE)
0.2
3D0100
OTHER
* * *
3D0201
SHOCK ABSORBER SUBSTITUTION (ONE)
0.4
3D0200
OTHER
* * *
0.4
0.4
REAR SUSPENSION ...........................................................................................
3E
REAR SPRINGS ................................................................................................ 3E-01
REAR SHOCK ABSORBER .......................................................................... 3E-02
3E
3E-01-02 REAR SUSPENSION
REAR SPRINGS
3E.01
REAR SHOCK ABSORBER
3E.02
COMPONENTS
POS
COMPONENTS
POS
Rear spring
1
Bush
2
Rear stopper
3
Rear shock absorber
4
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
REAR SUSPENSION 3E-01-02
MODEL CODE AND
REPAIR TIME
3E-01. REAR SPRINGS
3E-02. REAR SHOCK ABSORBER
AL01 AL02 AL03
1
3E0101
REAR SPRING ASSEMBLY SUBSTITUTION (ONE SIDE)
1.3
1.3
1.3
1
3E0102
REAR SPRING REPARIR
1.9
1.9
1.9
2
3E0103
SPRING BUSH OR CHASSIS SUBSTITUTION (ONE)
0.2
0.2
0.2
0.2
0.2
(REMOVAL SPRING)
3
4
3E0104
REAR STOPPER SUBSTITUTION (ONE)
0.2
3E0100
OTHER
* * *
3E0201
REAR SHOCK ABSORBER SUBSTITUTION (ONE)
0.4
3E0200
OTHER
* * *
0.4
0.4
WHEELS .....................................................................................................................
3F
WHEEL AND TYRES ....................................................................................... 3F-01
3F
3F-01 WHEELS
Wheel
WHEEL AND TYRES
3F.01
COMPONENTS
POS
1
Tyre
2
Wheel
3
COMPONENTS
POS
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
WHEELS 3F-01
MODEL CODES AND
REPAIR TIME
3F-01. WHEEL AND TYRES
AL01 AL02 AL03
1
3F0101
WHEEL SUBSTITUTION (ONE) (*)
0.5
0.5
0.5
2
3F0102
TYRE SUBSTITUTION (ONE) (*)
0.5
0.5
0.5
3
3F0103
WHEEL SUBSTITUTION (ONE)
0.2
0.2
0.2
EXCLUDES:
- Wheel balancing
3F0100
(*) INCLUDES WHEEL BALANCING
OTHER
* * *
PROPELLER SHAFT .........................................................................................
4
FRONT DRIVE SHAFT .................................................................................... 4A
REAR DRIVE SHAFT ....................................................................................... 4B
PROPELLER SHAFTS .................................................................................... 4C
4
.
FRONT DRIVE SHAFT ......................................................................................
4A
FRONT SHAFT ASSEMBLY .......................................................................... 4A-01
FRONT WHEEL HUB ASSEMBLY .............................................................. 4A-02
KING PIN ASSEMBLY ..................................................................................... 4A-03
4A
4A-01-02-03 FRONT DRIVE SHAFT
4 PROPELLER SHAFTS
FRONT SHAFT ASSEMBLY
4A-01
FRONT WHEEL HUB ASSEMBLY
4A-02
KING PIN ASSEMBLY
4A-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front axle assembly
1
Front wheel hub
6
King pin
13
Front axle housing
2
Front hub bearing
7
Steering knuckle
14
King pin assembly
3
Front hub oil seal
8
King pin bearing
15
Oil seal
4
Spindle
9
Steering knuckle
16
Axle shaft join
5
Free wheel assembly
10
Housing oil seal
17
Bolt stud
11
Left pitman arm
18
Shaft drive flange
12
Right pitman arm
19
4 PROPELLER SHAFTS
BASIC
POS OPERATION
CODE
C/V
FRONT DRIVE SHAFT 4A-01-02
MODEL CODES AND
REPAIR TIME
4A-01. FRONT SHAFT ASSEMBLY
4A-02. FRONT WHEEL HUB ASSEMBLY
AL01 AL02 AL03
1
4A0101
D / M FRONT SHAFT ASSEMBLY
2.4
2.4
2.4
2
4A0102
FRONT AXLE HOUSING SUBSTITUTION (*)
5.0
5.0
5.0
INCLUDES:
- Transfer elements
3
4A0103
D / M KING PIN ASSEMBLY (LEFT)
1.0
1.0
1.0
3
4A0104
D / M KING PIN ASSEMBLY (RIGHT)
1.2
1.2
1.2
4
4A0105
LEFT OIL SEAL SUBSTITUTION (*)
1.2
1.2
1.2
4
4A0106
RIGHT OIL SEAL SUBSTITUTION (*)
1.4
1.4
1.4
4
4A0107
OIL SEALS OF BOTH SIDES SUBSTITUTION (*)
2.3
2.3
2.3
5
020108
AXLE SHAFT JOIN SUBSTITUTION (ONE) (*)
1.4
1.4
1.4
5
020109
AXLE SHAFT JOIN SUBSTITUTION (TWO) (*)
2.6
2.6
2.6
4A0100
OTHER
* * *
6
4A0201
D / M FRONT WHEEL HUB (ONE SIDE)
1.0
1.0
1.0
6
4A0202
FRONT WHEEL HUB SUBSTITUTION (ONE SIDE)
1.6
1.6
1.6
INCLUDES:
- Transfer elements or installation new ones
6
4A0203
FRONT WHEEL HUB ADJUSTMENT (ONE SIDE)
0.9
0.9
0.9
7
4A0204
FRONT HUB BEARING SUBSTITUTION (ONE)
1.3
1.3
1.3
7
4A0205
FRONT HUB BEARING SUBSTITUTION (TWO)
1.6
1.6
1.6
8
4A0206
FRONT HUB OIL SEAL SUBSTITUTION (ONE SIDE)
1.1
1.1
1.1
(*) INCLUDES FILLING OR OIL LEVEL ADJUSTMENT AND/OR STEERING MEASURES
4 PROPELLER SHAFTS
4A-01
4A-02
KING PIN ASSEMBLY
4A-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front axle assembly
1
Front wheel hub
6
King pin
13
Front axle housing
2
Front hub bearing
7
Steering knuckle
14
King pin assembly
3
Front hub oil seal
8
King pin bearing
15
Oil seal
4
Spindle
9
Steering knuckle
16
Axle shaft join
5
Free wheel assembly
10
Housing oil seal
17
Bolt stud
11
Left pitman arm
18
Shaft drive flange
12
Right pitman arm
19
FRONT DRIVE SHAFT 4A-02-03
4 PROPELLER SHAFTS
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
4A-02. FRONT WHEEL HUB ASSEMBLY
4A-03. KING PIN ASSEMBLY
AL01 AL02 AL03
9
4A0207
D / M SPINDLE ASSEMBLY (ONE SIDE (*)
1.3
1.3
1.3
9
4A0208
D / M SPINDLE ASSEMBLY (TWO SIDES) (*)
2.4
2.4
2.4
9
4A0209
SPINDLE SUBSTITUTION OR REPARATION
0.3
0.3
0.3
(SEPARATED SPINDLE)
10
4A0210
FREE WHEEL ASSEMBLY SUBSTITUTION (ONE SIDE)
0.6
0.6
0.6
10
4A0211
FREE WHEEL ASSEMBLY REPARATION (ONE SIDE)
1.2
1.2
1.2
11
4A0212
BOLT STUD SUBSTITUTION (ONE)
0.2
0.2
0.2
0.9
0.9
0.9
0.5
0.5
(SEPARATED WHEEL HUB)
11
4A0213
BOLT STUD SUBSTITUTION (SET)
12
13
4A0214
SHAFT DRIVE FLANGE SUBSTITUTION (ONE SIDE)
0.5
4A0200
OTHER
* * *
4A0301
KING PIN SUBSTITUTION (ONE) (*)
0.5
0.5
0.5
1.6
1.6
1.6
1.8
1.8
1.8
EXCLUDES:
- King pin turning
13
4A0302
resistance measure
TURNING RESISTANCE OF LEFT KING PIN (CHECK) (*)
EXCLUDES:
- D/M or king pin substitution
13
4A0303
TURNING RESTANCE OF RIGHT KING PIN (CHECK) (*)
EXCLUDES:
- D/M or king pin substitution
14
4A0304
LEFT STEERING KNUCKLE SUBSTITUTION (*)
3.0
3.0
3.0
14
4A0305
RIGHT STEERING KNUCKLE SUBSTITUTION (*)
3.2
3.2
3.2
15
4A0306
LEFT KING PIN BEARING SUBSTITUTION (ONE) (*)
3.7
3.7
3.7
4 PROPELLER SHAFTS
4A-01
4A-02
KING PIN ASSEMBLY
4A-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front axle assembly
1
Front wheel hub
6
King pin
13
Front axle housing
2
Front hub bearing
7
Steering knuckle
14
King pin assembly
3
Front hub oil seal
8
King pin bearing
15
Oil seal
4
Spindle
9
Steering knuckle
16
Axle shaft join
5
Free wheel assembly
10
Housing oil seal
17
Bolt stud
11
Left pitman arm
18
Shaft drive flange
12
Right pitman arm
19
4 PROPELLER SHAFTS
BASIC
POS OPERATION
CODE
C/V
FRONT DRIVE SHAFT 4A-03
MODEL CODES AND
REPAIR TIME
4A-03. KING PIN ASSEMBLY
AL01 AL02 AL03
15
4A0307
LEFT KING PIN BEARINGS SUBSTITUTION (TWO) (*)
3.9
3.9
3.9
15
4A0308
RIGHT KING PIN BEARINGS SUBSTITUTION (ONE) (*)
3.9
3.9
3.9
15
4A0309
RIGHT KING PIN BEARINGS SUBSTITUTION (TWO) (*)
4.1
4.1
4.1
16
4A0310
LEFT KING PIN BEARING HOUSING SUBSTITUTION
(STEERING KNUCKLE) (*)
3.9
3.9
3.9
16
4A0311
RIGHT KING PIN BEARING HOUSING SUBSTITUTION
(STEERING KNUCKLE) (*)
4.1
4.1
4.1
17
4A0312
LEFT HOUSING OIL SEAL SUBSTITUTION (*)
1.3
1.3
1.3
17
4A0313
RIGHT HOUSING OIL SEAL SUBSTITUTION (*)
1.5
1.5
1.5
18
4A0314
LEFT PITMAN ARM SUBSTITUTION (*)
0.8
0.8
0.8
19
4A0315
RIGHT PITMAN ARM SUBSTITUTION (*)
1.0
1.0
1.0
4A0300
OTHER
* * *
REAR DRIVE SHAFT ..........................................................................................
4B
REAR SHAFT ASSEMBLY ............................................................................. 4B-01
REAR WHEEL HUB ASSEMBLY ................................................................ 4B-02
4B
4B-01-02 REAR DRIVE SHAFT
4 PROPELLER SHAFTS
REAR SHAFT ASSEMBLY
4B-01
REAR WHEEL HUB ASSEMBLY
4B-02
COMPONENTS
POS
COMPONENTS
POS
Rear shaft assembly
1
Wheel hub assembly
4
Rear shaft housing
2
Rear hub bearing
5
King pin
3
Oil seal
6
Spindle
7
Stud bolt
8
Shaft drive flange
9
COMPONENTS
POS
4 PROPELLER SHAFTS
BASIC
POS OPERATION
CODE
C/V
REAR DRIVE SHAFT 4B-01-02
MODEL CODES AND
REPAIR TIME
4B-01. REAR SHAFT ASSEMBLY
4B-02. REAR WHEEL HUB ASSEMBLY
AL01 AL02 AL03
1
4B0101
D / M REAR SHAFT ASSEMBLY (*)
2.9
2.9
2.9
2
4B0102
REAR SHAFT HOUSING SUBSTITUTION (*)
6.1
6.1
6.1
0.5
0.5
INCLUDES:
- Transfer elements
3
4B0103
KING PIN SUBSTITUTION (ONE)
0.5
4B0100
OTHER
* * *
4
4B0201
D / M WHEEL HUB ASSEMBLY (ONE SIDE)
1.0
1.0
1.0
4
4B0202
WHEEL HUB ASSEMBLY SUBSTITUTION (ONE SIDE)
1.6
1.6
1.6
INCLUDES:
- Transfer components or installation new ones
4
4B0203
WHEEL HUB ASSEMBLY ADJUSTMENT (ONE SIDE)
0.9
0.9
0.9
5
4B0204
REAR HUB BEARING SUBSTITUTION (ONE)
1.3
1.3
1.3
5
4B0205
REAR HUB BEARING SUBSTITUTION
1.6
1.6
1.6
6
4B0206
OIL SEAL SUBSTITUTION (ONE SIDE)
1.1
1.1
1.1
7
4B0207
SPINDLE SUBSTITUTION (ONE SIDE) (*)
1.2
1.2
1.2
7
4B0208
SPINDLE SUBSTITUTION (BOTH SIDES) (*)
2.2
2.2
2.2
8
4B0209
STUD BOLT SUBSTITUTION (ONE)
0.2
0.2
0.2
0.9
0.9
0.9
0.5
0.5
8
4B0210
STUD BOLT SUBSTITUTION (WHEEL SET)
9
4B0211
SHAFT DRIVE FLANGE SUBSTITUTION (ONE)
0.5
4B0200
OTHER
* * *
PROPELLER SHAFTS ......................................................................................
4C
PROPELLER SHAFT ....................................................................................... 4C-01
4C
4C-01 PROPELLER SHAFTS
4 PROPELLER SHAFTS
PROPELLER SHAFT
4C-01
COMPONENTS
POS
Propeller front shaft
1
Propeller rear shaft
2
COMPONENTS
POS
COMPONENTS
POS
4 PROPELLER SHAFTS
BASIC
POS OPERATION
CODE
C/V
PROPELLER SHAFTS 4C-01
MODEL CODES AND
REPAIR TIME
4C-01. PROPELLER SHAFT
AL01 AL02 AL03
1
4C0101
PROPELLER FRONT SHAFT SUBSTITUTION
0.7
0.7
0.7
1
4C0102
PROPELLER FRONT SHAFT REPARATION
1.0
1.0
1.0
2
4C0103
PROPELLER REAR SHAFT SUBSTITUTION
0.7
0.7
0.7
2
4C0104
PROPELLER REAR SHAFT REPARATION
1.0
1.0
1.0
4C0100
OTHER
* * *
BRAKE SYSTEM ..................................................................................................
05
PARKING BRAKE & DISC BRAKE COMPONENTS ............................ 05-01
HYDRAULIC CIRCUIT & SERVOBRAKE ................................................. 05-02
05
05-01 BRAKE SYSTEM
PARKING BRAKE & DISC BRAKE
COMPONENTS
05-01
COMPONENTS
05-01
COMPONENTS
POS
COMPONENTS
POS
Transmission brake
1
Parking cable brake assembly
11
Switch transmission brake
2
Brake bracket
12
Parking brake cable
3
Brake disc
13
Link assembly
4
Brake assembly
14
Expansion unit
5
Friction pads set
15
Brake plate
6
Front brake pistons
16
Brake drum
7
Rear brake disc
17
Brake shoes set
8
Rear brake assembly
18
Regulation unit
9
Rear brake pistons
19
Springs
10
COMPONENTS
POS
BRAKE SYSTEM 05-01
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
05-01. PARKING BRAKE & DISC BRAKE COMPONENTS
AL01 AL02 AL03
1
050101
TRANSMISSION BRAKE MEASURE
0.2
0.2
0.2
2
050102
SWITCH BRAKE TRANSMISSION SUBSTITUTION (*)
1.5
1.5
1.5
2
050103
SWHITCH BRAKE TRANSMISSION REPARATION (*)
2.2
2.2
2.2
3
050104
PARKING BRAKE CABLE SUBSTITUTION (*)
1.7
1.7
1.7
4
050105
LINK ASSEMBLY SUBSTITUTION (*)
0.6
0.6
0.6
5
050106
EXPANSION UNIT SUBSTITUTION (*)
1.2
1.2
1.2
6
050107
BRAKE PLATE SUBSTITUTION (*)
1.8
1.8
1.8
7
050108
BRAKE DRUM SUBSTITUTION (*)
0.7
0.7
0.7
8
050109
BRAKE SHOES DRUM SUBSTITUTION OR REVISION (*)
1.0
1.0
1.0
9
050110
REGULATION UNIT SUBSTITUTION (*)
1.2
1.2
1.2
10
050111
SPRINGS SUBSTITUTION (*)
1.0
1.0
1.0
11
050112
PARKING CABLE BRAKE ASSEMBLY SUBSTITUTION (*)
1.0
1.0
1.0
12
050113
BRAKE BRACKET SUBSTITUTION (ONE)
1.9
1.9
1.9
13
050114
FRONT BRAKE DISC SUBSTITUTION (ONE)
1.1
1.1
1.1
14
050115
FRONT BRAKE ASSEMBLY SUBSTITUTION (ONE) (**)
0.7
0.7
0.7
14
050116
FRONT BRAKE ASSEMBLY SUBSTITUTION (TWO)
1.0
1.0
1.0
15
050117
FRICTION PADS SET SUBSTITUTION (ONE WHEEL)
0.3
0.3
0.3
16
050118
FRONT BRAKE PISTONS REPARATION (ONE SIDE) (**)
0.9
0.9
0.9
16
050119
FRONT BRAKE PISTONS REPARATION (TWO SIDES) (**)
1.4
1.4
1.4
17
050120
REAR BRAKE DISC SUBSTITUTION (ONE)
1.3
1.3
1.3
(*) INCLUDES ADJUST FROM CONTROL TO THE TRANSMISSION
(**) INCLUDES PURGED PARTIAL OF CONTROLS
05-01 BRAKE SYSTEM
COMPONENTS
05-01
COMPONENTS
05-01
COMPONENTS
POS
COMPONENTS
POS
Transmission brake
1
Parking cable brake assembly
11
Switch transmission brake
2
Brake bracket
12
Parking brake cable
3
Brake disc
13
Link assembly
4
Brake assembly
14
Expansion unit
5
Friction pads set
15
Brake plate
6
Front brake pistons
16
Brake drum
7
Rear brake disc
17
Brake shoes set
8
Rear brake assembly
18
Regulation unit
9
Rear brake pistons
19
Springs
10
COMPONENTS
POS
BRAKE SYSTEM 05-01
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
05-01. PARKING BRAKE & DISC BRAKE COMPONENTS
AL01 AL02 AL03
18
050121
REAR BRAKE ASSEMBLY SUBSTITUTION (ONE) (**)
0.7
0.7
0.7
18
050122
REAR BRAKE ASSEMBLY SUBSTITUTION (TWO) (**)
1.0
1.0
1.0
19
050123
REAR BRAKE PISTON REPARATION (ONE SIDE) (**)
0.8
0.8
0.8
19
050124
REAR BRAKE PISTON REPARATION (TWO SIDES) (**)
1.2
1.2
1.2
050100
OTHER
* * *
(**) INCLUDES PURGED PARTIAL OF CONTROLS
05-02 BRAKE SYSTEM
HYDRAULIC CIRCUIT & SERVOBRAKE
05-02
05-02
05-02
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Brake pedal bracket
1
Brake five way joint
11
Pedal assembly and bracket
2
Brake 2 way joint
12
Brake master cylinder
3
LSP valve assembly
13
Servo brake
4
2 way valve to front brake pipe
14
Hydraulic circuit
5
15
Vacuum pump
6
5 way valve to LSP valve pipe
16
Hole
7
LSP valve to rear side pipe
17
Vacuum reservoir tank
8
3 way valve to rear brake pipe
18
Front, brake flexible hose
9
Master cylinder to 5 way valve pipe
19
Brake 3 way joint
10
20
LSP crossmember
21
BRAKE SYSTEM 05-02
BASIC
POS OPERATION
CODE
1
050201
C/V
MODEL CODES AND
REPAIR TIME
05-02. HYDRAULIC CIRCUIT & SERVOBRAKE
AL01 AL02 AL03
BRAKE PEDAL BRACKET SUBSTITUTION
2.4
2.4
2.4
2.2
2.2
2.2
INCLUDES:
- Measures and drain
2
050202
PEDAL ASSEMBLY AND BRACKET SUBSTITUTION
INCLUDES:
- Measures and drain
3
050203
BRAKE MASTER CYLINDER SUBSTITUTION (*)
1.2
1.2
1.2
4
050204
SERVO BRAKE SUBSTITUTION
1.4
1.4
1.4
INCLUDES:
- Measures
4
050205
SERVO BRAKE MEASURE
1.2
1.2
1.2
4
050206
SERVO BRAKE MEASURE CHECK
0.1
0.1
0.1
5
050207
HYDRAULIC SYSTEM COMPLETE DRAIN
0.7
0.7
0.7
5
050208
HYDRAULIC SYSTEM PARTIAL DRAIN
0.3
0.3
0.3
5
050209
BRAKE LIQUID SUBSTITUTION
1.0
1.0
1.0
6
050210
VACUUM PUMP SUBSTITUTION
1.0
1.0
1.0
INCLUDES:
- Vacuum circuit check
6
050211
VACUUM PUMP CHECK
0.4
0.4
0.4
7
050212
HOSE SUBSTITUTION (ONE)
0.2
0.2
0.2
8
050213
VACUUM RESERVOIR TANK SUBSTITUTION
0.4
0.4
0.4
9
050214
FRONT BRAKE FLEXIBLE HOSE SUBSTITUTION (COMPLETE SET) (*)
1.9
1.9
1.9
9
050215
FRONT BRAKE FLEXIBLE HOSE SUBSTITUTION (ONE) (*)
0.7
0.7
0.7
9
050216
FRONT BRAKE FLEXIBLE HOSE SUBSTITUTION (NEXT)
0.3
0.3
0.3
10
050217
BRAKE 3 WAY JOINT SUBSTITUTION (*)
1.1
1.1
1.1
10
050218
BRAKE 3 WAY JOINT SUBSTITUTION AFTER ANOTHER
INTERVENTION IN THE CIRCUIT
0.7
0.7
0.7
(*) INCLUDES FILLING, DRAIN OR HYDRAULIC SYSTEM LEVEL ADJUSTMENT
05-02 BRAKE SYSTEM
05-02
05-02
05-02
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Brake pedal bracket
1
11
2
Brake 2 way joint
12
3
LSP valve assembly
13
Servo brake
4
14
Hydraulic circuit
5
15
Vacuum pump
6
16
Hole
7
17
8
18
9
19
Brake 3 way joint
10
20
LSP crossmember
21
BRAKE SYSTEM 05-02
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
11
050219
BRAKE FIVE WAY JOINT SUBSTITUTION (*)
1.1
1.1
1.1
11
050220
BRAKE FIVE WAY JOINT SUBSTITUTION AFTER ANOTHER
0.5
0.5
0.5
12
050221
BRAKE TWO WAY JOINT SUBSTITUTION (*)
0.7
0.7
0.7
12
050222
BRAKE TWO WAY JOINT SUBSTITUTION AFTER ANOTHER
0.4
0.4
0.4
13
050223
LSP VALVE ASSEMBLY SUBSTITUTION (*)
1.3
1.3
1.3
13
050224
LSP VALVE ASSEMBLY MEASURE
0.2
0.2
0.2
13
050225
LSP VALVE ASSEMBLY SUBSTITUTION AFTER ANOTHER
0.9
0.9
0.9
14
050226
2 WAY VALVE TO FRONT BRAKE PIPE SUBSITUTION (*)
0.7
0.7
0.7
14
050227
2 WAY VALVE TO FRONT BRAKE PIPE SUBSITUTION AFTER
ANOTHER INTERVENTION IN THE CIRCUIT
0.4
0.4
0.4
15
050228
5 WAY VALVE FRONT BRAKE PIPE SUBSTITUTION (*)
0.7
0.7
0.7
15
050229
5 WAY VALVE TO FRONT BRAKE PIPE SUBSTITUTION
AFTER ANOTHER INTERVENTION IN THE CIRCUIT
0.4
0.4
0.4
16
050230
5 WAY VALVE TO LSP VALV. PIPE SUBSTITUTION (ONE) (*)
0.7
0.7
0.7
16
050231
5 WAY VALVE TO LSP VALVE PIPE SUBSTITUTION AFTER
0.4
0.4
0.4
17
050232
LSP VALVE TO REAR SIDE PIPE SUBSTITUTION (*)
0.7
0.7
0.7
17
050233
LSP VALVE TO REAR SIDE PIPE SUBSTITUTION AFTER
0.4
0.4
0.4
18
050234
3 WAY VALVE TO REAR BRAKE PIPE SUBSTITUTION (*)
0.7
0.7
0.7
18
050235
3 WAY VALVE TO REAR BRAKE PIPE SUBSTITUTION AFTER
0.4
0.4
0.4
19
050236
MASTER CYLINDER TO FIVE WAY VALVE PIPE
SUBSTITUTION (*)
0.7
0.7
0.7
05-02 BRAKE SYSTEM
05-02
05-02
05-02
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Brake pedal bracket
1
11
2
Brake 2 way joint
12
3
LSP valve assembly
13
Servo brake
4
14
Hydraulic circuit
5
15
Vacuum pump
6
16
Hole
7
17
8
18
9
19
Brake 3 way joint
10
20
LSP crossmember
21
BRAKE SYSTEM 05-02
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
19
050237
MASTER CYLINDER TO FIVE WAY VALVE PIPE
SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE
CIRCUIT
0.4
0.4
0.4
20
050238
MASTER CYLINDER TO 2 WAY VALVE PIPE (*)
0.7
0.7
0.7
20
050239
MASTER CYLINDER TO 2 WAY VALVE PIPE
SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE
CIRCUIT
0.4
0.4
0.4
21
050240
LSP CROSSMEMBER SUBSTITUTION
0.5
0.5
0.5
INCLUDES:
-LSPV valve measure
050200
OTHER
* * *
ENGINE AND ITS SYSTEMS .......................................................................
6
ENGINE ASSEMBLY ........................................................................................ 6A
ENGINE COOLING ............................................................................................ 6B
FEEDING AND EMISSION CONTROL ....................................................... 6C
ENGINE ELECTRICAL SYSTEM ................................................................. 6G
ENGINE EXHAUST SYSTEM ........................................................................ 6K
ENGINE LUBRICATION .................................................................... 6L
6
.
ENGINE ASSEMBLY ..........................................................................................
6A
STRIPPED ENGINE ......................................................................................... 6A-01
COMPLETE ENGINE ....................................................................................... 6A-02
CYLINDER BLOCK .......................................................................................... 6A-03
OIL PAN ................................................................................................................ 6A-04
CYLINDER HEAD ............................................................................................. 6A-05
CRANKSHAFT ................................................................................................... 6A-06
PISTONS AND CONNECTING RODS ........................................................ 6A-07
FLYWHEEL ENGINE ........................................................................................ 6A-08
CAMSHAFT AND TIMING ............................................................................... 6A-09
AUXILIARY ORGAN GROUP ......................................................................... 6A-10
FRONT ENGINE MOUNTING ........................................................................ 6A-11
FUEL INJECTION ............................................................................................. 6A-12
6A
6A-01-02 ENGINE
STRIPPED ENGINE
6A-01
COMPLETE ENGINE
6A-02
COMPONENTS
POS
COMPONENTS
POS
Stripped engine
1
Complete engine
2
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
C/V
ENGINE 6A-01-02
MODEL CODES AND
REPAIR TIME
6A-01. STRIPPED ENGINE
6A-02. COMPLETE ENGINE
AL01 AL02 AL03
D / M STRIPPED ENGINE
6A0101
20.5 20.5 20.5
INCLUDES:
- D / M complete engine
- Transfer components
- Timing setting
- Flywheel engine setting
- Injection pump setting
- Valve measure
EXCLUDES:
A
B
6A0100
- Diagnostic operations
1.2
1.0
1.2
1.0
1.2
1.0
OTHER
* * *
2
6A0201
D / M COMPLETE ENGINE
8.9
8.9
8.9
0.9
0.6
0.9
0.6
0.9
0.6
REMOVAL AND ENGINE MEASURES
7.8
7.8
7.8
0.3
0.4
0.3
0.4
0.3
0.4
INCLUDES:
- Necessary measures, levels and drain
- Electrical servicing
- External washing of engine on the vehicle
EXCLUDES:
A
B
2
6A0202
(SEPARATED ENGINE)
INCLUDES:
- Removal of main parts
- Washing of dismounted parts
- Diameter measure of casings
- Diameter measure of crankpins
- Measure of pistons
- Diameter measure of camshaft holder and camheight
- D / M engine on bench
- Loose parts control
EXCLUDES:
A
B
- Removal of pistons and connecting rods
ADDITIONAL TIME MECHANICAL INYECTION ENGINE
6A-01-02 ENGINE
STRIPPED ENGINE
6A-01
COMPLETE ENGINE
6A-02
COMPONENTS
POS
COMPONENTS
POS
Stripped engine
1
Complete engine
2
COMPONENTS
POS
BASIC
POS OPERATION
CODE
2
C/V
ENGINE 6A-02
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0203
REMOVAL,CLEAN,VERIFICATION, MEASURE AND 15.7 15.7 15.7
INSTALATION OF ENGINE
(SEPARATED ENGINE)
INCLUDES:
- D / M of main parts
- Diameter measure of crankpins
- Measure of pistons
- Diameter measure of camshaft and cam height supports
- D / M engine on bench
- Loose parts control
- Clearance control between crankpins and bushes with
calibrated thread
- Control and measure of valve set
EXCLUDES:
A
B
2
6A0204
- Removal of pistons and connecting rods
NORMAL ENGINE REPARATION
0.4
0.5
0.4
0.5
0.4
0.5
25.6 25.6 25.6
(SEPARATED ENGINE)
INCLUDES:
- D / M of engine on bench
- Removal and instalation of engine
- Pistons and segments substitution
- Measure and balancing of piston and connecting rods weight
- Valve and seating rectification
- Revision and tare of injectors
- Control of clearance between crankpins and bearings with
calibrated thread
EXCLUDES:
- Engine on bench test
- Measures after road test
A
B
0.4
0.5
0.4
0.5
0.4
0.5
6A-01-02 ENGINE
STRIPPED ENGINE
6A-01
COMPLETE ENGINE
6A-02
COMPONENTS
POS
COMPONENTS
POS
Stripped engine
1
Complete engine
2
COMPONENTS
POS
BASIC
POS OPERATION
CODE
2
C/V
ENGINE 6A-02
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0205
GENERAL ENGINE REPARATION
48.5 48.5 48.5
(SEPARATED ENGINE)
INCLUDES:
- Operations included in normal reparation 6A.02.04
- Connecting rod bearings and main bearing substitution
- Auxiliary organs group reparation
- Cylinder head planning
- Cramkshaft rectification
- Rectification of cylinders
- Revision and tare of injector pump (mechanical injection)
- Revision of oil pump and water pump
- Revision of generator and engine starting
- Revision of turbo-charger
- Revision of depressor
- Revision of high pressure pump (Common Rail)
EXCLUDES:
0.4
3.1
0.4
3.1
0.4
3.1
ENGINE TO BRAKE TEST
3.5
3.5
3.5
1.5
1.5
1.5
ADDITIONAL TIME COMMON RAIL ENGINE
0.5
0.5
0.5
6A0208
EXTERNAL WASHING ENGINE ON VEHICLE
0.5
0.5
0.5
6A0200
OTHER
* * *
A
B
2
- Hydraulic Cylinder head test and substitution of caps
- Rectification superior surface of block
- Rectification steering wheel and indented crown wheel
- Water and oil gallery caps substitution
6A0206
(SEPARATED ENGINE)
2
6A0207
MEASURES AFTER ENGINE REPARATION
(ENGINE IN VEHICLE)
INCLUDES:
- Accelerator control measure (mechanical injection)
- Verification and adjustment of hose and brake line sealing
- Eventual measure of valve clearance
- Adjustment with analyser (Common Rail)
C
2
6A-03-04 ENGINE
CYLINDER BLOCK
6A-03
OIL PAN
6A-04
OIL PAN
6A-04
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Upper block
1
Oil pan
8
Oil filter plug
18
Lock plug
2
Oil flat gasket
9
Oil level tube
19
Lower block
3
Oil pan screw
10
Oil dipstick
20
Engine flat gasket
4
Threaded plug
11
Oil nozzle
5
Engine breather assembly
12
Cylinder ball
6
Breather
13
Engine cover and flat gasket
7
Rubber sleeve
14
Rubber sleeve
15
O ring
16
Oil filter neck
17
ENGINE 6A-03-04
BASIC
POS OPERATION
CODE
1
6A0301
C/V
MODEL CODES AND
REPAIR TIME
6A-03. CYLINDER BLOCK
6A-04. OIL PAN
AL01 AL02 AL03
PLAN BLOCK UPPER BASE
1.5
1.5
1.5
(NAKED BLOCK)
1
6A0302
NAKED BLOCK WASHING
0.5
0.5
0.5
2
6A0303
WATER OR LOCK PLUG CAP SUBSTITUTION
0.1
0.1
0.1
2.3
2.3
2.3
2.3
2.3
2.3
0.2
0.2
0.2
3.0
3.0
3.0
3.6
3.6
3.6
0.1
0.1
0.1
0.3
0.3
0.3
ENGINE COVER AND FLAT GASKET SUBSTITUTION
5.2
5.2
5.2
ENGINE COVER AND FLAT GASKET SUBSTITUTION
0.8
0.8
0.8
(NAKED BLOCK)
3
6A0304
D / M LOWER BLOCK TO ELIMINATE LOSS
(SEPARATED ENGINE)
4
6A0305
ENGINE FLAT GASKET SUBSTITUTION
(SEPARATED ENGINE)
5
6A0306
OIL NOZZLE SUBSTITUTION (ONE)
(SEPARATED INFERIOR BLOCK)
6
6A0307
D / M CYLINDER WALL
(NAKED BLOCK)
6
6A0308
CASING WALL BABOONING AND EMERYING
(NAKED BLOCK)
6
6A0309
CYLINDER CASING MEASURE (ONE)
(SEPARATED CONNECTING ROD AND PISTON)
6
6A0310
CYLINDER CASING MEASURE (SET)
(SEPARATED CONNECTING RODS AND PISTONS)
7
6A0311
7
6A0312
(SEPARATED ENGINE)
6A0300
OTHER
* * *
8
6A0401
D / M OIL PAN
0.9
0.9
0.9
8
6A0402
D / M OIL PAN
0.7
0.7
0.7
0.1
0.1
0.1
0.1
0.1
0.1
(SEPARATED ENGINE)
8
6A0403
REVIEW OIL PAN THREAD CAP
(EMPTIED OIL)
8
6A0404
OIL PAN FLAT GASKET SUPPORT PLAN CONTROL
(SEPARATED HOUSING)
6A-03-04 ENGINE
CYLINDER BLOCK
6A-03
OIL PAN
6A-04
OIL PAN
6A-04
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Upper block
1
Oil pan
8
Oil filter plug
18
Lock plug
2
Oil flat gasket
9
Oil level tube
19
Lower block
3
Oil pan screw
10
Oil dipstick
20
Engine flat gasket
4
Threaded plug
11
Oil nozzle
5
Engine breather assembly
12
Cylinder ball
6
Breather
13
Engine cover and flat gasket
7
Rubber sleeve
14
Rubber sleeve
15
O ring
16
Oil filter neck
17
ENGINE 6A-04
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6A-04. OIL PAN
AL01 AL02 AL03
9
6A0405
OIL FLAT GASKET SUBSTITUTION
0.9
0.9
0.9
10
6A0406
RE-TIGHTEN OIL PUMP SCREW
0.2
0.2
0.2
11
6A0407
D / M OIL THREADED PLUG
0.3
0.3
0.3
12
6A0408
D / M ENGINE BREATHER ASSEMBLY
1.0
1.0
1.0
13
6A0409
D / M OIL BREATHER
0.5
0.5
0.5
14
6A0410
D / M RUBBER SLEEVE (ONE)
0.3
0.3
0.3
15
6A0411
D / M RUBBER SLEEVE TO ATMOSPHERE
0.1
0.1
0.1
16
6A0412
CONDENSER UNION TO BLOCK “O“ RING SUBSTITUTION
0.5
0.5
0.5
17
6A0413
D / M OIL FILTER NECK
0.2
0.2
0.2
18
6A0414
D / M OIL FILTER NECK AND JOINT SUBSTITUTION
0.1
0.1
0.1
19
6A0415
D / M OIL LEVEL TUBE
0.3
0.3
0.3
20
6A0416
D / M OIL DIPSTICK
0.1
0.1
0.1
6A0400
OTHER
* * *
6A-05 ENGINE
CYLINDER HEAD
6A-05
CYLINDER HEAD
6A-05
COMPONENTS
POS
COMPONENTS
POS
Cylinder head
1
Engine valve spring assembly
11
Cylinder head gasket
2
Valve guides
12
Lock plug
3
Injector housing
4
Head cover gasket and cylinder
5
Engine flat gasket and cover
6
Cylinder head cover
7
Valve and seat assembly
8
Valve seat
9
Valves
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
C/V
ENGINE 6A-05
MODEL CODES AND
REPAIR TIME
6A-05. HEAD CYLINDER
AL01 AL02 AL03
HEAD CYLINDER, ENGINE OIL AND FILTER SUBSTITUTION 13.9 13.9 13.9
6A0501
INCLUDES:
A
B
1
6A0502
- Washing
- Hydraulic test
- Cap substitution, if necessary
- Timing adjustment
- Valve set measure
0.2
0.2
0.2
0.2
0.2
0.2
D / M CYLINDER HEAD
7.8
7.8
7.8
0.2
0.2
0.2
0.2
0.2
0.2
D / M CYLINDER HEAD
2.2
2.2
2.2
0.2
0.2
0.2
TRANSFER CYLINDER HEAD COMPONENTS
4.4
0.4
0.4
0.5
0.5
0.5
1.0
1.0
1.0
2.0
2.0
2.0
0.4
0.4
0.4
0.3
0.3
0.3
INCLUDES:
- Timing adjustment
EXCLUDES:
A
B
1
6A0503
- Measure and testing of valve set
- Washing
(SEPARATED ENGINE)
INCLUDES AND EXCLUDES:
B
1
6A0504
- The same as operation 6A0502
(SEPARATED CYLINDER HEAD)
1
6A0505
CYLINDER HEAD PLANNING
(SEPARATED CYLINDER HEAD AND DISMOUNTED COMPONENTS)
1
6A0506
HYDRAULIC TEST
1
6A0507
COMPRESSION CONTROL
INCLUDES:
- Perform of two tests
1
6A0508
COMPRESSION CONTROL
(SEPARATED INJECTORS)
1
6A0509
CYLINDER HEAD WASHING
6A-05 ENGINE
CYLINDER HEAD
6A-05
CYLINDER HEAD
6A-05
COMPONENTS
POS
COMPONENTS
POS
Cylinder head
1
11
2
Valve guides
12
Lock plug
3
Injector housing
4
5
6
Cylinder head cover
7
8
Valve seat
9
Valves
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
2
C/V
ENGINE 6A-05
MODEL CODES AND
REPAIR TIME
6A-05. CYLINDER HEAD
AL01 AL02 AL03
6A0510
9.5
9.5
9.5
0.2
0.2
0.2
0.2
0.2
0.2
LOCK PLUG SUBSTITUTION (ONE)
0.2
0.2
0.2
0.2
0.2
0.2
0.5
0.5
0.5
CYLINDER HEAD GASKET, ENGINE OIL AND FILTER
SUBSTITUTION
INCLUDES:
A
B
3
6A0511
-The same as for OP. 6A0502
-Washing
-Hydraulic test
-Eventual substitution of caps
4
6A0512
INJECTOR HOUSING RECTIFICATION (ONE)
(SEPARATED CYLINDER HEAD AND INJECTOR)
4
6A0513
INJECTOR HOUSING RECTIFICATION (SET)
(SEPARATED CYLINDER HEAD AND INJECTOR)
5
6A0514
D / M HEAD COVER GASKET AND CYLINDER
0.4
0.4
0.4
6
6A0515
D / M ENGINE FLAT GASKET AND COVER
1.1
1.1
1.1
6
6A0516
D / M ENGINE FLAT GASKET AND COVER
0.8
0.8
0.8
D / M CYLINDER HEAD COVER
0.1
0.1
0.1
VALVE AND SEAT ASSEMBLY RECTIFICATION
14.6 14.6 14.6
(SEPARATED ENGINE)
7
6A0517
8
6A0518
INCLUDES:
- Checking and adjustment of valve set
- Valve sealing control
- Descaling of cinder
- Valve spring control
EXCLUDES:
A
B
8
6A0519
- Valve guide substitution
0.2
0.2
0.2
0.2
0.2
0.2
VALVE AND SEAT ASSEMBLY RECTIFICATION
6.6
6.6
6.6
0.2
0.2
0.2
(SEPARATED ENGINE)
- The same as for OP. 6A0518
B
6A-05 ENGINE
CYLINDER HEAD
6A-05
CYLINDER HEAD
6A-05
COMPONENTS
POS
COMPONENTS
POS
Cylinder head
1
11
2
Valve guides
12
Lock plug
3
Injector housing
4
5
6
Cylinder head cover
7
8
Valve seat
9
Valves
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
8
C/V
ENGINE 6A-05
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0520
VALVE SUBSTITUTION AND SEAT RECTIFICATION
15.1 15.1 15.1
INCLUDES:
- Compression control
- Washing
- Cinder descaling
- Valve spring control
EXCLUDES:
A
B
8
6A0521
-Valve guide substitution
-Diagnostic operations
0.2
0.2
0.2
0.2
0.2
0.2
VALVE SEALING CONTROL
0.2
0.2
0.2
0.5
0.5
0.5
0.4
0.4
0.4
3.3
3.3
3.3
0.8
0.8
0.8
0.7
0.7
0.7
9
6A0522
VALVE SEAT RECTIFICATION (ONE)
(SEPARATED VALVE)
INCLUDES:
- Cinder descaling
EXCLUDES:
- Rectification and descaling of valves
9
6A0523
NEXT VALVE SEAT RECTIFICATION
(SEPARATED VALVE)
9
6A0524
VALVE SEAT RECTIFICATION (SET)
(SEPARATED VALVES)
9
6A0525
VALVE SEAT SUBSTITUTION (ONE)
(SEPARATED VALVES)
INCLUDES:
- Rectification of valve seating
EXCLUDES:
9
6A0526
NEXT VALVE SEAT SUBSTITUTION
(SEPARATED VALVE)
6A-05 ENGINE
CYLINDER HEAD
6A-05
CYLINDER HEAD
6A-05
COMPONENTS
POS
COMPONENTS
POS
Cylinder head
1
11
2
Valve guides
12
Lock plug
3
Injector housing
4
5
6
Cylinder head cover
7
8
Valve seat
9
Valves
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
9
6A0527
C/V
ENGINE 6A-05
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
VALVE SEAT RECTIFICATION (SET)
5.7
5.7
5.7
3.1
3.1
3.1
0.2
0.2
0.2
0.1
0.1
0.1
0.9
0.9
0.9
0.1
0.1
0.1
0.3
0.3
0.3
0.1
0.1
0.1
0.3
0.3
0.3
0.1
0.1
0.1
1.0
1.0
1.0
(SEPARATED VALVES)
INCLUDES:
- Rectification of valve seating
EXCLUDES:
10
6A0528
D / M VALVES AND SPRING CONTROL (SET)
INCLUDES:
EXCLUDES:
- Descaling of cinder
10
6A0529
DESCALING AND RECTIFICATION VALVE (ONE)
(SEPARATED VALVE)
10
6A0530
DESCALING AND RECTIFICATION NEXT VALVE
(SEPARATED VALVE)
10
6A0531
DESCALING AND RECTIFICATION VALVE (SET)
(SEPARATED VALVE)
10
6A0532
DESCALING VALVE (ONE)
(SEPARATED VALVE)
10
6A0533
DESCALING VALVE (SET)
(SEPARATED VALVE)
11
6A0534
ENGINE VALVE SPRING ASSY. CONTROL (ONE VALVE)
(SEPARATED SPRINGS)
12
6A0535
VALVE GUIDE SUBSTITUTION (ONE)
(SEPARATED VALVE)
INCLUDES:
- Reamed guide
12
6A0536
NEXT VALVE GUIDE SUBSTITUTION
(SEPARATED VALVE)
INCLUDES:
- Reamed guide
12
6A0537
VALVE GUIDE SUBSTITUTION (SET)
(SEPARATED VALVE)
INCLUDES:
- Reamed guide
6A0500
OTHER
* * *
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
PISTONS AND CONNECTING RODS
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
Connecting rod and piston assembly
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
Clutch to flywheel pin
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
Flywheel of dustguard covering
21
Crankshaft pulley
8
ENGINE 6A-06
BASIC
POS OPERATION
CODE
1
1
6A0601
C/V
6A-06. CRANKSHAFT
AL01 AL02 AL03
A
6A0602
A
2
MODEL CODES AND
REPAIR TIME
6A0603
D / M FRONT CRANKSHAFT SEAL COVER
2.2
0.2
2.2
0.2
2.2
0.2
D / M FRONT CRANKSHAFT SEAL COVER
1.4
1.4
1.4
(ENGINE SEPARATED)
0.2
0.2
0.2
D / M REAR CRANKSHAFT SEAL COVER
7.2
7.2
7.2
1.3
1.3
1.3
3.0
3.0
3.0
1.3
1.3
1.3
0.3
0.3
0.3
6.5
6.5
6.5
0.2
0.2
0.2
0.2
0.2
0.2
2.4
2.4
2.4
INCLUDES:
C
2
6A0604
- Phased flywheel
(SEPARATED GEAR BOX)
INCLUDES:
C
2
6A0605
- Phased flywheel
(SEPARATED FLYWHEEL)
3
6A0606
D / M OF CRANKSHAFT
(SEPARATED ENGINE)
INCLUDES:
- Instalation and removal engine on bench
- D / M connecting rods and pistons assembly
- D / M crankpin main bearing and connecting rods
- Clearance control between crankpins and bearings with
calibrated thread
- Washing
EXCLUDES:
A
B
3
6A0607
- Conduct cleaning
- Alignment verification
- Static balancing control of crankshaft
- Valve set measure and control
D / M CRANKSHAFT
(SEPARATED ENGINE, CONNECTING ROD AND PISTONS)
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
ENGINE 6A-06
BASIC
POS OPERATION
CODE
3
C/V
MODEL CODES AND
REPAIR TIME
6A-06. CRANKSHAFT
AL01 AL02 AL03
CRANKSHAFT AND ONE CONNECTING ROD SUBSTITUTION 17.2 17.2 17.2
6A0608
INCLUDES:
- External washing of engine on vehicle
- Installation and removal engine on bench
- D / M pistons with connecting rod assemblies
- Washing
- D / M main bearing crankpins and connecting rods
- Clearance control between crankpins and bearings with
calibrated thread
- Valve set measure and control
- Piston and segments substitution
- Static balancing of crankshaft control
EXCLUDES:
A
B
3
6A0609
- Conduct washing
- Verification alignment
0.9
0.7
0.9
0.7
0.9
0.7
MEASURE CONNECTING ROD CRANKPINS AND
CRANKSHAFT MAIN BEARING
0.4
0.4
0.4
0.4
0.4
0.4
4.1
4.1
4.1
0.3
0.3
0.3
(SEPARATED CRANKSHAFT)
3
6A0610
VERIFY CRANKSHAFT MAIN BEARING ALIGNMENT
4
6A0611
CLEARANCE CONTROL BETWEEN CRANKPINS AND MAIN
BEARINGS WITH CALIBRATED THREAD
(SEPARATED ENGINE)
INCLUDES:
- Installation and removal engine on work bench
4
6A0612
DIAMETER MEASURE MAIN BEARING CRANKPINS
5
6A0613
VISUAL CONTROL CONNECTING ROD CRANKPIN (ONE)
1.1
1.1
1.1
5
6A0614
VISUAL CONTROL CONNECTING ROD CRANKPIN (ONE)
0.2
0.2
0.2
0.1
0.1
0.1
0.2
0.2
0.2
0.1
0.1
0.1
(SEPARATED HOUSING)
5
6A0615
VISUAL CONTROL NEXT CONNECTING ROD CRANKPIN
(SEPARATED HOUSING)
5
6A0616
CLEARANCE CONTROL BETWEEN CONNECTING ROD AND
BEARING CRANKPIN, MEASURED WITH CALIBRATED
THREAD (ONE CONNECTING ROD)
(SEPARATED CONNECTING ROD COVER)
5
6A0617
DIAMETER MEASURE CONNECT. ROD CRANKPIN (ONE)
(SEPARATED CONNECTING ROD-PISTON ASSEMBLY)
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
BASIC
POS OPERATION
CODE
5
C/V
ENGINE 6A-06-07
MODEL CODES AND
REPAIR TIME
6A-06. CRANKSHAFT
6A-07. PISTONS AND CONNECTING RODS
AL01 AL02 AL03
6A0618
CONNECTING ROD CRANKPINS DIAMETER MEASURE
(FOUR)
0.3
0.3
0.3
0.2
0.2
0.2
0.8
0.8
0.8
1.0
1.0
1.0
1.3
0.2
1.3
0.2
1.3
0.2
5
6A0619
CONNECTING ROD CRANKPINS DIAMETER MEASURE
(FOUR)
6
6A0620
CRANKSHAFT CAMSHAFT PINION SUBSTITUTION
(SEPARATED TIMING BELT)
7
6A0621
DIAMETER MEASURE INSIDE MAIN BEARINGS (SET)
8
6A0622
A
6A0600
9
6A0701
D / M CRANKSHAFT PULLEY
OTHER
* * *
CONNECTING ROD ALIGNMENT CONTROL (ONE)
0.2
0.2
0.2
0.1
0.1
0.1
0.5
0.5
0.5
0.8
0.8
0.8
(CONNECTING ROD SEPARATED FROM ITS PISTON)
9
6A0702
NEXT CONNECTING ROD ALIGNMENT CONTROL
9
6A0703
CONNECTING RODS ALIGNMENT CONTROL (SET)
10
6A0704
WEIGHT AND ALIGNMENT CONTROL PISTONS AND
CONNECTING RODS (SET)
10
6A0705
D / M CONNECTING ROD AND PISTON ASSEMBLY (ONE)
10.0 10.0 10.0
INCLUDES:
- Clearance control between crankpin and bearing with calibrated
thread
EXCLUDES:
- Diameter measure of pistons
- Descaling and cleaning of pistons
- Piston and segment substitution
A
B
10
6A0706
0.2
0.1
0.2
0.1
0.2
0.1
1.5
1.5
1.5
(SEPARATED HEAD CYLINDER)
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
BASIC
POS OPERATION
CODE
10
C/V
ENGINE 6A-07
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0707
D / M NEXT CONNECTING ROD AND PISTON ASSEMBLY
0.5
0.5
0.5
3.7
3.7
3.7
0.2
0.1
0.2
0.1
0.2
0.1
D / M NEXT CONNECTING ROD AND PISTON ASSEMBLY
0.4
0.4
0.4
(SEPARATED HEAD CYLINDER AND HOUSING)
10
6A0708
(SEPARATED ENGINE)
INCLUDES:
thread
EXCLUDES:
A
B
10
6A0709
(SEPARATED ENGINE, HEAD CYLINDER AND HOUSING)
10
6A0710
D / M CONNECTING ROD AND PISTON ASSEMBLY (SET)
11.7 11.7 11.7
INCLUDES:
thread
EXCLUDES:
A
B
10
6A0711
0.2
0.1
0.2
0.1
0.2
0.1
3.2
3.2
3.2
5.3
5.3
5.3
0.2
0.1
0.2
0.1
0.2
0.1
(SEPARATED HEAD CYLINDER)
10
6A0712
(SEPARATED ENGINE)
INCLUDES:
thread
EXCLUDES:
A
B
-Diameter measure of pistons
-Diameter measure of casings
-Descaling and cleaning of pistons
-Piston and segment substitution
-Diagnostic operations
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
ENGINE 6A-07
BASIC
POS OPERATION
CODE
10
C/V
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0713
CONNECTING ROD PISTONS, PISTON RING AND 15.8 15.8 15.8
BEARINGS SUBSTITUTION (SET)
INCLUDES:
- Piston rings and pistons adaptation
EXCLUDES:
A
B
11
6A0714
0.2
0.1
0.2
0.1
0.2
0.1
DIAMETER MEASURE INSIDE CONNECTING ROD BEAR
(ONE)
0.2
0.2
0.2
0.1
0.1
0.1
0.5
0.5
0.5
0.5
0.5
0.5
2.0
2.0
2.0
0.1
0.1
0.1
0.4
0.4
0.4
0.3
0.3
0.3
11
6A0715
DIAMETER MEASURE INSIDE NEXT CONNECTING ROD
BEAR
11
6A0716
DIAMETER MEASURE INSIDE CONNECTING ROD BEAR
(SET)
12
6A0717
PISTON, GUDGEON PIN & PISTON RING SUBSTITUTION (ONE)
INCLUDES:
EXCLUDES:
-Counterweight and alignment of pistons and connecting rods
-Substitution of bearings for gudgeon pins of pistons in connect. rods
12
6A0718
PISTON, GUDGEON PIN & PISTON RING SUBSTITUTION (SET)
INCLUDES:
EXCLUDES:
-Counterweight and alignment of pistons and connecting rods
-Substitution of bearings for gudgeon pins of pistons in connect. rods
12
6A0719
D / M A CONNECTING ROD PISTON (ONE)
12
6A0720
D / M A CONNECTING ROD PISTON (SET)
12
6A0721
COUNTERWEIGHT PISTONS AND CONNECTING RODS
(SET)
(CONNECTING RODS SEPARATED FROM THEIR PISTONS)
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
BASIC
POS OPERATION
CODE
12
C/V
ENGINE 6A-07
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0722
PISTON CLEANING (ONE)
0.1
0.1
0.1
0.4
0.4
0.4
12
6A0723
PISTON CLEANING (SET)
(CONNECTING RODS SEPARATED FROM THEIR PISTONS)
13
PISTON RINGS SUBSTITUTION (FOUR PISTONS)
6A0724
14.3 14.3 14.3
INCLUDES:
- External washing of engine in vehicle
- Compression control
- Counterweight and alignment pistons and connecting rods
assembly
EXCLUDES:
A
B
13
6A0725
- Substitution of bearings for gudgeon pins pistons in connecting
rods
0.2
0.1
0.2
0.1
0.2
0.1
CLEANING, CONTROL AND SUBSTITUTION PISTON RINGS
(ONE PISTON)
0.4
0.4
0.4
1.6
1.6
1.6
0.2
0.2
0.2
0.6
0.6
0.6
0.4
0.4
0.4
1.1
1.1
1.1
13
6A0726
CLEANING, CONTROL AND SUBSTITUTION OF PISTON
RINGS (FOUR PISTONS)
14
6A0727
MEASURE BEARING FOR PISTON GUDGEON PIN (ONE
CONNECTING ROD)
(SEPARATED CONNECTING ROD-PISTON ASSEMBLIES)
14
6A0728
MEASURE BEARING FOR PISTON GUDGEON PIN (FOUR
CONNECTING RODS)
(SEPARATED CONNECTING ROD-PISTON ASSEMBLIES)
14
6A0729
SUBSTITUTION AND REAMING BEARING FOR PISTON
GUDGEON PIN (ONE CONNECTING ROD)
INCLUDES:
- Diameter measure of bearing
14
6A0730
SUBSTITUTION AND REAMING BEARING FOR PISTON
GUDGEON PIN (FOUR CONNECTING ROD)
INCLUDES:
- Diameter measure of bearing
6A0700
OTHER
* * *
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
BASIC
POS OPERATION
CODE
C/V
ENGINE 6A-08
MODEL CODES AND
REPAIR TIME
6A-08. FLYWHEEL ENGINE
AL01 AL02 AL03
15
6A0801
D / M EXTREME SUPPORT BEARING PLATE OF PRIMARY
GEAR BOX SHAFT
4.9
4.9
4.9
15
6A0802
GEAR BOX SHAFT
0.7
0.7
0.7
0.2
0.2
0.2
0.1
0.1
0.1
6.9
6.9
6.9
1.3
1.3
1.3
D / M FLYWHEEL
2.7
2.7
2.7
1.3
1.3
1.3
D / M FLYWHEEL
2.1
2.1
2.1
1.3
1.3
1.3
D / M FLYWHEEL
0.7
0.7
0.7
0.8
0.8
0.8
RECTIFICATION FLYWHEEL
0.5
0.5
0.5
0.5
0.5
0.5
15
6A0803
GEAR BOX SHAFT
(SEPARATED CLUTCH ASSEMBLY)
16
6A0804
PRIMARY BEARING EXTREME GEAR BOX SHAFT
SUBSTITUTION
(SEPARATED BEARING PLATE)
17
6A0805
D / M FLYWHEEL
INCLUDES:
C
17
6A0806
- Phased flywheel
INCLUDES:
C
17
6A0807
- Phased flywheel
(SEPARATED CLUTCH ASSEMBLY)
INCLUDES:
C
17
6A0808
- Phased flywheel
(SEPARATED ENGINE AND CLUTCH)
INCLUDES:
C
17
6A0809
- Phased flywheel
18
6A0810
SUBSTITUTION FLYWHEEL INDENTED CROWN WHEEL
6A-06-07-08 ENGINE
CRANKSHAFT
6A-06
6A-07
FLYWHEEL ENGINE
6A-08
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front catch cover
1
Connecting rod
9
Bearing cover
15
Rear catch cover
2
10
Primary bearing
16
Crankshaft
3
Connecting rod bear
11
Flywheel
17
Main bearings set
4
Piston assembly
12
Ring gear
18
Connecting rod bear
5
Piston ring
13
19
Camshaft pinion
6
Bush
14
Flywheel housing
20
Main bearings
7
21
Crankshaft pulley
8
BASIC
POS OPERATION
CODE
19
C/V
ENGINE 6A-08
MODEL CODES AND
REPAIR TIME
6A-08. FLYWHEEL ENGINE
AL01 AL02 AL03
6A0811
SUBSTITUTION CLUTCH TO FLYWHEEL PIN (ONE)
0.3
0.3
0.3
0.2
0.2
0.2
2.2
2.2
2.2
5.0
5.0
5.0
1.3
1.3
1.3
19
6A0812
SUBSTITUTION CLUTCH TO FLYWHEEL PIN (NEXT)
20
6A0813
D / M FLYWHEEL HOUSING
INCLUDES:
- D/M and sensor revolutions setting
21
D / M DUSTGUARD PLATE OF FLYWHEEL COVERING
6A0814
INCLUDES:
- Phased flywheel
- D/M and sensor revolutions setting
C
21
6A0800
OTHER
* * *
6A-09 ENGINE
CAMSHAFT AND TIMING
6A-09
CAMSHAFT AND TIMING
6A-09
COMPONENTS
POS
COMPONENTS
POS
Camshaft
1
Belt tensioner assembly
11
Cam
2
Engine bearing
12
Front seal cover and joint
3
Protection front
13
Plunger and tappet assembly
4
Protection upper
14
Tappet
5
Protection lower
15
Plunger
6
Camshaft pinion
7
Pinion and belt assembly
8
Timing belt
9
Injection pump drive gear
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
C/V
MODEL CODES AND
REPAIR TIME
6A.09. CAMSHAFT AND TIMING
AL01 AL02 AL03
6A0901
D / M CAMSHAFT
5.5
5.8
5.5
5.8
5.5
5.8
0.2
0.3
0.2
0.3
0.2
0.3
D / M CAMSHAFT
3.9
3.9
3.9
0.2
0.3
0.2
0.3
0.2
0.3
DIAMETER MEASURE CAMSHAFT SUPPORTS AND CAM
HEIGHT
0.4
0.4
0.4
4.6
0.2
4.6
0.2
4.6
0.2
D / M FRONT SEAL COVER CAMSHAFT
1.2
1.2
1.2
INCLUDES:
A
C
1
ENGINE 6A-09
6A0902
- Diameter measure of camshaft supports and cam height
- Measure of revolution meter sensor of camshaft (Common Rail)
(SEPARATED ENGINE)
INCLUDES:
A
C
2
6A0903
- Diameter measure of camshaft supports and cam height
- Measure of revolution meter sensor of camshaft (Common Rail)
(SEPARATED CAMSHAFT)
3
6A0904
D / M FRONT SEAL COVER CAMSHAFT
A
3
6A0905
4
6A0906
VALVE SET CONTROL
1.2
1.2
1.2
4
6A0907
VALVE SET CONTROL
0.4
0.4
0.4
0.8
0.8
0.8
0.1
0.1
0.1
0.8
0.8
0.8
0.7
0.7
0.7
(SEPARATED PLUNGER COVER)
4
6A0908
VALVE SET CONTROL
(SEPARATED ENGINE)
5
6A0909
VALVE SET MEASURE (SUBSTITUTION ONE TAPPET)
(AFTER CONTROL)
5
6A0910
VALVE SET MEASURE (SUBSTITUTION SET TAPPETS)
(AFTER CONTROL)
5
6A0911
VALVE SET MEASURE (SUBSTITUTION SET TAPPETS)
(AFTER CONTROL, SEPARATED ENGINE)
6A-09 ENGINE
CAMSHAFT AND TIMING
6A-09
CAMSHAFT AND TIMING
6A-09
COMPONENTS
POS
COMPONENTS
POS
Camshaft
1
11
Cam
2
Engine bearing
12
3
Protection front
13
4
Protection upper
14
Tappet
5
Protection lower
15
Plunger
6
Camshaft pinion
7
8
Timing belt
9
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
6
C/V
ENGINE 6A-09
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
6A0912
D / M PLUNGERS AND CONTROL
5.5
5.5
5.5
0.2
0.2
0.2
D / M PLUNGERS AND CONTROL
4.1
4.1
4.1
0.1
0.1
0.1
0.1
0.1
0.1
INCLUDES:
EXCLUDES:
- Diameter measure of camshaft support and cam height
A
6
6A0913
(SEPARATED ENGINE)
INCLUDES:
- Instalation and removal of engine on bench
EXCLUDES:
- Diameter measure of camshaft support and cam height
7
6A0914
D / M CAMSHAFT PINION
INCLUDES:
- Measure of revolution counter sensor of camshaft (Common Rail)
C
8
6A0915
CONTROL PHASED TIMING
1.7
1.7
1.7
8
6A0916
CONTROL PHASED TIMING
0.4
0.4
0.4
3.3
0.2
3.3
0.2
3.3
0.2
TIMING BELT SUBSTITUTION
1.1
1.1
1.1
(SEPARATED ENGINE)
0.2
0.2
0.2
0.2
0.2
0.2
(SEPARATED FRONT TIMING COVER)
9
6A0917
A
9
6A0918
A
9
6A0919
(AFTER ANOTHER TIMING INTERVENTION)
9
6A0920
TIMING BELT TENSION TEST
1.4
1.4
1.4
9
6A0921
TIMING BELT TENSION TEST
0.1
0.1
0.1
0.2
0.2
0.2
3.2
3.2
3.2
(SEPARATED FRONT TIMING COVER)
10
6A0922
D / M INJECTION PUMP DRIVE GEAR
11
6A0923
D / M TIMING BELT
6A-09 ENGINE
CAMSHAFT AND TIMING
6A-09
CAMSHAFT AND TIMING
6A-09
COMPONENTS
POS
COMPONENTS
POS
Camshaft
1
11
Cam
2
Engine bearing
12
3
Protection front
13
4
Protection upper
14
Tappet
5
Protection lower
15
Plunger
6
Camshaft pinion
7
8
Timing belt
9
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
11
6A0924
C/V
ENGINE 6A-09
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
D / M BELT TENSIONER ASSEMBLY
0.2
0.2
0.2
0.2
0.2
0.2
11
6A0925
BELT TENSIONER ASSEMBLY REVISION
(SEPARATED TENSIONER)
12
6A0926
ENGINE BEARING TIMING SUBSTITUTION
3.1
3.1
3.1
12
6A0927
ENGINE BEARING TIMING REVISION
0.1
0.1
0.1
0.2
0.2
0.2
12
6A0928
TIMING BELT FIXED TENSOR ROLLER SUBSTITUTION
13
6A0929
D / M PROTECTION FRONT
1.3
1.3
1.3
14
6A0930
D / M PROTECTION UPPER
0.2
0.2
0.2
0.8
0.8
0.8
15
6A0931
D / M PROTECTION LOWER
(SEPARATED CRANKSHAFT PULLEY)
6A0900
OTHER
* * *
6A-10-11 ENGINE
AUXILIARY ORGANS GROUP
6A-10
FRONT ENGINE MOUNTING
6A-11
COMPONENTS
POS
COMPONENTS
POS
Bracket housing assembly
1
Cushion
Front joint and flat gasket
2
Front bracket
6
7
Cover
3
Bracket cushion
8
Upper joint and flat gasket
4
Sealings and coupling guides
5
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
C/V
ENGINE 6A-10
MODEL CODES AND
REPAIR TIME
6A-10. AUXILIARY ORGANS GROUP
AL01 AL02 AL03
6A1001
D / M BRACKET HOUSING ASSEMBLY
4.4
4.4
4.4
0.2
0.9
0.2
0.9
0.2
0.9
1.4
1.4
1.4
0.2
0.9
0.2
0.9
0.2
0.9
2.0
2.0
2.0
0.2
0.2
0.2
1.8
1.8
1.8
7.0
0.2
0.9
7.0
0.2
0.9
7.0
0.2
0.9
D / M FRONT JOIN AND FLAT GASKET
0.7
0.7
0.7
INCLUDES:
- Coupling conduct sealing substitution
- Timing setting
- Engine oil level
EXCLUDES:
A
B
1
6A1002
- D / M injector pump
- D / M depressor
- D / M hydraulic steering pump
- D / M oil filter
- D / M heat interchanger
(SEPARATED ENGINE)
A
B
1
6A1003
- The same as for OP. 6A0101B
(SEPARATED AUXILIARY ORGANS GROUP)
INCLUDES:
- D / M injector pump
- D / M depressor
- D / M hydraulic steering pump
- D / M oil filter
- D / M heat interchanger
EXCLUDES:
- Transfer exterior components
1
6A1004
TRANSFER EXTERIOR COMPONENTS
(SEPARATED BRACKET HOUSING AND REMOVAL AUXILIARY ORGANS)
1
6A1005
(SEPARATED AUXILIARY ORGANS GROUP AND INJECTION PUMP)
1
6A1006
D / M AND REVISION BRACKET HOUSING ASSEMBLY
A
B
2
6A1007
6A-10-11 ENGINE
6A-10
FRONT ENGINE MOUNTING
6A-11
COMPONENTS
POS
COMPONENTS
POS
Bracket housing assembly
1
Cushion
Front joint and flat gasket
2
Front bracket
6
7
Cover
3
Bracket cushion
8
Upper joint and flat gasket
4
Sealings and coupling guides
5
COMPONENTS
POS
BASIC
POS OPERATION
CODE
3
C/V
MODEL CODES AND
REPAIR TIME
6A-10. AUXILIARY ORGANS GROUP
6A-11. FRONT ENGINE SUPPORTS
AL01 AL02 AL03
6A1008
B
3
ENGINE 6A-10-11
6A1009
D / M COVER AND JOINT
0.6
0.6
0.6
(SEPARATED ENGINE)
0.7
0.7
0.7
1.1
0.2
3.9
1.1
0.2
3.9
1.1
0.2
3.9
D / M COVER AND JOINT
A
B
4
6A1010
D / M UPPER JOINT AND FLAT GASKET
0.3
0.3
0.3
5
6A1011
SUBSTITUTION COUPLING CONDUCT SEALING OF
0.3
0.3
0.3
(SEPARATED AUXILIARY ORGANS GROUP)
INCLUDES:
- External cleaning
6A1000
OTHER
* * *
6
6A1101
FRONT CUSHION SUBSTITUTION (ONE)
0.8
0.8
0.8
6
6A1102
FRONT CUSHION SUBSTITUTION (TWO)
0.9
0.9
0.9
7
6A1103
FRONT BRACKET SUBSTITUTION (ONE)
1.1
1.1
1.1
7
6A1104
FRONT BRACKET SUBSTITUTION (TWO)
1.5
1.5
1.5
8
6A1105
BRACKET CUSHION SUBSTITUTION (ONE)
0.1
0.1
0.1
6A1100
OTHER
* * *
6A-12 ENGINE
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Injection assembly
1
Fuel injector
11
Limiting valve flow
Injection pump bush
2
Fuel line to electro valve
12
Over pressure valve
22
LDA device
3
Fuel line to plug
13
Pressure sensor
23
Electrical pear
4
Accelerator cable
14
High pressure pipe
24
KSB device
5
Accelerator pedal
15
Pedal accelerator sensor
25
KSB device thermal sensor
6
High pressure fuel pump
16
Injector pump joint
7
Pumping separation tank
17
LDA device air pressure pipe
8
High pressure regulator
18
Injector leftover pipe
9
Joint a pump holder
19
Fuel injection pipe
10
High pressure hydraulic accumulator
20
21
BASIC
POS OPERATION
CODE
1
6A1201
C/V
ENGINE 6A-12
MODEL CODES AND
REPAIR TIME
6A-12. FUEL INJECTION
AL01 AL02 AL03
B
D / M AND TARE INJECTION PUMP (*)
7.4
7.4
7.4
4.7
4.7
4.7
1.0
1.0
1.0
INCLUDES:
- Washing
1
6A1202
B
D / M, MEASURE, PHASED AND DRAIN INJECTION PUMP
EXCLUDES:
- D / M dragging hub
1
6A1203
B
D / M PHASED INJECTION PUMP
(SEPARATED ENGINE)
EXCLUDES:
- D / M dragging hub
1
6A1204
B
D / M AND REVISION INJECTION PUMP (*)
11.3 11.3 11.3
INCLUDES:
- Washing
1
6A1205
B
3.0
3.0
3.0
6.1
6.1
6.1
3.1
3.1
3.1
3.3
3.3
3.3
MEASURE, INITIAL INJECTION ADJUSTMENT AND PHASED 0.8
INJECTION PUMP
0.8
0.8
REVISION INJECTION PUMP
(SEPARATED INJECTION PUMP)
1
6A1206
B
REVISION AND TARE INJECTION PUMP
1
6A1207
B
BENCH TARE INJECTION PUMP
1
6A1208
B
MEASURE AND PHASED INJECTION PUMP
(ENGINE IN VEHICLE)
1
6A1209
B
(SEPARATED ENGINE)
1
6A1210
1
6A1211
B
MEASURE SLOW MOTION
0.2
0.2
0.2
EXTERNAL WASHING INJECTION PUMP
0.1
0.1
0.1
(*) INCLUDES AIR DRAIN
6A-12 ENGINE
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Injection assembly
1
Fuel injector
11
Limiting valve flow
Injection pump bush
2
12
Over pressure valve
22
LDA device
3
Fuel line to plug
13
Pressure sensor
23
Electrical pear
4
Accelerator cable
14
High pressure pipe
24
KSB device
5
Accelerator pedal
15
25
6
16
Injector pump joint
7
17
8
18
9
Joint a pump holder
19
Fuel injection pipe
10
20
21
BASIC
POS OPERATION
CODE
2
6A1212
C/V
ENGINE 6A-12
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
B
D / M INJECTION PUMP BUSH
0.2
0.2
0.2
2.0
2.0
2.0
0.2
0.2
0.2
1.5
1.5
1.5
3
6A1213
B
D / M, TEST AND MEASURE LDA DEVICE
3
6A1214
B
LDA DEVICE REVISION
(SEPARATED LDA DEVICE)
3
6A1215
B
TEST AND MEASURE LDA DEVICE
4
6A1216
B
ELECTRICAL PEAR DEVICE SUBSTITUTION AND DRAIN
0.4
0.4
0.4
4
6A1217
B
ELECTRICAL PEAR DEVICE SUBSTITUTION
0.1
0.1
0.1
0.4
0.4
0.4
KSB DEVICE THERMAL SENSOR
0.3
0.3
0.3
SUBSTITUTION INJECTION PUMP JOINT DUE TO
LEAKAGE (*)
4.7
4.7
4.7
D / M LDA DEVICE AIR PRESSURE PIPE
0.2
0.2
0.2
D / M INJECTION PIPE LEFTOVER
0.5
0.5
0.5
D / M FUEL INJECTION PIPE (ONE)
0.3
0.5
0.3
0.5
0.3
0.5
5
6A1218
B
AUTOMATIC INJECTION ADVANCE DEVICE SUBSTITUTION
(KSB)
INCLUDES:
- Necessary measures
EXCLUDES:
- D / M injection pump
6
6A1219
7
6A1220
B
INCLUDES:
8
6A1221
9
6A1222
10
6A1223
B
B
6A-12 ENGINE
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Injection assembly
1
Fuel injector
11
Limiting valve flow
Injection pump bush
2
12
Over pressure valve
22
LDA device
3
Fuel line to plug
13
Pressure sensor
23
Electrical pear
4
Accelerator cable
14
High pressure pipe
24
KSB device
5
Accelerator pedal
15
25
6
16
Injector pump joint
7
17
8
18
9
Joint a pump holder
19
Fuel injection pipe
10
20
21
BASIC
POS OPERATION
CODE
10
C/V
6A1224
11
6A1225
D / M INJECTOR (ONE)
6A1226
6A1227
D / M FUEL INJECTION PIPES (SET)
B
11
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
B
11
ENGINE 6A-12
D / M INJECTORS (SET)
0.5
0.7
0.5
0.7
0.5
0.7
0.4
0.5
0.4
0.5
0.4
0.5
B
1.2
0.4
1.2
0.4
1.2
0.4
B
D / M AND TARE INJECTORS (SET)
2.2
2.2
2.2
D / M INJECTORS (SET)
0.3
0.3
0.3
B
(SEPARATED ENGINE)
0.2
0.2
0.2
B
D / M AND REVISION INJECTOR (ONE)
1.4
1.4
1.4
2.6
2.6
2.6
0.2
0.2
0.2
0.8
0.8
0.8
0.1
0.1
0.1
0.2
0.2
0.2
INCLUDES:
11
11
6A1228
6A1229
INCLUDES:
11
6A1230
B
D / M AND REVISION INJECTORS (SET)
INCLUDES:
11
6A1231
B
REVISION AND TARE INJECTOR (ONE)
(SEPARATED INJECTOR)
11
6A1232
B
REVISION AND TARE INJECTORS (SET)
11
6A1233
B
INJECTOR CONTROL (ONE)
(SEPARATED INJECTION)
11
6A1234
B
INJECTORS CONTROL (SET)
6A-12 ENGINE
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Injection assembly
1
Fuel injector
11
Limiting valve flow
Injection pump bush
2
12
Over pressure valve
22
LDA device
3
Fuel line to plug
13
Pressure sensor
23
Electrical pear
4
Accelerator cable
14
High pressure pipe
24
KSB device
5
Accelerator pedal
15
25
6
16
Injector pump joint
7
17
8
18
9
Joint a pump holder
19
Fuel injection pipe
10
20
21
BASIC
POS OPERATION
CODE
11
6A1235
C/V
ENGINE 6A-12
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
B
CONTROL AND TARE INJECTOR (ONE)
0.1
0.1
0.1
0.4
0.4
0.4
11
6A1236
B
CONTROL AND TARE INJECTORS (SET)
12
6A1237
FUEL LINE TO ELECTROVALVE
0.2
0.2
0.2
13
6A1238
FUEL LINE TO PLUG
0.1
0.1
0.1
14
6A1239
D / M ACCELERATOR CABLE
0.3
0.1
0.3
0.1
0.3
0.1
D / M ACCELERATOR PEDAL
0.5
0.5
0.5
C
15
6A1240
16
6A1241
C
D / M HIGH PRESSURE FUEL PUMP (*)
0.8
0.8
0.8
16
6A1242
C
D / M HIGH PRESSURE FUEL PUMP
0.3
0.3
0.3
1.6
1.6
1.6
(SEPARATED ENGINE)
16
6A1243
C
HIGH PRESSURE PUMP FUNCTIONING CONTROL ON
BENCH
(SEPARATED ENGINE)
17
6A1244
C
D / M PUMPING SEPARATION DEVICE
0.2
0.2
0.2
17
6A1245
C
D / M PUMPING SEPARATION DEVICE
0.1
0.1
0.1
(SEPARATED HIGH PRESSURE PUMP)
18
6A1246
C
D / M HIGH PRESSURE REGULATOR
0.3
0.3
0.3
18
6A1247
C
D / M HIGH PRESSURE REGULATOR
0.1
0.1
0.1
0.8
0.8
0.8
(SEPARATED HIGH PRESSURE PUMP)
19
6A1248
C
D / M JOIN AND PUMP HOLDER (*)
6A-12 ENGINE
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
FUEL INJECTION
6A-12
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Injection assembly
1
Fuel injector
11
Limiting valve flow
Injection pump bush
2
12
Over pressure valve
22
LDA device
3
Fuel line to plug
13
Pressure sensor
23
Electrical pear
4
Accelerator cable
14
High pressure pipe
24
KSB device
5
Accelerator pedal
15
25
6
16
Injector pump joint
7
17
8
18
9
Joint a pump holder
19
Fuel injection pipe
10
20
21
BASIC
POS OPERATION
CODE
C/V
ENGINE 6A-12
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
20
6A1249
C
D / M HIGH PRESSURE HYDRAULIC ACCUMULATOR
0.9
0.9
0.9
20
6A1250
C
SUBSTITUTION
ACCUMULATOR
1.2
1.2
1.2
HIGH
PRESSURE
HYDRAULIC
INCLUDES:
21
6A1251
C
D / M LIMITING VALVE FLOW (ONE)
0.2
0.2
0.2
21
6A1252
C
D / M LIMITING VALVE FLOW (SET)
0.4
0.4
0.4
22
6A1253
C
D / M OVERPRESSURE VALVE
0.2
0.2
0.2
23
6A1254
C
D / M PRESSURE SENSOR
0.2
0.2
0.2
24
6A1255
C
D / M HIGH PRESSURE PUMP PIPE TO HYDRAULIC
ACCUMULATOR
0.2
0.2
0.2
25
6A1256
C
D / M PEDAL ACCELERATOR SENSOR
0.4
0.4
0.4
INDIVIDUAL CHECK PEDAL ACCELERATOR SENSOR
0.2
0.2
0.2
OTHER
* * *
EXCLUDES:
- Rheostat check
25
6A1257
6A1200
C
ENGINE COOLING ...............................................................................................
6B
WATER PUMP, THERMOSTAT AND HEAT EXCHANGER TUBING ........ 6B-01
VENTILATOR AND CONTROL BELTS ..................................................... 6B-02
WATER RADIATOR AND DEGASING BOX .............................................. 6B-03
WATER HOSES ................................................................................................. 6B-04
6B
6B-01-02 ENGINE COOLING
WATER PUMP, THERMOSTAT AND HEAT
EXCHANGER TUBING
6B-01
VENTILATOR AND CONTROL BELTS
6B-02
COMPONENTS
POS
COMPONENTS
POS
Water pump
1
Accesory belt
Heat exchanger pipe
2
Compressor belt A/C
10
11
Heat exchanger pipe
3
Water pump pulley and fan assembly
12
Heat exchanger hoses
4
Cooling fan
13
5
Water pump adaptor
6
Connection pipe to thermostat
7
Thermostat assembly
8
Thermostat body
9
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
C/V
6B0101
6B0102
A
1
6B0103
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
4.1
0.2
4.1
0.2
4.1
0.2
D / M WATER PUMP
0.9
0.9
0.9
(SEPARATED ENGINE)
0.2
0.2
0.2
WATER PUMP VERIFICATION
0.2
0.2
0.2
D / M WATER PUMP (*)
A
1
6B-01. WATER PUMP, THERMOSTAT AND HEAT EXCHANGER
TUBING
6B-02. VENTILATOR AND CONTROL BELTS
ENGINE COOLING 6B-01-02
(SEPARATED PUMP)
2
6B0104
D / M WATER HEAT EXCHANGER INLET PIPE (*)
0.8
0.8
0.8
3
6B0105
D / M WATER HEAT EXCHANGER OUTLET PIPE (*)
0.8
0.8
0.8
4
6B0106
WATER HEAT EXCHANGER INLET HOSE SUBSTITUTION (*)
0.5
0.5
0.5
5
6B0107
WATER HEAT EXCHANGER OUTLET HOSE SUBSTITUTION (*)
0.5
0.5
0.5
6
6B0108
D / M ADAPTOR AND JOINT WATER PUMP(*)
0.7
0.7
0.7
7
6B0109
D / M CONNECTION PIPE TO THERMOSTAT (*)
2.0
2.0
2.0
8
6B0110
D / M THERMOSTAT AND JOINTS (*)
0.4
0.4
0.4
8
6B0111
THERMOSTAT CHECK
0.2
0.2
0.2
2.0
2.0
(SEPARATED THERMOSTAT)
9
6B0112
D / M THERMOSTAT BODY OR ITS JOINT (*)
2.0
6B0100
OTHER
* * *
10
6B0201
ACCESORY BELT SUBSTITUTION
0.7
0.7
0.7
10
6B0202
ACCESORY BELT REGULATION
0.2
0.2
0.2
11
6B0203
AIR CONDITIONER COMPRESSOR BELT SUBSTITUTION
0.8
0.8
0.8
11
6B0204
AIR CONDITIONER COMPRESSOR BELT TENSION
REGULATION
0.3
0.3
0.3
12
6B0205
D / M WATER PUMP PULLEY AND FAN ASSEMBLY
2.3
0.2
2.3
0.2
2.3
0.2
A
(*) INCLUDES FILLING, DRAIN OR COOLING LEVEL ADJUSTMENT
WATER PUMP, THERMOSTAT AND HEAT
EXCHANGER TUBING
6B-01
VENTILATOR AND CONTROL BELTS
6B-02
COMPONENTS
POS
COMPONENTS
POS
Water pump
1
Accesory belt
Heat exchanger pipe
2
Compressor belt A/C
10
11
Heat exchanger pipe
3
Water pump pulley and fan assembly
12
4
Cooling fan
13
5
Water pump adaptor
6
Connection pipe to thermostat
7
Thermostat assembly
8
Thermostat body
9
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
ENGINE COOLING 6B-02
MODEL CODES AND
REPAIR TIME
6B-02. VENTILATOR AND CONTROL BELTS
AL01 AL02 AL03
13
6B0206
D / M COOLING FAN
0.4
0.4
0.4
13
6B0207
D / M COOLING FAN
0.1
0.1
0.1
(SEPARATED ENGINE)
6B0200
OTHER
* * *
WATER RADIATOR AND
DEGASING BOX
6B-03
WATER HOSE
6B-04
WATER HOSE
6B-04
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Radiator assembly
1
Hose assembly
8
Lower radiator hose clamps
18
Water radiator
2
Radiator inlet hose
9
Hose clamps
19
Fan protector
3
Radiator hoses
10
Radiator bracket assembly
4
Radiator outlet hose
11
Degasing box
5
Hose by-pass
12
Pressure plug
6
Valve heater
13
Expansion tank bracket
7
Fauce to heater hose
14
15
Drain hose
16
Heater hose clamp
17
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6B-03. WATER RADIATOR AND DEGASING BOX
AL01 AL02 AL03
1
6B0301
D / M WATER RADIATOR ASSEMBLY, INTERCOOLER AND
GUIDE (*)
0.8
0.8
0.8
2
6B0302
WATER RADIATOR SUBSTITUTION (*)
1.2
1.2
1.2
1.8
1.8
1.8
0.4
0.4
0.4
0.3
0.3
0.3
INCLUDES:
- Transfer components with separated air conditioner
2
6B0303
WATER RADIATOR SUBSTITUTION AND PRESSURE TEST
(*)
INCLUDES:
- Radiator washing
- Transfer components with separated air conditioner
2
6B0304
TRANSFER RADIATOR COMPONENTS
(SEPARATED RADIATOR ASSEMBLY)
2
6B0305
RADIATOR SEALING TEST
2
6B0306
MEASURE ANTI-FREEZE PROPORTION AND REFILLING
0.3
0.3
0.3
2
6B0307
CIRCUIT REFILLING AND COOLING LEVEL ADJUSTMENT
0.1
0.1
0.1
2
6B0308
COOLING SOLUTION EMPTYING
0.2
0.2
0.2
2
6B0309
COOLING SOLUTION SUBSTITUTION
0.3
0.3
0.3
2
6B0310
WATER RADIATOR WASHING
0.3
0.3
0.3
3
6B0311
D / M WATER RADIATOR FAN PROTECTOR
0.4
0.4
0.4
4
6B0312
D / M WATER RADIATOR BRACKET (ONE)
0.2
0.2
0.2
5
6B0313
D / M DEGASING BOX (*)
0.3
0.3
0.3
6
6B0314
D / M PRESSURE PLUG
0.1
0.1
0.1
7
6B0315
D / M EXPANSION TANK BRACKET
0.3
0.3
0.3
(SEPARATED TANK)
6B0300
OTHER
* * *
WATER RADIATOR AND
DEGASING BOX
6B-03
WATER HOSE
6B-04
WATER HOSE
6B-04
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Radiator assembly
1
Hose assembly
8
Lower radiator hose clamps
18
Water radiator
2
Radiator inlet hose
9
Hose clamps
19
Fan protector
3
Radiator hoses
10
4
Radiator outlet hose
11
Degasing box
5
Hose by-pass
12
Pressure plug
6
Valve heater
13
Expansion tank bracket
7
14
15
Drain hose
16
Heater hose clamp
17
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6B-04. WATER HOSES
AL01 AL02 AL03
8
6B0401
COOLING CIRCUIT HOSE SUBSTITUTION (SET) (*)
1.3
1.3
1.3
8
6B0402
VISUAL LOSS CONTROL IN COOLING CIRCUIT AND
RETIGHTENING OF CLAMPS
0.3
0.3
0.3
9
6B0403
RADIATOR INLET HOSE SUBSTITUTION (*)
0.3
0.3
0.3
10
6B0404
RADIATOR HOSE SUBSTITUTION (ONE) (*)
0.2
0.2
0.2
11
6B0405
RADIATOR OULET HOSE SUBSTITUTION (*)
0.4
0.4
0.4
12
6B0406
HOSE BY-PASS AND HEATING RETURN SUBSTITUTION (*)
0.5
0.5
0.5
13
6B0407
VALVE HEATER SUBSTITUTION (*)
0.7
0.7
0.7
14
6B0408
FAUCE TO ENGINE HOSE SUBSITUTION (*)
0.4
0.4
0.4
15
6B0409
FAUCE TO HEATER HOSE SUBSITUTION (*)
0.4
0.4
0.4
16
6B0410
DEGASING BOX DRAIN HOSE SUBSTITUTION
0.1
0.1
0.1
17
6B0411
HEATER HOSE CLAMP SUBSTITUTION (ONE) (*)
0.4
0.4
0.4
17
6B0412
(NEXT) HEATER HOSE CLAMP SUBSTITUTION
0.1
0.1
0.1
17
6B0413
HEATER HOSE CLAMP RETIGHTENING
0.2
0.2
0.2
18
6B0414
RADIATOR HOSE CLAMP SUBSTITUTION (ONE) (*)
0.3
0.3
0.3
18
6B0415
(NEXT) HOSE CLAMP SUBSTITUTION
0.1
0.1
0.1
19
6B0416
HOSE CLAMP SUBSTITUTION (ONE) (*)
0.2
0.2
0.2
19
6B0417
(NEXT) HOSE CLAMP SUBSTITUTION
0.1
0.1
0.1
6B0400
OTHER
* * *
FEEDING AND EMISSION CONTROL ...................................................
6C
FUEL FEEDING ................................................................................................. 6C-01
AIR OVERFEEDING ......................................................................................... 6C-02
SENSORS, THERMISTORS AND ENGINE CONTROL SWITCHES ........ 6C-03
6C
6C-01 FEEDING AND EMISSION CONTROL
FUEL FEEDING
6C-01
FUEL FEEDING
6C-01
FUEL FEEDING
6C-01
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Fuel tank
1
Feeding hose
12
Fuel filter element
23
Fuel filter cap and lock
2
Return hose
13
Fuel feeding circuit
24
Fuel cap lock cylinder set
3
Clamp
15
Pre-filter hose to fuel pump
25
Fuel inlet box
4
Hose pipe to filter
16
Fuel pump hose to pipe
26
Pressure control valve assembly
5
Hose filter to pump
17
Fuel pre-filter
27
Ventilation hose
6
Hose multiple connector to pipe
18
Fuel pump bracket
28
Fuel tank filler hose
7
Injector return hose
19
Fuel pump
29
Fuel lever gauge
8
Underhood fuel hose set
20
Multiple return connector
30
Fuel feeding pipe
9
Hose clamps
21
Return filter hose
31
Return pipe
10
Fuel filter assembly
22
BASIC
POS OPERATION
CODE
1
6C0101
C/V
FEEDING AND EMISSION CONTROL 6C-01
MODEL CODES AND
REPAIR TIME
6C-01. FUEL FEEDING
AL01 AL02 AL03
D / M FUEL TANK (*)
1.1
1.1
1.1
0.2
0.2
0.2
0.2
0.2
0.2
1.6
1.6
1.6
0.2
0.2
0.2
0.3
0.3
0.3
0.3
0.3
0.3
EXCLUDES:
- Fuel emptying
- External and internal washing
1
6C0102
TRANSFER COMPONENTS OF FUEL TANK
(SEPARATED TANK)
1
6C0103
FUEL EMPTYING AND FILLING
(SEPARATED TANK)
1
6C0104
D / M AND FUEL TANK CLEANING (*)
EXCLUDES:
- Fuel emptying
1
6C0105
EXTERNAL CLEANING OF FUEL TANK
(SEPARATED TANK AND FUEL EMPTYING)
1
6C0106
INTERNAL CLEANING OF FUEL TANK
(SEPARATED TANK AND FUEL EMPTYING)
1
6C0107
EXTERNAL PAINTING OF FUEL TANK
(SEPARATED TANK)
2
6C0108
SUBSTITUTION FUEL FILLER CAP AND LOCK, LOSS
ELIMINATION
0.1
0.1
0.1
3
6C0109
SUBSTITUTION FUEL CAP AND LOCK CYLINDER SET
0.2
0.2
0.2
4
6C0110
D / M FUEL INLET BOX
0.5
0.5
0.5
5
6C0111
SUBSTITUTION TANK PRESSURE CONTROL VALVE, OR
ITS HOSES
0.5
0.5
0.5
INCLUDES:
- Valve check
6
6C0112
TANK VENTILATION HOSE SUBSTITUTION
1.4
1.4
1.4
7
6C0113
FUEL TANK FILLER HOSE SUBSTITUTION
0.5
0.5
0.5
8
6C0114
D / M FUEL LEVER GAUGE (*)
1.3
1.3
1.3
8
6C0115
D / M FUEL LEVER GAUGE
0.2
0.2
0.2
(SEPARATED TANK)
FUEL FEEDING
6C-01
FUEL FEEDING
6C-01
FUEL FEEDING
6C-01
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Fuel tank
1
Feeding hose
12
Fuel filter element
23
2
Return hose
13
24
3
Clamp
15
25
Fuel inlet box
4
Hose pipe to filter
16
26
5
Hose filter to pump
17
Fuel pre-filter
27
Ventilation hose
6
18
Fuel pump bracket
28
7
19
Fuel pump
29
Fuel lever gauge
8
20
30
Fuel feeding pipe
9
Hose clamps
21
Return filter hose
31
Return pipe
10
22
BASIC
POS OPERATION
CODE
8
6C0116
C/V
MODEL CODES AND
REPAIR TIME
6C-01. FUEL FEEDING
AL01 AL02 AL03
FUEL LEVER GAUGE SUBSTITUTION (*)
1.5
1.5
1.5
INCLUDES:
- Gauge cleaning and check
9
6C0117
FUEL FEEDING PIPE SUBSTITUTION (*)
0.3
0.3
0.3
10
6C0118
FUEL RETURN PIPE SUBSTITUTION
0.2
0.2
0.2
11
6C0119
FUEL RETURN AND FEEDING PIPES SUBSTITUTION (*)
0.5
0.5
0.5
12
6C0120
FEEDING HOSE TO PIPE OR TO PREFILTER
SUBSTITUTION (*)
1.1
1.1
1.1
13
6C0121
RETURN HOSE TO TANK FUEL SUBSTITUTION (*)
1.0
1.0
1.0
14
6C0122
RETURN AND FEEDING HOSES SUBSTITUTION (*)
1.2
1.2
1.2
15
6C0123
CLAMP SUBSTITUTION
0.1
0.1
0.1
16
6C0124
FEEDING HOSE PIPE TO FUEL FILTER SUBSTITUTION (*)
0.3
0.3
0.3
17
6C0125
HOSE FILTER TO PUMP SUBSTITUTION (*)
0.3
0.3
0.3
18
6C0126
HOSE MULTIPLE CONNECTOR TO PIPE SUBSTITUTION
0.2
0.2
0.2
19
6C0127
FUEL RETURN INJECTOR HOSE SUBSTITUTION
0.2
0.2
0.2
20
6C0128
SUBSTITUTION UNDERHOOD FUEL HOSE SET (*)
0.9
0.9
0.9
21
6C0129
SUBSTITUTION HOSE CLAMP TO BODY (ONE)
0.1
0.1
0.1
FUEL FEEDING
6C-01
FUEL FEEDING
6C-01
FUEL FEEDING
6C-01
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Fuel tank
1
Feeding hose
12
Fuel filter element
23
2
Return hose
13
24
3
Clamp
15
25
Fuel inlet box
4
Hose pipe to filter
16
26
5
Hose filter to pump
17
Fuel pre-filter
27
Ventilation hose
6
18
Fuel pump bracket
28
7
19
Fuel pump
29
Fuel lever gauge
8
20
30
Fuel feeding pipe
9
Hose clamps
21
Return filter hose
31
Return pipe
10
22
BASIC
POS OPERATION
CODE
22
C/V
MODEL CODES AND
REPAIR TIME
6C-01. FUEL FEEDING
AL01 AL02 AL03
6C0130
FUEL FILTER ASSEMBLY SUBSTITUTION (*)
0.3
0.3
0.3
ADDITIONAL TIME ENGINE COMMON RAIL
0.2
0.2
0.2
INCLUDES:
C
22
6C0131
AIR DRAIN IN THE FUEL FEEDING CIRCUIT
0.1
0.1
0.1
23
6C0132
FUEL FILTER ELEMENT SUBSTITUTION (*)
0.2
0.2
0.2
0.1
0.1
0.1
VISUAL CONTROL OF CLAMPS, HOSES AND PIPES,
LOSSES AND RETIGHTENING
0.4
0.4
0.4
INCLUDES:
C
24
6C0133
INCLUDES:
- Substitution of clamps
25
6C0134
C
PREFILTER HOSE TO FUEL PUMP SUBSTITUTION (*)
0.2
0.2
0.2
26
6C0135
C
FUEL PUMP HOSE TO PIPE SUBSTITUTION (*)
0.2
0.2
0.2
27
6C0136
FUEL PREFILTER SUBSTITUTION (*)
0.2
0.2
0.2
28
6C0137
C
D / M FUEL PUMP BRACKET (*)
0.4
0.4
0.4
29
6C0138
C
D / M FUEL PUMP (*)
0.3
0.3
0.3
30
6C0139
C
D / M RETURN MULTIPLE CONNECTOR (*)
0.4
0.4
0.4
31
6C0140
C
FILTER RETURN HOSE SUBSTITUTION
0.2
0.2
0.2
6C0100
(*) INCLUDES AIR DRAINAGE
OTHER
* * *
AIR OVERFEEDING
6C-02
AIR OVERFEEDING
6C-02
COMPONENTS
POS
COMPONENTS
POS
Air cleaner assembly
1
Intercooler
11
Filter element
2
Turbocharger
12
Band
3
Pressure limiting valve
13
Air cleaner bracket
4
Intake manifold
14
Filter to turbo hose
5
Air inlet elbow
15
Turbo to pipe hose
6
Clamp
16
Blow pipe
7
Blow hose to intercooler
8
Intercooler to intake hose
9
Hose assembly
10
6C-02
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6C-02. AIR OVERFEEDING
AL01 AL02 AL03
1
6C0201
D / M AIR CLEANER ASSEMBLY
0.2
0.2
0.2
2
6C0202
D / M FILTER ELEMENT
0.4
0.4
0.4
INCLUDES:
- Filter cleaning
2
6C0203
FILTER ELEMENT SUBSTITUTION
0.3
0.3
0.3
3
6C0204
BAND SUBSTITUTION (ONE)
0.1
0.1
0.1
4
6C0205
D / M AIR CLEANER BRACKET
0.4
0.4
0.4
5
6C0206
D / M AIR FILTER HOSE TO INLET TURBOCHARGER
0.2
0.2
0.2
6
6C0207
D / M TURBO TO PIPE HOSE
0.2
0.2
0.2
7
6C0208
D / M BLOW PIPE
0.3
0.3
0.3
8
6C0209
D / M INTERCOOLER BLOW HOSE
0.2
0.2
0.2
9
6C0210
D / M INTERCOOLER TO INTAKE HOSE
0.2
0.2
0.2
10
6C0211
VISUAL CONTROL HOSES AND RETIGHTENING CLAMPS
0.2
0.2
0.2
0.6
0.6
0.6
INCLUDES:
- Clamp substitution
11
6C0212
D / M INTERCOOLER
INCLUDES:
- External cleaning
11
6C0213
INTERCOOLER SUBSTITUTION
0.5
0.5
0.5
11
6C0214
EXTERNAL CLEANING INTERCOOLER IN VEHICLE
0.2
0.2
0.2
12
6C0215
D / M TURBOCHARGER
1.9
1.9
1.9
12
6C0216
D / M TURBOCHARGER
1.0
1.0
1.0
0.3
0.3
0.3
2.5
2.5
2.5
(SEPARTED ENGINE)
12
6C0217
D / M TURBOCHARGER
(SEPARATED EXHAUST MANIFOLD)
12
6C0218
TURBOCHARGER REVISION
(SEPARATED TURBOCHARGER)
AIR OVERFEEDING
6C-02
AIR OVERFEEDING
6C-02
COMPONENTS
POS
COMPONENTS
POS
Air cleaner assembly
1
Intercooler
11
Filter element
2
Turbocharger
12
Band
3
Pressure limiting valve
13
Air cleaner bracket
4
Intake manifold
14
Filter to turbo hose
5
Air inlet elbow
15
Turbo to pipe hose
6
Clamp
16
Blow pipe
7
Blow hose to intercooler
8
Intercooler to intake hose
9
Hose assembly
10
6C-02
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6C-02. AIR OVERFEEDING
AL01 AL02 AL03
13
6C0219
TURBOCHARGER PRESSURE LIMITING VALVE
SUBSTITUTION
2.3
2.3
2.3
13
6C0220
TURBOCHARGER PRESSURE LIMITING VALVE CONTROL
AND REGULATION
2.1
2.1
2.1
14
6C0221
D / M INTAKE MANIFOLD OR SUBSTITUTE JOINTS
1.0
1.0
1.0
0.4
0.4
0.4
1.2
1.2
1.2
0.1
0.1
0.1
INTAKE MANIFOLD SUBSTITUTION
0.6
0.6
0.6
0.1
0.1
0.1
EXCLUDES:
14
6C0222
D / M INTAKE MANIFOLD OR SUBSTITUTE JOINTS
(SEPARATED ENGINE)
EXCLUDES:
14
6C0223
INTAKE MANIFOLD SUBSTITUTION
INCLUDES:
C
14
6C0224
(SEPARATED ENGINE)
INCLUDES:
C
15
6C0225
D / M INLET ELBOW TO INTAKE MANIFOLD OR JOINT
SUBSTITUTION
0.2
0.2
0.2
15
6C0226
INLET ELBOW TO INTAKE MANIFOLD SUBSTITUTION
0.5
0.5
0.5
INCLUDES:
15
6C0227
RETIGHTENING INTAKE MANIFOLD AND EXHAUST
0.2
0.2
0.2
16
6C0228
CLAMP SUBSTITUTION (ONE)
0.1
0.1
0.1
6C0200
OTHER
* * *
6C-03 FEEDING AND EMISION CONTROL
SENSORS, THERMISTORS AND ENGINE
CONTROL SWITCHES
6C-03
CONTROL SWITCHES
6C-03
COMPONENTS
POS
COMPONENTS
POS
K.S.B temperature sensor device
1
Clogging fuel filter switch
11
Temperature thermistor
2
Water level sensor
12
Thermostarting temperature sensor
3
Preheating resistor
13
Light control temperature switch
4
Engine R.P.M. sensor
14
Electromagnetic pulley temperature switch
5
Air temperature sensor
15
R.P.M. sensor
6
Oil pressure switch
7
Tester
8
Camshaft R.P.M. sensor
9
Fuel heating control switch
10
COMPONENTES
POS
BASIC
POS OPERATION
CODE
1
6C0301
2
C/V
6C-03. SENSORS, THERMISTORS AND ENGINE CONTROL
SWITCHES
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
D / M TEMPERATURE SENSOR FOR K.S.B. DEVICE
FUNCTIONING (*) (**)
0.3
0.3
0.3
6C0302
D / M INSTRUMENT PANEL TEMPERATURE THERMISTOR
(*) (**)
0.3
0.3
0.3
3
6C0303
D / M TEMPERATURE SENSOR FOR THERMOSTARTING
FUNCTIONING (*) (**)
0.3
0.3
0.3
4
6C0304
D / M TEMPERATURE SWITCH FOR INSTRUMENT PANEL
CONTROL LIGHT FEEDING (*) (**)
0.3
0.3
0.3
5
6C0305
D / M TEMPERATURE SWITCH FOR FAN ELECTROMAGNETIC
PULLEY FEEDING (*) (**)
0.3
0.3
0.3
6
6C0306
D / M ENGINE R.P.M. SENSOR
0.5
0.5
0.5
B
B
INCLUDES:
- Individual check, OP .6C0308
- Sensor measure
7
6C0307
D / M ENGINE OIL PRESSURE SWITCH (*)
0.3
0.3
0.3
8
6C0308
CHECKING ONE SENSOR, THERMISTOR OR SWITCH
0.1
0.1
0.1
8
6C0309
COMPLETE ENGINE CHECK
1.2
1.2
1.2
INCLUDES:
- Sensor and switch check
- Compression check
- Compression leakage check
- Exhaust fumes check
9
6C0310
C
D / M CAMSHAFT R.P.M. SENSOR (*)
0.4
0.4
0.4
10
6C0311
C
D / M FUEL HEATING CONTROL SWITCH (*)
0.2
0.2
0.2
11
6C0312
C
D / M CLOGGING FUEL FILTER SIGNAL SWITCH (*)
0.2
0.2
0.2
12
6C0313
C
D / M WATER LEVEL SENSOR (*)
0.2
0.2
0.2
(*) INCLUDES: Individual check, OP .6C.03.080
(**) INCLUDES FILLING, DRAIN OR COOLING LEVEL ADJUSTMENT
6C-03 FEEDING AND EMISION CONTROL
CONTROL SWITCHES
6C-03
CONTROL SWITCHES
6C-03
COMPONENTS
POS
COMPONENTS
POS
K.S.B temperature sensor device
1
Clogging fuel filter switch
11
Temperature thermistor
2
Water level sensor
12
Thermostarting temperature sensor
3
Preheating resistor
13
Light control temperature switch
4
Engine R.P.M. sensor
14
Electromagnetic pulley temperature switch
5
Air temperature sensor
15
R.P.M. sensor
6
Oil pressure switch
7
Tester
8
Camshaft R.P.M. sensor
9
Fuel heating control switch
10
COMPONENTES
POS
BASIC
POS OPERATION
CODE
C/V
6C-03. SENSORS, THERMISTORS AND ENGINE CONTROL
SWITCHES
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
13
6C0314
C
D / M PRE-HEATING RESISTOR(*)
0.3
0.3
0.3
14
6C0315
C
D / M ENGINE R.P.M. SENSOR (*)
0.2
0.2
0.2
15
6C0316
C
D / M AIR TEMPERATURE SENSOR
0.1
0.1
0.1
OTHER
* * *
6C0300
(*) INCLUDES: Individual check, OP .6C.03.080
(**) INCLUDES FILLING, DRAIN OR COOLING LEVEL ADJUSTMENT
ENGINE ELECTRICAL SYSTEM ...............................................................
6G
GENERATOR AND BATTERY ...................................................................... 6G-01
STARTING MOTOR .......................................................................................... 6G-02
THERMO-STARTING ....................................................................................... 6G-03
6G
6G-01-02-03 ENGINE ELECTRICAL SYSTEM
GENERATOR AND BATTERY
6G-01
STARTING MOTOR
6G-02
THERMO-STARTING AND E.C.M.
CONTROL UNIT
6G-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Generator assembly
1
Rectifier bridge
2
Starting motor assembly
13
Thermo-starter
Voltage regulator
3
Starting motor yoke
14
Preheat electrovalve
18
Pulley
4
Solenoid
15
Engine control unit (E.C.M)
19
Retainer
5
Brushes
16
Injection system tester
20
Bearing
6
Generator support
7
Belt tensioner
8
Battery
9
Battery positive cable
10
Battery negative cable
11
Battery bracket
12
17
BASIC
POS OPERATION
CODE
C/V
ENGINE ELECTRICAL SYSTEM 6G-01
MODEL CODES AND
REPAIR TIME
6G-01. GENERATOR AND BATTERY
AL01 AL02 AL03
1
6G0101
D / M GENERATOR
0.6
0.6
0.6
1
6G0102
D / M GENERATOR
0.3
0.3
0.3
1.3
1.3
1.3
(SEPARATED ENGINE)
1
6G0103
GENERATOR SUBSTITUTION, INSTALLATION CONTROL
AND CHARGE
INCLUDES:
- Bench test
- Washing
1
6G0104
D / M AND GENERATOR REVISION
2.2
2.2
2.2
1
6G0105
COMPLETE GENERATOR REVISION
1.6
1.6
1.6
1.2
1.2
1.2
0.3
0.3
0.3
0.1
0.1
0.1
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
(SEPARATED GENERATOR)
INCLUDES:
- Everything included in operation 6G0106
- Coil, diodes and regulator control
1
6G0106
PARTIAL GENERATOR REVISION
INCLUDES:
- Manifold cleaning
- Brush substitution
- Bearing substitution
- Bench test
EXCLUDES:
- Coil, diodes and regulator control
1
6G0107
GENERATOR BENCH TEST
1
6G0108
GENERATOR WASHING
2
6G0109
RECTIFIER BRIDGE SUBSTITUTION
EXCLUDES:
- Bench test
2
6G0110
RECTIFIED BRIDGE ON BENCH CONTROL
3
6G0111
D / M VOLTAGE REGULATOR (EXTERNAL INCORPORATED
TYPE)
EXCLUDES:
- Bench test
6G-01
STARTING MOTOR
6G-02
CONTROL UNIT
6G-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Generator assembly
1
Rectifier bridge
2
13
Thermo-starter
Voltage regulator
3
Starting motor yoke
14
18
Pulley
4
Solenoid
15
19
Retainer
5
Brushes
16
20
Bearing
6
Generator support
7
Belt tensioner
8
Battery
9
10
11
Battery bracket
12
17
BASIC
POS OPERATION
CODE
3
6G0112
C/V
MODEL CODES AND
REPAIR TIME
6G-01. GENERATOR AND BATTERY
AL01 AL02 AL03
D / M VOLTAGE REGULATOR (EXTERNAL INCORPORATED
TYPE)
0.1
0.1
0.1
0.3
0.3
0.3
0.5
0.5
0.5
0.2
0.2
0.2
0.6
0.6
0.6
0.3
0.3
0.3
0.6
0.6
0.6
0.4
0.4
0.4
D / M BATTERY
0.2
0.2
0.2
BATTERY CHARGE CONTROL
0.3
0.3
0.3
EXCLUDES:
- Bench test
3
6G0113
VOLTAGE REGULATOR TEST (EXTERNAL INCORPORATED
TYPE)
4
6G0114
GENERATOR PULLEY SUBSTITUTION
INCLUDES:
- Belt tension adjustment
4
6G0115
GENERATOR PULLEY SUBSTITUTION
5
6G0116
D / M RETAINER GENERATOR
INCLUDES:
6
6G0117
D / M GENERATOR BEARING
INCLUDES:
7
6G0118
D / M GENERATOR SUPPORT
INCLUDES:
8
6G0119
D / M BELT TENSIONER
INCLUDES:
9
6G0120
9
6G0121
INCLUDES:
- Electrolyte levelling
- Electrolyte density control and terminal state
10
6G0122
D / M BATTERY POSITIVE CABLE
0.3
0.3
0.3
11
6G0123
D / M BATTERY NEGATIVE CABLE
0.3
0.3
0.3
12
6G0124
D / M BATTERY BRACKET
0.2
0.2
0.2
6G0100
OTHER
* * *
6G-01
STARTING MOTOR
6G-02
CONTROL UNIT
6G-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Generator assembly
1
Rectifier bridge
2
13
Thermo-starter
Voltage regulator
3
Starting motor yoke
14
18
Pulley
4
Solenoid
15
19
Retainer
5
Brushes
16
20
Bearing
6
Generator support
7
Belt tensioner
8
Battery
9
10
11
Battery bracket
12
17
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6G-02. STARTING MOTOR
AL01 AL02 AL03
13
6G0201
D / M STARTING MOTOR ASSEMBLY
1.2
1.2
1.2
13
6G0202
STARTING MOTOR SUBSTITUTION
1.4
1.4
1.4
3.4
3.4
3.4
1.7
1.7
1.7
2.2
2.2
2.2
0.2
0.2
0.2
0.9
0.9
0.9
0.3
0.3
0.3
0.3
0.3
0.3
INCLUDES:
- Bench test
13
6G0203
D / M AND STARTING MOTOR REIVISION
INCLUDES:
- Bench test
13
6G0204
PARTIAL STARTING MOTOR REVISION
(SEPARATED STARTING MOTOR)
INCLUDES:
- Manifold cleaning
- Brush substitution
- Bearing substitution
- Contactor revision
- Bench test
- Gearwheel coupling
EXCLUDES:
- Brush support revision
- D / M of inductor coils
13
6G0205
COMPLETE STARTING MOTOR REVISION
INCLUDES:
- Everything included in operation 6G0204
- Brush support revision
- D / M of inductor coils
13
6G0206
STARTING MOTOR ON BENCH TEST
14
6G0207
STARTING MOTOR YOKE SUBSTITUTTION
15
6G0208
D / M STARTING MOTOR SELENOID
16
6G0209
STARTING MOTOR BRUSHES SUBSTITUTION
EXCLUDES:
- Bench test
6G0200
OTHER
* * *
6G-01
STARTING MOTOR
6G-02
CONTROL UNIT
6G-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Generator assembly
1
Rectifier bridge
2
13
Thermo-starter
Voltage regulator
3
Starting motor yoke
14
18
Pulley
4
Solenoid
15
19
Retainer
5
Brushes
16
20
Bearing
6
Generator support
7
Belt tensioner
8
Battery
9
10
11
Battery bracket
12
17
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
6G-03. THERMO-STARTING AND E.C.M. CONTROL UNIT
AL01 AL02 AL03
17
6G0301
THERMO-STARTER PLUG FUNCTIONING CONTROL
0.3
0.3
0.3
17
6G0302
THERMOSTARTING PLUG SUBSTITUTION
0.3
0.3
0.3
INCLUDES:
- Functioning control
18
6G0303
PREHEAT ELECTROVALVE FUNCTIONING CONTROL
0.2
0.2
0.2
18
6G0304
PREHEAT ELECTROVALVE SUBSTITUTION
0.3
0.3
0.3
0.5
0.5
0.5
0.4
0.4
0.4
INCLUDES:
- Functioning control
19
6G0305
C
D / M MOTOR CONTROL UNIT (E.C.M.)
EXCLUDES:
- Injection system check
20
6G0306
C
INJECTION SYSTEM CHECK
INCLUDES:
- Diagnosis of equipment preparation
6G0300
OTHER
* * *
ENGINE EXHAUST SYSTEM .......................................................................
6K
EXHAUST MANIFOLD ..................................................................................... 6K-01
MUFFLER ............................................................................................................ 6K-02
6K
6K-01-02 ENGINE EXHAUST SYSTEM
EXHAUST MANIFOLD
6K-01
MUFFLER
6K-02
COMPONENTS
POS
COMPONENTS
POS
Protection
1
Turbo smokes outlet elbow
5
Retainer
2
Flat gasket
6
Exhaust manifold
3
Seal ring
7
Exhaust manifold gasket
4
Exhaust front pipe
8
Center exhaust pipe
9
Rear exhaust pipe (rear silencer)
10
Muffler mounting
11
Exhaust pipe assembly
12
COMPONENTS
POS
6 ENGINE AND ITS SYTEMS
BASIC
POS OPERATION
CODE
ENGINE EXHAUST SYSTEM 6K-01-02
6K-01. EXHAUST MANIFOLD
C/V
6K-02. MUFFLER
MODEL CODES AND
REPAIR TIME
AL01 AL02 AL03
1
6K0101
D / M PROTECTION
0.2
0.2
0.2
2
6K0102
D / M EXHAUST MANIFOLD RETAINER
0.2
0.2
0.2
3
6K0103
D / M EXHAUST MANIFOLD
1.9
1.9
1.9
3
6K0104
D / M EXHAUST MANIFOLD
1.2
1.2
1.2
(SEPARATED ENGINE)
3
6K0105
RETIGHTENING EXHAUST AND ADMISSION MANIFOLD
0.2
0.2
0.2
4
6K0106
EXHAUST MANIFOLD GASKETS SUBSTITUTION
1.6
1.6
1.6
4
6K0107
EXHAUST MANIFOLD GASKETS SUBSTITUTION
0.9
0.9
0.9
(SEPARATED ENGINE)
6K0100
OTHER
* * *
5
6K0201
D / M TURBOCHARGER SMOKES OUTLET ELBOW
0.5
0.5
0.5
6
6K0202
TURBOCHARGER FLAT GASKET SUBSTITUTION
0.3
0.3
0.3
7
6K0203
SUBSTITUTION SEAL RING (ONE)
0.2
0.2
0.2
8
6K0204
D / M EXHAUST FRONT PIPE
0.4
0.4
0.4
9
6K0205
D / M EXHAUST CENTER PIPE
0.4
0.4
0.4
10
6K0206
D / M REAR EXHAUST PIPE (REAR SILENCER)
0.3
0.3
0.3
11
6K0207
EXHAUST PIPE MUFFLER MOUNTING SUBSTITUTION
(ONE)
0.1
0.1
0.1
12
6K0208
LEAKAGE CHECK AND CLAMPS RETIGHTENING
0.3
0.3
0.3
6K0200
OTHER
* * *
ENGINE LUBRICATION ....................................................................................
6L
OIL PUMP ............................................................................................................ 6L-01
OIL FILTER AND COOLER ............................................................................ 6L-02
TURBOCHARGER LUBRICATION ............................................................. 6L-03
6L
6L-01-02-03 ENGINE LUBRICATION
OIL PUMP
6L-01
OIL FILTER AND COOLER
6L-02
CHARGER LUBRICATION
6L-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Oil pump gear
1
Oil filter
4
Oil line to turbocharger
12
Oil pump valve
2
Oil filter bracket
5
Oil line return to turbocharger
13
Suction strainer
3
Heat exchanger (cooler)
6
Rubber sleeve return from turbocharger
14
Heat exchanger joint
7
Flanged socket
15
Heat exchanger support
8
Oil return pipe assembly
16
Retainer
9
Engine flat gasket
10
Support assembly
11
BASIC
POS OPERATION
CODE
1
C/V
ENGINE LUBRICATION 6L-01-02
MODEL CODES AND
REPAIR TIME
6L-01. OIL PUMP
6L-02. OIL FILTER AND COOLER
AL01 AL02 AL03
6L0101
D / M OIL PUMP
3.9
3.9
3.9
0.2
3.7
0.2
3.7
0.2
3.7
OIL PUMP WEAR CONTROL
0.2
0.2
0.2
1.2
1.2
1.2
3.7
3.7
3.7
OIL PUMP VALVE SUBSTITUTION
0.4
0.4
0.4
1.1
1.1
1.1
INCLUDES:
- Oil pressure check
- Necessary adjustments and measures
- Phased injector pump (mechanical injection)
A
B
1
6L0102
(SEPARATED ORGAN GROUP AND DISMOUNTED AUXILIARY ORGANS)
2
6L0103
OIL PUMP VALVE SUBSTITUTION
INCLUDES:
EXCLUDES:
- Oil pressure test
B
2
6L0104
(SEPARATED ENGINE)
INCLUDES:
EXCLUDES:
- Oil pressure test
B
2
6L0105
OIL PRESSURE CHECK
0.5
0.5
0.5
3
6L0106
D / M SUCTION STRAINER
1.2
1.2
1.2
0.1
0.1
0.1
INCLUDES:
- Inhaler cleaning
3
6L0107
SUCTION STRAINER CLEANING
(SEPARATED SUCTION STRAINER )
6L0100
OTHER
* * *
4
6L0201
ENGINE OIL FILTER SUBSTITUTION
0.2
0.2
0.2
4
6L0202
ENGINE OIL LEVEL CONTROL
0.1
0.1
0.1
4
6L0203
ADD OIL TO ENGINE
0.1
0.1
0.1
4
6L0204
ENGINE OIL SUBSTITUTION
0.3
0.3
0.3
OIL PUMP
6L-01
6L-02
CHARGER LUBRICATION
6L-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Oil pump gear
1
Oil filter
4
12
Oil pump valve
2
Oil filter bracket
5
13
Suction strainer
3
6
14
7
Flanged socket
15
8
16
Retainer
9
Engine flat gasket
10
Support assembly
11
BASIC
POS OPERATION
CODE
C/V
ENGINE LUBRICATION 6L-02
MODEL CODES AND
REPAIR TIME
6L-02. OIL FILTER AND COOLER
AL01 AL02 AL03
4
6L0205
ENGINE OIL AND FILTER SUBSTITUTION
0.4
0.4
0.4
5
6L0206
D / M OIL FILTER BRACKET
0.4
0.4
0.4
6
6L0207
D / M HEAT EXCHANGER (OIL COOLER)
0.6
0.6
0.6
0.3
0.3
0.3
0.1
0.1
0.1
0.2
0.2
0.2
INCLUDES:
- Cooling solution filling, drain and level
- Exchanger cleaning
6
6L0208
D / M HEAT EXCHANGER (OIL COOLER)
(SEPARATED ENGINE)
INCLUDES:
- Exchanger cleaning
6
6L0209
HEAT EXCHANGER CLEANING (OIL COOLER)
(SEPARATED EXCHANGER)
7
6L0210
HEAT EXCHANGER JOINT SUBSTITUTION
(CONNECTED COOLER HOSES)
8
6L0211
D / M HEAT EXCHANGER SUPPORT
0.8
0.8
0.8
8
6L0212
D / M HEAT EXCHANGER SUPPORT
0.2
0.2
0.2
(SEPARATED ENGINE)
9
6L0213
D / M RETAINER
0.1
0.1
0.1
10
6L0214
HEAT EXCHANGER FLAT GASKET TO FILTER BRACKET
SUBSTITUTION
0.4
0.4
0.4
11
6L0215
D / M FILTER SUPPORT ASSEMBLY AND EXCHANGER
SUPPORT
0.9
0.9
0.9
0.6
0.6
0.6
INCLUDES:
- Cooling solution filling, drain and level
11
6L0216
D / M FILTER SUPPORT ASSEMBLY AND EXCHANGER
SUPPORT
(SEPARATED ENGINE)
6L0200
OTHER
* * *
OIL PUMP
6L-01
6L-02
CHARGER LUBRICATION
6L-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Oil pump gear
1
Oil filter
4
12
Oil pump valve
2
Oil filter bracket
5
13
Suction strainer
3
6
14
7
Flanged socket
15
8
16
Retainer
9
Engine flat gasket
10
Support assembly
11
BASIC
POS OPERATION
CODE
C/V
ENGINE LUBRICATION 6L-03
MODEL CODES AND
REPAIR TIME
6L-03. TURBOCHARGER LUBRICATION
AL01 AL02 AL03
12
6L0301
D / M OIL LINE TO TURBOCHARGER
0.4
0.4
0.4
13
6L0302
D / M OIL LINE RETURN FROM TURBOCHARGER
0.4
0.4
0.4
14
6L0303
RUBBER SLEEVE RETURN FROM TURBOCHARGER
SUBSTITUTION
0.2
0.2
0.2
15
6L0304
D / M FLANGED SOCKET OIL RETURN FROM
TURBOCHARGER
0.2
0.2
0.2
16
6L0305
D / M OIL RETURN PIPE ASSEMBLY OF
TURBOCHARGER
0.4
0.4
0.4
6L0300
OTHER
* * *
TRANSMISSION ....................................................................................................
7
GEAR BOX .......................................................................................................... 7A
CLUTCH ............................................................................................................... 7C
TRANSFER ......................................................................................................... 7D
FRONT AND REAR DIFFERENTIAL .......................................................... 7E
7
.
GEAR BOX ................................................................................................................
7A
TRANSMISSION CASE ................................................................................... 7A-01
INTERNAL ORGANS ....................................................................................... 7A-02
GEAR SHIFTING CONTROL ......................................................................... 7A-03
7A
7A-01-02-03 GEAR BOX
7 TRANSMISSION
TRANSMISSION CASE
7A-01
INTERNAL ORGANS
7A-02
GEAR SHIFTING CONTROL
7A-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Gear box and transfer assembly
1
Gear shifting fork and shaft
11
Gear shift case upper plate
Gear box
2
Trasmission main pinion and bearing
12
Gear selector assembly
19
Input shaft bearing retainer & oil seal
3
Transmission main shaft
13
Lever positioning assembly
20
Clutch housing
4
Main shaft rear bearing
14
Gear shift case
21
Transmission case assembly
5
Counter shaft and components
15
Lever assembly
22
Extension case
6
5th gear assembly
16
Control lever knob
23
Extension case oil seal
7
Reverse gear assembly
17
Gear lever dustguard
24
Oil filler and level plug
8
Drain plug
9
Back up lamp switch
10
18
7 TRANSMISSION
BASIC
POS OPERATION
CODE
GEAR BOX 7A-01-02
C/V
MODEL CODES AND
REPAIR TIME
7A-01. TRANSMISSION CASE
7A-02. INTERNAL ORGANS
AL01 AL02 AL03
1
7A0101
D-M OR SUBSTITUTION GEAR BOX AND TRANSFER
ASSEMBLY (**)
4.2
4.2
4.2
2
7A0102
D / M GEAR BOX
1.0
1.0
1.0
0.2
0.2
(SEPARATED FROM VEHICLE GEAR BOX AND TRANSFER ASSEMBLY)
2
7A0103
GEAR BOX OIL SUBSTITUTION
0.2
2
7A0104
GEAR BOX GENERAL REPAIR (*)
12.2 12.2 12.2
3
7A0105
INPUT SHAFT BEARING RETAINER OR OIL SEAL
SUBSTITUTION (**)
4.5
4.5
4.5
4
7A0106
CLUTCH HOUSING SUBSTITUTION (**)
5.6
5.6
5.6
5
7A0107
TRANSMISSION CASE ASSEMBLY SUBSTITUTION (*)
5.6
5.6
5.6
6
7A0108
GEAR BOX EXTENSION CASE SUBSTITUTION (**)
4.5
4.5
4.5
7
7A0109
GEAR BOX EXTENSION CASE OIL SEAL SUBSTITUTION
(**)
4.8
4.8
4.8
8
7A0110
OIL FILLER AND LEVEL PLUG SUBSTITUTION
0.1
0.1
0.1
9
7A0111
DRAIN PLUG SUBSTITUTION (**)
0.2
0.2
0.2
10
7A0112
BACK UP LAMP SWITCH ASSEMBLY SUBSTITUTION
0.1
0.1
0.1
7A0100
OTHER
* * *
11
7A0201
GEAR SHIFTING FORK AND SHAFT SUBSTITUTION OR
REPAIR (*)
8.2
12
7A0202
TRANSMISSION
SUBSTITUTION (*)
13
7A0203
TRANSMISSION MAIN SHAFT OR COMPONENTS 11.7 11.7 11.7
SUSBSTITUTION (*)
14
7A0204
MAIN SHAFT REAR BEARING SUBSTITUTION (*)
15
7A0205
COUNTER SHAFT OR COMPONENTS SUBSTITUTION (*) 11.7 11.7 11.7
MAIN
PINION
(*) INCLUDES FORK AND SHAFT ASSEMBLY ADJUSTMENT AND FILLING OR OIL LEVEL ADJUSTMENT
(**) INCLUDES FILLING AND OIL LEVEL ADJUSTMENT
AND
8.2
8.2
BEARING 10.7 10.7 10.7
10.2 10.2 10.2
7A-01-02-03 CAJA DE CAMBIOS
7 TRANSMISSION
TRANSMISSION CASE
7A-01
INTERNAL ORGANS
7A-02
GEAR SHIFTING CONTROL
7A-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Gear box and transfer assembly
1
Gear shifting fork and shaft
11
Gear shift case upper plate
Gear box
2
Trasmission main pinion and bearing
12
Gear selector assembly
19
Input shaft bearing retainer & oil seal
3
Transmission main shaft
13
20
Clutch housing
4
Main shaft rear bearing
14
Gear shift case
21
Transmission case assembly
5
Counter shaft and components
15
Lever assembly
22
Extension case
6
5th gear assembly
16
Control lever knob
23
Extension case oil seal
7
Reverse gear assembly
17
Gear lever dustguard
24
Oil filler and level plug
8
Drain plug
9
Back up lamp switch
10
18
GEAR BOX 7A-02-03
7 TRANSMISSION
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
7A-02. INTERNAL ORGANS
7A-03. GEAR SHIFTING CONTROL
AL01 AL02 AL03
16
7A0206
A COMPONENT SUBSTITUTION OR 5TH GEAR ASSEMBLY
REPAIR (*)
17
7A0207
A COMPONENT SUBSTITUTION OR REVERSE GEAR 10.7 10.7 10.7
ASSEMBLY REPAIR (*)
7A0200
OTHER
* * *
18
7A0301
GEAR SHIFT CASE UPPER PLATE SUBSTITUTION
6.0
6.0
6.0
19
7A0302
SELECTOR ASSEMBLY REPAIR
6.4
6.4
6.4
20
7A0303
GEAR LEVER POSITIONING ASSEMBLY REPAIR
0.5
0.5
0.5
21
7A0304
GEAR SHIFT CASE SUBSTITUTION
5.9
5.9
5.9
22
7A0305
GEAR LEVER ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
22
7A0306
GEAR LEVER ASSEMBLY REPAIR
0.5
0.5
0.5
23
7A0307
GEAR CONTROL LEVER KNOB SUBSTITUTION
0.1
0.1
0.1
24
7A0308
GEAR LEVER DUSTGUARD SUBSTITUTION
0.2
0.2
0.2
7A0300
OTHER
* * *
(*) INCLUDES FILLING, DRAIN OR OIL LEVEL ADJUSTMENT
5.7
5.7
5.7
CLUTCH ......................................................................................................................
7C
HYDRAULIC COMPONENTS ....................................................................... 7C-01
MECHANICAL COMPONENTS .................................................................... 7C-02
7C
7C-01-02 CLUTCH
7 TRANSMISSION
HYDRAULIC COMPONENTS
7C-01
MECHANICAL COMPONENTS
7C-02
COMPONENTS
POS
COMPONENTS
POS
Master cylinder
1
Disc and clutch assembly
Tank assembly
2
Clutch release arm
8
9
Plug
3
Bracket and pedal assembly
10
Auxiliary cylinder
4
Pedal assembly
11
Master cylinder pipe to tank
5
Tank bracket
12
Auxiliary cylinder pipe to master cylinder
6
Clutch release bearing
13
Slave cylinder hose
7
COMPONENTS
POS
CLUTCH 7C-01-02
7 TRANSMISSION
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
7C-01. HYDRAULIC COMPONENTS
7C-02. MECHANICAL COMPONENTS
AL01 AL02 AL03
1
7C0101
MASTER CYLINDER SUBSTITUTION (*)
2.1
2.1
2.1
1
7C0102
MASTER CYLINDER REPAIR
0.3
0.3
0.3
(SEPARATED MASTER CYLINDER)
2
7C0103
CLUTCH LIQUID TANK ASSEMBLY SUBSTITUTION (*)
0.4
0.4
0.4
2
7C0104
HYDRAULIC SYSTEM DRAIN
0.2
0.2
0.2
2
7C0105
CLUTCH LIQUID SUBSTITUTION
0.5
0.5
0.5
3
7C0106
PLUG SUBSTITUTION
0.1
0.1
0.1
4
7C0107
AUXILIARY CYLINDER SUBSTITUTION (*)
0.6
0.6
0.6
4
7C0108
AUXILIARY CYLINDER REPAIR
0.3
0.3
0.3
(SEPARATED MASTER CYLINDER)
5
7C0109
MASTER CYLINDER PIPE TO TANK SUBSTITUTION (*)
0.4
0.4
0.4
6
7C0110
AUXILIARY CYLINDER PIPE TO MASTER CYLINDER
SUBSTITUTION (*)
0.5
0.5
0.5
7
7C0111
SLAVE CYLINDER HOSE SUBSTITUTION (*)
0.4
0.4
0.4
7C0100
OTHER
* * *
8
7C0201
DISC AND/OR CLUTCH SUBSTITUTION
5.2
5.2
5.2
9
7C0202
CLUTCH RELEASE ARM SUBSTITUTION
4.6
4.6
4.6
10
7C0203
BRACKET AND PEDAL ASSEMBLY SUBSTITUTION (*)
3.2
3.2
3.2
2.9
2.9
2.9
INCLUDES:
- Transfer elements
11
7C0204
CLUTCH PEDAL ASSEMBLY SUBSTITUTION (*)
(*) INCLUDES FILLING, DRAIN OR HYDRAULIC SYSTEM LEVEL
7C-01-02 CLUTCH
7 TRANSMISSION
HYDRAULIC COMPONENTS
7C-01
MECHANICAL COMPONENTS
7C-02
COMPONENTS
POS
COMPONENTS
POS
Master cylinder
1
Disc and clutch assembly
Tank assembly
2
Clutch release arm
8
9
Plug
3
Bracket and pedal assembly
10
Auxiliary cylinder
4
Pedal assembly
11
Master cylinder pipe to tank
5
Tank bracket
12
Auxiliary cylinder pipe to master cylinder
6
Clutch release bearing
13
Slave cylinder hose
7
COMPONENTS
POS
7 TRANSMISSION
BASIC
POS OPERATION
CODE
CLUTCH 7C-02
C/V
MODEL CODES AND
REPAIR TIME
7C-02. MECHANICAL COMPONENTS
AL01 AL02 AL03
11
7C0205
CLUTCH PEDAL ASSEMBLY REPAIR (*)
3.2
3.2
3.2
12
7C0206
CLUTCH LIQUID TANK BRACKET SUBSTITUTION (*)
0.5
0.5
0.5
13
7C0207
CLUTCH RELEASE BEARING SUBSTITUTION
4.5
4.5
4.5
7C0200
OTHER
* * *
TRANSFER ................................................................................................................
7D
TRANSFER CASE ............................................................................................ 7D-01
INTERNAL ORGANS ....................................................................................... 7D-02
TRANSFER SELECTOR LEVER ................................................................ 7D-03
7D
7D-01-02-03 TRANSFER
7 TRANSMISSION
TRANSFER CASE
7C-01
INTERNAL ORGANS
7D-02
TRANSFER SELECTOR LEVER
7D-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Transfer assembly
1
Transfer gear shifting, shaft and yoke
11
Lever spacer
20
Transfer case
2
Input gear assembly
12
Lever case
21
Front output case
3
Counter gear assembly
13
22
Filler cap
4
Output front shaft assembly
14
Lever boot
23
Drain plug
5
Main shaft assembly
15
Lever knob
24
Lower case cover
6
Out rear shaft assembly
16
Shift control lever assembly
25
Side cover
7
Speedometer assembly
17
Power cover
8
Input gear
18
Tachometer case
9
Middle shaft inner "O" ring
19
4WD switch assembly
10
TRANSFER 7D-01-02
7 TRANSMISION
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIMES
7D-01. TRANSFER CASE
7D-02. INTERNAL ORGANS
AL01 AL02 AL03 AS02 AS03
1
7D0101
D / M TRANSFER ASSEMBLY (*)
3.4
3.4
3.4
1
7D0102
D / M TRANSFER ASSEMBLY (**)
1.0
1.0
1.0
0.2
3.4
(SEPARATED GEAR BOX AND TRANSFER ASSEMBLY OF VEHICLE)
1
7D0103
TRANSFER OIL SUBSTITUTION
0.2
1
7D0104
TRANSFER GENERAL REPARATION (*)
10.0 10.0 10.0
2
7D0105
TRANSFER CASE ASSEMBLY SUBSTITUTION (*)
9.6
9.6
9.6
3.2
3.2
3.2
INCLUDES:
- Transfer elements
3
7D0106
FRONT OUTPUT CASE SUBSTITUTION (*)
INCLUDES:
- Transfer elements
4
7D0107
TRANSFER FILLER CAP SUBSTITUTION (**)
0.1
0.1
0.1
5
7D0108
TRANSFER DRAIN PLUG SUBSTITUTION (**)
0.2
0.2
0.2
6
7D0109
LOWER CASE COVER SUBSTITUTION (**)
0.4
0.4
0.4
7
7D0110
SIDE COVER SUBSTITUTION (**)
0.4
0.4
0.4
8
7D0111
POWER COVER SUBSTITUTION
0.2
0.2
0.2
9
7D0112
TACHOMETER REPAIR OR CASE SUBSTITUTION (**)
2.1
2.1
2.1
0.3
0.3
INCLUDES:
- Transfer elements
10
11
7D0113
4WD SWITCH ASSEMBLY SUBSTITUTION
0.3
7D0100
OTHER
* * *
7D0201
TRANSFER GEAR SHIFTING, FORK AND YOKE ASSEMBLY
SUBSTITUTION OR REPAIR
1.2
(SEPARATED TRANSFER )
(*) INCLUDES FORK AND SHAFT ASSEMBLY ADJUSTMENT AND OIL LEVEL FILLING OR ADJUSTMENT
(**) INCLUDES OIL LEVEL FILLING AND ADJUSTMENT
1.2
1.2
7 TRANSMISSION
TRANSFER CASE
7C-01
INTERNAL ORGANS
7D-02
7D-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Transfer assembly
1
11
Lever spacer
20
Transfer case
2
Input gear assembly
12
Lever case
21
Front output case
3
13
22
Filler cap
4
14
Lever boot
23
Drain plug
5
Main shaft assembly
15
Lever knob
24
Lower case cover
6
16
25
Side cover
7
17
Power cover
8
Input gear
18
Tachometer case
9
19
4WD switch assembly
10
TRANSFER 7D-02-03
7 TRANSMISION
BASIC
POS OPERATION
CODE
12
7D0202
C/V
MODEL CODES AND
REPAIR TIMES
7D-02. INTERNAL ORGANS
7D-03. TRANSFER SELECTOR LEVER
INNER BEARING OR INPUT BEARING ASSEMBLY TO
TRANSFER SUBSTITUTION OR REPAIR
0.5
0.5
0.5
(SEPARATED TRANSFER BOX)
13
7D0203
COUNTER TRANSFER BEARING ASSEMBLY SUBSTITUTION
OR REPAIR (**)
2.0
2.0
2.0
14
7D0204
OUTPUT FRONT SHAFT ASSEMBLY SUBSTITUTION OR
REPAIR (*)
3.0
3.0
3.0
15
7D0205
MAIN SHAFT ASSEMBLY SUBSTITUTION OR REPAIR (*)
8.5
8.5
8.5
16
7D0206
OUTPUT REAR SHAFT ASSEMBLY SUBSTITUTION OR
REPAIR (*)
1.8
1.8
1.8
17
7D0207
SPEEDOMETER ASSEMBLY SUBSTITUTION OR REPAIR (**)
2.1
2.1
2.1
18
7D0208
EXTERIOR BEARING OR INPUT BEARING TO TRANSFER
SUBSTITUTION
1.2
1.2
1.2
18
7D0209
D / M INPUT BEARING TO TRANSFER
1.0
1.0
1.0
19
7D0210
MIDDLE SHAFT INNER "O" RING SUBSTITUTION (**)
3.7
3.7
3.7
INCLUDES:
- D / M transfer box
7D0200
OTHER
* * *
20
7D0301
LEVER SPACER SUBSTITUTION
4.1
4.1
4.1
21
7D0302
LEVER CASE SUBSTITUTION
3.9
3.9
3.9
22
7D0303
POSITIONING LEVER ASSEMBLY SUBSTITUTION OR
ADJUSTMENT
3.7
3.7
3.7
23
7D0304
LEVER BOOT SUBSTITUTION
0.9
0.9
0.9
24
7D0305
LEVER KNOB SUBSTITUTION
0.1
0.1
0.1
25
7D0306
SHIFT CONTROL LEVER ASSEMBLY SUBSTITUTION
0.5
0.5
0.5
7 TRANSMISSION
TRANSFER CASE
7C-01
INTERNAL ORGANS
7D-02
7D-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Transfer assembly
1
11
Lever spacer
20
Transfer case
2
Input gear assembly
12
Lever case
21
Front output case
3
13
22
Filler cap
4
14
Lever boot
23
Drain plug
5
Main shaft assembly
15
Lever knob
24
Lower case cover
6
16
25
Side cover
7
17
Power cover
8
Input gear
18
Tachometer case
9
19
4WD switch assembly
10
7 TRANSMISION
BASIC
POS OPERATION
CODE
25
TRANSFER 7D-03
C/V
MODEL CODES AND
REPAIR TIMES
7D-03. TRANSFER SELECTOR LEVER
7D0307
SHIFT CONTROL LEVER ASSEMBLY REPAIR
0.8
7D0300
OTHER
* * *
0.8
0.8
FRONT AND REAR DIFFERENTIAL ........................................................
7E
FRONT DIFFERENTIAL GEAR .................................................................... 7E-01
REAR DIFFERENTIAL GEAR ....................................................................... 7E-02
7E
7E-01-02 FRONT AND REAR DIFFERENTIAL
7 TRANSMISSION
FRONT DIFFERENTIAL GEAR
7E-01
REAR DIFFERENTIAL GEAR
7E-02
COMPONENTS
POS
COMPONENTS
POS
Front differential assembly
1
Rear differential assembly
5
Pinion oil seal
2
Pinion oil seal
6
Bevel pinion
3
Bevel pinion
7
Bevel pinion and gear assembly
4
Bevel pinion and gear assembly
8
COMPONENTS
POS
7 TRANSMISSION
BASIC
POS OPERATION
CODE
FRONT AND REAR DIFFERENTIAL 7E-01-02
C/V
MODEL CODES AND
REPAIR TIME
7E-01. FRONT DIFFERENTIAL GEAR
7E-02. REAR DIFFERENTIAL GEAR
AL01 AL02 AL03
1
7E0101
FRONT DIFFERENTIAL ASSEMBLY SUBSTITUTION (*)
4.0
4.0
4.0
1
7E0102
FRONT DIFFERENTIAL OIL SUBSTITUTION
0.2
0.2
0.2
1
7E0103
FRONT DIFFERENTIAL ASSEMBLY GENERAL REPAIR (*)
7.7
7.7
7.7
2
7E0104
PINION OIL SEAL SUBSTITUTION (*)
0.8
0.8
0.8
3
7E0105
BEVEL PINION PRE-CHARGE ADJUSTMENT
1.3
1.3
1.3
0.8
0.8
0.8
2.8
2.8
2.8
3.0
3.0
3.0
(SEPARATED GROUP)
4
7E0106
CLEARANCE BETWEEN TEETH ADJUSTMENT
(SEPARATED GROUP)
4
7E0107
FRONT DIFFERENTIAL GROUP ADJUSTMENTS AND REVISION
(GRUPO SEPARADO)
4
7E0108
BEVEL PINION AND GEAR ASSEMBLY SUBSTITUTION
(SEPARATED GROUP)
7E0100
OTHER
* * *
5
7E0201
REAR DIFFERENTIAL ASSEMBLY SUBSTITUTION (*)
2.9
2.9
2.9
5
7E0202
REAR DIFFERENTIAL OIL SUBSTITUTION
0.2
0.2
0.2
5
7E0203
REAR DIFFERENTIAL ASSEMBLY GENERAL REPAIR (*)
6.8
6.8
6.8
6
7E0204
PINION OIL SEAL SUBSTITUTION (*)
0.8
0.8
0.8
7
7E0205
BEVEL PINION PRE-CHARGE ADJUSTMENT
1.3
1.3
1.3
0.8
0.8
0.8
2.8
2.8
2.8
3.0
3.0
3.0
(SEPARATED GROUP)
8
7E0206
CLEARANCE BETWEEN TEETH ADJUSTMENT
(SEPARATED GROUP)
8
7E0207
REAR DIFFERENTIAL GROUP ADJUSTMENTS AND REVISION
(SEPARATED GROUP)
8
7E0208
BEVEL PINION AND GEAR ASSEMBLY SUBSTITUTION
(SEPARATED GROUP)
7E0200
(*) INCLUDES OIL LEVEL ADJUSTMENT
OTHER
* * *
BODY ELECTRICAL SYSTEM ...................................................................
08
WIRING AND RELAYS ..................................................................................... 08-01
SWITCHES .......................................................................................................... 08-02
INDICATORS ...................................................................................................... 08-03
HEADLAMP ......................................................................................................... 08-04
OTHER LAMPS .................................................................................................. 08-05
08
08-01-02-03 BODY ELECTRICAL SYSTEM
WIRING AND RELAYS
08-01
SWITCHES
08-02
INDICATORS
08-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Wiring main harness
1
Turn signal switch asssembly
11
Combinated speedometer assembly
20
Instrument panel harness
2
Wiper and lamp switch control assembly
12
Fuel and temp meter body assembly
21
Wiring floor harness
3
Stering lock assembly
13
Speedometer body assembly
22
Wiring engine harness
4
Return signal indicator assembly
14
Tachometer body assembly
23
Rear deffoger wire
5
Rear deffoger switch assembly
15
Bulb socket
24
Inner harness
6
Rear fog lamps switch
16
Front glass
25
Low pitched horn assembly
7
Stop lamp switch
17
Window plate
26
Horn assembly
8
Parking brake lamp switch
18
Case and printed circuit
27
Fuse box bracket
9
Cigarette lighter assembly
19
Speedometer cable assembly
28
Relays
10
Clock assembly
29
BODY ELECTRICAL SYSTEM 08-01-02
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
08-01. WIRING AND RELAYS
08-02. SWITCHES
AL01 AL02 AL03
1
080101
WIRING MAIN HARNESS SUBSTITUTION
2.0
2.0
2.0
2
080102
INSTRUMENT PANEL HARNESS SUBSTITUTION
2.0
2.0
2.0
3
080103
WIRING FLOOR HARNESS SUBSTITUTION
0.8
0.1
0.8
0.1
0.8
0.1
4
C
C
1.8
0.1
1.8
0.1
1.8
0.1
080104
WIRING ENGINE HARNESS SUBSTITUTION
5
080105
REAR DEFFOGER WIRE SUBSTITUTION
0.5
0.5
-
6
080106
INNER HARNESS SUBSTITUTION
0.7
0.7
0.7
7
080107
ANTENNA ASSEMBLY SUBSTITUTION
0.5
0.5
0.5
8
080108
LOW PITCHED HORN ASSEMBLY SUBSTITUTION (ONE)
0.2
0.2
0.2
9
080109
FUSE BOX BRACKET SUBSTITUTION
0.8
0.8
0.8
INCLUDES:
- Transfer elements
10
080110
INDICATOR RELAY SUBSTITUTION (*)
0.2
0.2
0.2
10
080111
THERMO-STARTING RELAY SUBSTITUTION (ONE)(*)
0.3
0.3
0.3
10
080112
ELECTRO-VENTILATOR RELAY SUBSTITUTION (*)
0.3
0.3
0.3
10
080113
LIGHT RELAY SUBSTITUTION (ONE)(*)
0.2
0.2
0.2
10
080114
TIMING RELAY SUBSTITUTION (*)
0.2
0.2
0.2
080100
OTHER
* * *
11
080201
TURN SIGNAL SWITCH ASSEMBLY SUBSTITUTION
0.5
0.5
0.5
12
080202
WIPER AND LAMPS SWITCH CONTROL SUBSTITUTION
0.5
0.5
0.5
13
080203
STERING LOCK ASSEMBLY SUBSTITUTION
0.8
0.8
0.8
(*) INCLUDES INDIVIDUAL CHECKING
08-01-02-03 BODY ELECTRICAL SYSTEM
WIRING AND RELAYS
08-01
SWITCHES
08-02
INDICATORS
08-03
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Wiring main harness
1
Turn signal switch asssembly
11
Combinated speedometer assembly
20
Instrument panel harness
2
Wiper and lamp switch control assembly
12
Fuel and temp meter body assembly
21
Wiring floor harness
3
Stering lock assembly
13
Speedometer body assembly
22
Wiring engine harness
4
Return signal indicator assembly
14
Tachometer body assembly
23
Rear deffoger wire
5
Rear deffoger switch assembly
15
Bulb socket
24
Inner harness
6
Rear fog lamps switch
16
Front glass
25
Low pitched horn assembly
7
Stop lamp switch
17
Window plate
26
Horn assembly
8
Parking brake lamp switch
18
Case and printed circuit
27
Fuse box bracket
9
Cigarette lighter assembly
19
Speedometer cable assembly
28
Relays
10
Clock assembly
29
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
08-02. SWITCHES
08-03. INDICATORS
AL01 AL02 AL03
14
080204
RETURN SIGNAL INDICATOR ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
15
080205
REAR DEFFOGER SWITCH SUBSTITUTION
0.2
0.2
-
16
080206
REAR FOG LAMP SWITCH ASSEMBLY SUBSTITUTION
0.2
0.2
0.2
17
080207
STOP LAMP SWITCH SUBSTITUTION (ONE)
0.3
0.3
0.3
INCLUDES:
- Measure
18
080208
PARKING LAMP SWITCH SUBSTITUTION
1.1
1.1
1.1
19
080209
CIGARETTE LIGHTER ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
080200
OTHER
* * *
20
080301
D / M OR COMBINATE SPEEDOMETER ASSEMBLY
SUBSTITUTION
0.5
0.5
0.5
21
080302
FUEL TEMP METER BODY ASSEMBLY SUBSTITUTION
0.6
0.6
0.6
22
080303
SPEEDOMETER BODY ASSEMBLY SUBSTITUTION
0.6
0.6
0.6
23
080304
TACHOMETER BODY ASSEMBLY SUBSTITUTION
0.6
0.6
0.6
24
080305
BULB SOCKET SUBSTITUTION (ONE)
0.1
0.1
0.1
(SEPARATED COMBINATE SPEEDOMETER)
25
080306
FRONT GLASS SUBSTITUTION
0.6
0.6
0.6
26
080307
WINDOW PLATE SUBSTITUTION
0.7
0.7
0.7
27
080308
CASE AND PRINTED CIRCUIT SUBSTITUTION
0.9
0.9
0.9
28
080309
SPEEDOMETER CABLE ASSEMBLY SUBSTITUTION
0.9
0.9
0.9
29
080310
CLOCK ASSEMBLY SUBSTITUTION
0.2
0.2
0.2
080300
OTHER
* * *
08-04-05 BODY ELECTRICAL SYSTEM
HEADLAMP
08-04
OTHER LAMPS
08-05
COMPONENTS
POS
COMPONENTS
POS
Headlamp assembly
1
Front turn lamp assembly
6
Side lamp assembly
2
Front turn bulb
7
Bulb
3
Side turn signal lamp assembly
8
Lamp regulator unit
4
Turn lamp bracket and bulb
9
Headlamp bracket unit
5
Rear lamp assembly
10
Rear lamp lens and bulb
11
License lamp assembly
12
License lamp lens and bulb
13
Room lamp assembly
14
Room lamp lens and bulb
15
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
080401
C/V
MODEL CODES AND
REPAIR TIME
08-04. HEADLAMP
08-05. OTHER LAMPS
AL01 AL02 AL03
HEADLAMP ASSEMBLY SUBSTITUTION (ONE)
0.5
0.5
0.5
0.4
0.4
0.4
INCLUDES:
- Headlamp alignment
2
080402
SIDE LAMP ASSEMBLY SUBSTITUTION
INCLUDES:
- Side lamp alignment
2
080403
SIDE LAMP ALIGNMENT
0.2
0.2
0.2
3
080404
BULB SUBSTITUTION (ONE)
0.1
0.1
0.1
4
080405
LAMP REGULATION UNIT SUBSTITUTION (ONE)
0.6
0.6
0.6
0.6
0.6
0.6
INCLUDES:
5
080406
HEADLAMP BRACKET UNIT SUBSTITUTION (ONE)
INCLUDES:
080400
OTHER
* * *
6
080501
FRONT TURN LAMP ASSEMBLY SUBSTITUTION (ONE)
0.4
0.4
0.4
7
080502
FRONT TURN BULB SUBSTITUTION
0.1
0.1
0.1
8
080503
SIDE TURN SIGNAL LAMP ASSEMBLY SUBSTITUTION (ONE)
0.2
0.2
0.2
9
080504
TURN LAMP BRACKET AND BULB SUBSTITUTION (ONE)
0.1
0.1
0.1
10
080505
REAR LAMP ASSEMBLY SUBSTITUTION (ONE)
0.6
0.6
0.6
11
080506
REAR LAMP LENS OR LAMP SUBSTITUTION (ONE)
0.2
0.2
0.2
11
080507
REAR LAMP SUBSTITUTION (NEXT)
0.1
0.1
0.1
12
080508
LICENSE LAMP ASSEMBLY SUBSTITUTION (ONE)
0.3
0.3
0.3
13
080509
LICENSE LAMP LENS AND BULB SUBSTITUTION (ONE)
0.1
0.1
0.1
08-04-05 BODY ELECTRICAL SYSTEM
HEADLAMP
08-04
OTHER LAMPS
08-05
COMPONENTS
POS
COMPONENTS
POS
Headlamp assembly
1
Front turn lamp assembly
6
Side lamp assembly
2
Front turn bulb
7
Bulb
3
Side turn signal lamp assembly
8
Lamp regulator unit
4
Turn lamp bracket and bulb
9
Headlamp bracket unit
5
Rear lamp assembly
10
Rear lamp lens and bulb
11
License lamp assembly
12
License lamp lens and bulb
13
Room lamp assembly
14
Room lamp lens and bulb
15
COMPONENTS
POS
BODY ELECTRICAL SYSTEM 08-05
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
08-05. OTHER LAMPS
AL01 AL02 AL03
14
080510
ROOM LAMP ASSEMBLY SUBSTITUTION
0.3
0.3
0.3
15
080511
ROOM LAMP LENS AND BULB SUBSTITUTION
0.1
0.1
0.1
080500
OTHER
* * *
BODY AND FRAME .............................................................................................
09
BODY PANELS .................................................................................................. 09-01
ROOF AND MOLDINGS .................................................................................. 09-02
DOORS AND LOCKS ...................................................................................... 09-03
TRIMS AND DOOR REGULATOR ............................................................... 09-04
WINDOWS GLASS ............................................................................................ 09-05
SEATS AND SEAT BELTS ............................................................................. 09-06
INNER GARNISHES ......................................................................................... 09-07
RUBBERS AND WEATHERSTRIP PROFILES ...................................... 09-08
CHASSIS FRAME ASSEMBLY ..................................................................... 09-09
09
09-01-02 BODY AND FRAME
BODY PANELS
09-01
ROOF AND MOLDINGS
09-02
COMPONENTS
POS
COMPONENTS
POS
Gear shift case and floor panel
1
Abutment assembly
9
Dash panel assembly
2
Roof panel assembly
10
Frnot window panel assembly
3
Front wide assembly
11
Gear shift case panel assembly
4
Rear wide assembly
12
Floor panel and body member assembly
5
Molding
13
Inner column and side body reine assembly
6
Outer rearview mirror assembly
14
Rear body
7
Roof and side rear body assembly
15
Side rear body
8
COMPONENTS
POS
BODY AND FRAME 09-01-02
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-01. BODY PANELS
09-02. ROOF AND MOLDINGS
AL01 AL02 AL03
1
090101
GEAR SHIFT CASE AND FLOOR PANEL SUBSTITUTION
27.7 23.0 23.0
2
090102
DASH PANEL ASSEMBLY SUBSTITUTION (*)
22.7 22.7 23.3
INCLUDES:
3
090103
FRONT WINDOW PANEL ASSEMBLY SUBSTITUTION (*)
1.6
1.6
2.2
0.6
1.2
INCLUDES:
3
090104
D / M FRONT WINDOW PANEL ASSEMBLY
0.6
4
090105
GEAR SHIFT CASE PANEL ASSEMBLY SUBSTITUTION
15.6 15.6 15.6
5
090106
L/H BODY MEMBER AND FLOOR PANEL SUBSTITUTION
17.0 14.0 14.0
5
090107
R/H BODY MEMBER AND FLOOR PANEL SUBSTITUTION
12.0 9.6
6
090108
INNER COLUMN AND SIDE BODY REINE ASSEMBLY
SUBSTITUTION (ONE)
8.3
-
-
7
090109
REAR BODY SUBSTITUTION (*)
7.3
6.7
6.7
2.6
1.8
-
-
0.8
-
1.2
0.4
-
-
0.8
-
9.6
(SEPARATED ROOF AND SIDE REAR BODY, OP. 090207)
8
090110
LEFT SIDE REAR BODY SUBSTITUTION (*)
D
8
090111
D / M LEFT SIDE REAR BODY
D
8
090112
(REMOVAL ROOF)
ADDITIONAL TIME FOR SLIDING GLASS
2.7
1.9
-
(REMOVAL ROOF)
-
0.8
-
D / M RIGHT SIDE REAR BODY
1.3
0.5
-
(REMOVAL ROOF)
-
0.8
-
RIGHT SIDE REAR BODY SUBSTITUTION (*)
D
8
(REMOVAL ROOF)
090113
D
090100
OTHER
* * *
9
090201
ABUTMENT ASSEMBLY SUBSTITUTION (ONE)
0.4
0.4
0.4
10
090202
D / M, OR ROOF PANEL ASSEMBLY SUBSTITUTION
3.2
-
2.8
0.4
-
D
ADDITIONAL TIME FOR SLIDING GLASS ON SIDE REAR BODY
(*) INCLUDES TRANSFER OF ELEMENTS
BODY PANELS
09-01
ROOF AND MOLDINGS
09-02
COMPONENTS
POS
COMPONENTS
POS
Gear shift case and floor panel
1
Abutment assembly
9
Dash panel assembly
2
Roof panel assembly
10
Frnot window panel assembly
3
Front wide assembly
11
Gear shift case panel assembly
4
Rear wide assembly
12
Floor panel and body member assembly
5
Molding
13
Inner column and side body reine assembly
6
Outer rearview mirror assembly
14
Rear body
7
Roof and side rear body assembly
15
Side rear body
8
COMPONENTS
POS
BODY AND FRAME 09-02
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-02. ROOF AND MOLDINGS
AL01 AL02 AL03
11
090203
FRONT WIDE ASSEMBLY SUBSTITUTION (ONE)
0.3
0.3
0.3
12
090204
REAR WIDE ASSEMBLY SUBSTITUTION (ONE)
0.3
0.3
0.3
13
090205
MOLDING SUBSTITUTION (ONE)
0.3
0.3
0.3
14
090206
OUTER REVIEW MIRROR ASSEMBLY SUBSTITUTION (ONE)
0.2
0.2
0.2
15
090207
D / M ROOF AND SIDE REAR BODY ASSEMBLY
3.0
-
2.6
0.5
-
D
090200
ADDITIONAL TIME FOR SLIDING GLASS ON SIDE REAR BODY
OTHER
* * *
09-03 BODY AND FRAME
DOORS AND LOCKS
09-03
DOORS AND LOCKS
09-03
COMPONENTS
POS
COMPONENTS
POS
Front door assembly
1
Spare tyre support assembly
11
Rear side door assembly
2
Inner handle
12
Rear door assembly
3
Front door lock
4
Side door lock
5
Rear door lock
6
Front and center door hinges
7
Rear door hinges
8
Door open stopper assembly
9
Rear door open stopper assembly
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
090301
C/V
MODEL CODES AND
REPAIR TIME
09-03. DOORS AND LOCKS
AL01 AL02 AL03
FRONT DOOR ASSEMBLY SUBSTITUTION (ONE)
2.2
2.2
2.2
2.4
-
-
1.7
1.7
-
INCLUDES:
- Transfer elements
2
090302
REAR SIDE DOOR ASSEMBLY SUBSTITUTION (ONE)
INCLUDES:
- Transfer elements
3
090303
REAR DOOR ASSEMBLY SUBSTITUTION
INCLUDES:
- Transfer elements
4
090304
FRONT DOOR LOCK SUBSTITUTION (ONE)
0.5
0.5
0.5
5
090305
SIDE DOOR LOCK SUBSTITUTION (ONE)
0.6
-
-
6
090306
REAR DOOR LOCK SUBSTITUTION
0.6
0.6
-
7
090307
FRONT AND CENTER DOOR HINGE SUBSTITUTION (ONE)
0.3
0.3
0.3
8
090308
REAR DOOR HINGE SUBSTITUTION (ONE)
0.3
0.3
-
9
090309
FRONT OR CENTER DOOR OPEN STOPPER SUBSTITUTION
(ONE)
0.4
0.4
0.4
10
090310
REAR DOOR OPEN STOPPER ASSEMBLY SUBSTITUTION
0.5
0.4
-
11
090311
SPARE TYRE SUPPORT ASSEMBLY SUBSTITUTION
0.3
0.3
-
12
090312
INNER HANDLE SUBSTITUTION (ONE)
0.4
0.4
-
090300
OTHER
* * *
TRIMS AND DOOR REGULATOR
09-04
WINDOW GLASS
09-05
COMPONENTS
POS
COMPONENTS
POS
Front door trim
1
Windshield glass
9
Center door trim
2
Front door window glass
10
Rear door trim
3
Side window rear glass
11
Window regulator assembly
4
Side window glass assembly
12
Regulator holder assembly
5
Side window glass
13
Front or center door handles
6
Rear door glass
14
Rear door handle
7
Fixed glass
15
Plain washer
8
Front door glass guides
16
Side rear door glass guides
17
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-04. TRIMS AND DOOR REGULATOR
09-05. WINDOW GLASS
AL01 AL02 AL03
1
090401
FRONT DOOR TRIM SUBSTITUTION (ONE)
0.2
0.2
0.2
2
090402
CENTER DOOR TRIM SUBSTITUTION (ONE)
0.2
-
-
3
090403
REAR DOOR TRIM SUBSTITUTION (ONE)
0.3
0.3
-
4
090404
FRONT OR CENTER DOOR WINDOW REGULATOR
ASSEMBLY SUBSTITUTION (ONE)
0.6
0.6
0.6
5
090405
FRONT OR CENTER REGULATOR HOLDER ASSEMBLY
SUBSTITUTION (ONE)
0.4
0.4
0.4
6
090406
FRONT OR CENTER DOOR HANDLE SUBSTITUTION (ONE)
0.2
0.2
0.2
7
090407
REAR DOOR HANDLE SUBSTITUTION
0.2
0.2
-
8
090408
PLAIN WASHER SUBSTITUTION (ONE)
0.1
0.1
0.1
090400
OTHER
* * *
9
090501
WINDSHIELD GLASS SUSBSTITUTION
0.9
0.9
0.9
10
090502
FRONT DOOR WINDOW GLASS SUBSTITUTION (ONE DOOR)
0.8
0.8
0.8
11
090503
SIDE WINDOW REAR GLASS SUBSTITUTION (ONE DOOR)
0.8
-
-
12
090504
SIDE WINDOW GLASS ASSEMBLY SUBSTITUTION (ONE
LATERAL)
0.6
0.6
-
13
090505
SIDE WINDOW GLASS SUBSTITUTION (ONE LATERAL)
0.4
0.4
-
14
090506
REAR DOOR GLASS SUBSTITUTION
0.5
0.5
-
15
090507
FIXED GLASS SUBSTITUTION (ONE)
1.0
-
-
16
090508
FRONT DOOR GLASS GUIDE SUBSTITUTION (ONE DOOR)
1.6
1.6
1.6
16
090509
FRONT DOOR GLASS GUIDE SUBSTITUTION (ONE GUIDE)
0.4
0.4
0.4
16
090510
FRONT DOOR GLASS GUIDE SUBSTITUTION (NEXT)
0.2
0.2
0.2
TRIMS AND DOOR REGULATOR
09-04
WINDOW GLASS
09-05
COMPONENTS
POS
COMPONENTS
POS
Front door trim
1
Windshield glass
9
Center door trim
2
Front door window glass
10
Rear door trim
3
Side window rear glass
11
Window regulator assembly
4
Side window glass assembly
12
Regulator holder assembly
5
Side window glass
13
Front or center door handles
6
Rear door glass
14
Rear door handle
7
Fixed glass
15
Plain washer
8
Front door glass guides
16
Side rear door glass guides
17
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-05. WINDOW GLASS
AL01 AL02 AL03
17
090511
SIDE REAR DOOR GLASS GUIDE SUBSTITUTION (ONE
DOOR)
1.6
-
-
17
090512
FIXED SIDE REAR DOOR GLASS GUIDE SUBSTITUTION
(ONE GUIDE)
0.2
-
-
17
090513
SIDE REAR DOOR MOBILE GLASS GUIDE SUBSTITUTION
(ONE GUIDE)
0.4
-
-
17
090514
SIDE REAR DOOR MOBILE GLASS GUIDE SUBSTITUTION
(NEXT GUIDE)
0.2
-
-
090500
OTHER
* * *
SEATS AND SEAT BELTS
09-06
INNER GARNISHES
09-07
INNER GARNISHES
09-07
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front seat
1
Instrument panel assembly
10
Back door scuff
20
Center seat
2
Instrument panel cover
11
Inner side window rear trim
21
Side rear seat
3
Service hole cover
12
Side sill rear scuff
22
Front belt assembly
4
Speaker hole cover
13
Inner center windshield trim
23
Rolling cover
5
Front ashtray
14
Inner center windshield side trim
24
Buckle
6
Sunvisor
15
Inner side upper trim
25
Rear belt assembly
7
Inner rearview mirror
16
Inner column trim
26
Buckle and torgue assembly
8
Front floor carpet
17
Rear belt trim clip
27
Rear belt buckle assembly
9
Rear floor carpet
18
Inner side window trim
28
Side sill front scuff
19
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-06. SEATS AND SEAT BELTS
09-07. INNER GARNISHES
AL01 AL02 AL03
1
090601
FRONT SEAT SUBSTITUTION (ONE)
0.5
0.5
0.5
2
090602
CENTER SEAT SUBSTITUTION
0.7
-
-
3
090603
SIDE REAR SEAT SUBSTITUTION (ONE)
0.5
0.5
0.5
4
090604
FRONT BELT ASSEMBLY SUBSTITUTION (ONE)
0.5
0.5
0.5
5
090605
ROLLING COVER SUBSTITUTION (ONE)
0.2
0.2
0.2
6
090606
BUCKLE SUBSTITUTION (ONE)
0.2
0.2
0.2
7
090607
REAR BELT ASSEMBLY SUBSTITUTION (ONE)
0.5
-
-
8
090608
BUCKLE AND TORGUE ASSEMBLY SUBSTITUTION
0.2
-
-
9
090609
REAR BELT BUCKLE ASSEMBLY SUBSTITUTION
0.2
-
-
090600
OTHER
* * *
090701
INSTRUMENT PANEL ASSEMBLY SUBSTITUTION
3.5
3.5
3.5
10
INCLUDE:
10
090702
D / M INSTRUMENT PANEL ASSEMBLY
2.6
2.6
2.6
11
090703
INSTRUMENT PANEL COVER SUBSTITUTION
0.2
0.2
0.2
12
090704
SERVICE HOLE COVER SUBSTITUTION
0.2
0.2
0.2
13
090705
SPEAKER HOLE COVER SUBSTITUTION (ONE)
0.1
0.1
0.1
14
090706
FRONT ASHTRAY SUBSTITUTION
0.2
0.2
0.2
15
090707
SUNVISOR SUBSTITUTION (ONE)
0.2
0.2
0.2
16
090708
INNER REARVIEW MIRROR SUBSTITUTION
0.2
0.2
0.2
17
090709
FRONT FLOOR CARPET ASSEMBLY AND GEAR BOX
COVERING SUBSTITUTION
2.4
2.4
2.4
SEATS AND SEAT BELTS
09-06
INNER GARNISHES
09-07
INNER GARNISHES
09-07
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Front seat
1
Instrument panel assembly
10
Back door scuff
20
Center seat
2
Instrument panel cover
11
Inner side window rear trim
21
Side rear seat
3
Service hole cover
12
Side sill rear scuff
22
Front belt assembly
4
Speaker hole cover
13
Inner center windshield trim
23
Rolling cover
5
Front ashtray
14
Inner center windshield side trim
24
Buckle
6
Sunvisor
15
Inner side upper trim
25
Rear belt assembly
7
Inner rearview mirror
16
Inner column trim
26
Buckle and torgue assembly
8
Front floor carpet
17
Rear belt trim clip
27
Rear belt buckle assembly
9
Rear floor carpet
18
Inner side window trim
28
Side sill front scuff
19
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-07. INNER GARNISHES
AL01 AL02 AL03
18
090710
REAR FLOOR CARPET SUBSTITUTION
1.0
1.0
1.0
19
090711
SIDE SILL FRONT SCUFF SUBSTITUTION (ONE)
0.3
0.3
0.3
20
090712
BACK DOOR SCUFF SUBSTITUTION (ONE)
0.2
-
-
21
090713
INNER SIDE WINDOW REAR TRIM SUBSTITUTION (ONE)
0.5
0.5
-
22
090714
SIDE SILL REAR SCUFF SUBSTITUTION
0.3
0.3
0.3
23
090715
INNER CENTER WINDSHIELD TRIM SUBSTITUTION
0.6
0.6
-
24
090716
INNER CENTER WINDSHIELD SIDE TRIM SUBSTITUTION
(ONE)
0.5
0.5
-
25
090717
INNER SIDE UPPER TRIM SUBSTITUTION (ONE)
0.6
0.6
-
26
090718
INNER COLUMN TRIM SUBSTITUTION (ONE)
0.6
-
-
27
090719
REAR BELT TRIM CLIP SUBSTITUTION (ONE)
0.3
-
-
28
090720
INNER SIDE WINDOW TRIM SUBSTITUTION (ONE)
0.5
0.5
-
090700
OTHER
* * *
RUBBERS AND
WEATHERSTRIP PROFILES
09-08
RUBBERS AND
09-08
COMPONENTS
POS
COMPONENTS
POS
Roof weatherstrip
1
Front door weatherstrip
11
Upper side roof rubber
2
Center door side weatherstrip
12
Side rear roof rubber
3
Center door weatherstrip
13
Lower rear body rubber
4
Windshield weatherstrip
14
Lower windshield weatherstrip
5
Front fender weatherstrip
15
Rear door weatherstrip
6
Air cleaner protector
16
Rear window weatherstrip
7
Hood latch release protector
17
Window weatherstrip
8
18
Side window rubber
9
Rear door rubber
19
Front door side weatherstrip
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
1
090801
C/V
MODEL CODES AND
REPAIR TIME
09-08. RUBBER AND WEATHERSTRIP PROFILES
AL01 AL02 AL03
ROOF WEATHERSTRIP SUBSTITUTION
0.2
0.2
-
0.2
0.2
-
0.1
0.1
-
0.2
0.2
-
0.2
0.2
0.2
(SEPARATED WINDSHIELD, OP.090104)
2
090802
UPPER SIDE ROOF RUBBER SUBSTITUTION (ONE)
(SEPARATED ROOF)
3
090803
SIDE REAR ROOF RUBBER (ONE)
(SEPARATED ROOF)
4
090804
LOWER REAR BODY RUBBER SUBSTITUTION (ONE)
(SEPARATED ROOF AND LATERAL ASSEMBLY, OP. 090207)
5
090805
LOWER WINDSHIELD WEATHERSTRIP SUBSTITUTION
(SEPARATED WINDSHIELD, OP.090104)
6
090806
REAR DOOR WEATHERSTRIP SUBSTITUTION
0.2
0.2
-
7
090807
REAR WINDOW WEATHERSTRIP SUBSTITUTION
0.5
0.5
-
8
090808
WINDOW WEATHERSTRIP SUBSTITUTION (ONE)
0.2
0.2
-
9
090809
SIDE WINDOW RUBBER SUBSTITUTION (ONE)
0.5
0.5
-
10
090810
FRONT DOOR SIDE WEATHERSTRIP SUBSTITUTION (ONE)
0.5
0.5
0.5
11
090811
FRONT DOOR WEATHERSTRIP SUBSTITUTION (ONE)
0.3
0.3
0.3
12
090812
CENTER DOOR SIDE WEATHERSTRIP SUBSTITUTION
(ONE)
0.5
-
-
13
090813
CENTER DOOR WEATHERSTRIP SUBSTITUTION (ONE)
0.3
-
-
14
090814
WINDSHIELD WEATHERSTRIP SUBSTITUTION
0.9
0.9
0.9
15
090815
FRONT FENDER WEATHERSTRIP SUBSTITUTION (ONE)
0.1
0.1
0.1
16
090816
AIR CLEANER PROTECTOR SUBSTITUTION
0.2
0.2
0.2
RUBBERS AND
09-08
RUBBERS AND
09-08
COMPONENTS
POS
COMPONENTS
POS
Roof weatherstrip
1
Front door weatherstrip
11
Upper side roof rubber
2
Center door side weatherstrip
12
Side rear roof rubber
3
Center door weatherstrip
13
Lower rear body rubber
4
Windshield weatherstrip
14
Lower windshield weatherstrip
5
Front fender weatherstrip
15
6
Air cleaner protector
16
Rear window weatherstrip
7
Hood latch release protector
17
Window weatherstrip
8
18
Side window rubber
9
Rear door rubber
19
Front door side weatherstrip
10
COMPONENTS
POS
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-08. RUBBER AND WEATHERSTRIP PROFILES
AL01 AL02 AL03
17
090817
HOOD LACTH RELEASE SUBSTITUTION
0.1
0.1
0.1
18
090818
REAR DOOR WEATHERSTRIP SUBSTITUTION
0.5
0.5
-
19
090819
REAR DOOR RUBBER SUBSTITUTION
0.3
0.3
-
090800
OTHER
* * *
CHASSIS FRAME ASSEMBLY
09-09
09-09
09-09
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Frame assembly
1
Rear spring bracket assembly
12
Muffler bracket
23
1st crossmember
2
Frame bracket
13
Rear muffler bracket
24
Engine rear bracket
3
Rear strut bracket assembly
14
Fuel tank bracket assembly
25
Front frame bracket assembly
4
15
LSPV fixed bracket
26
5
Rear box bracket assembly
16
6th crossmember assembly
27
Front strut pin
6
Crossmember 6th reinforcement
17
Rear towing hook
28
Instrument panel front bracket
7
Front spring bracket assembly
18
Side abutment bracket assembly
29
Instrument panel bracket assembly
8
Front cushion bracket assembly
19
2nd crossmember
30
Engine bracket assembly
9
Front towing hook
20
3rd crossmember
31
Box Nº 1 bracket assembly
10
Hose brake flexible bracket
21
4th crossmember
32
11
Join coupling plate assembly
22
BASIC
POS OPERATION
CODE
1
C/V
MODEL CODES AND
REPAIR TIME
09-09. CHASSIS FRAME ASSEMBLY
AL01 AL02 AL03
090901
BODY TO CHASSIS SEPARATION AND UNION
10.0 10.0 10.0
INCLUDES:
- Systems and circuits tolerance and adjustments
C
1
090902
CHASSIS FRAME ASSEMBLY SUBSTITUTION
0.2
0.2
0.2
20.0 20.0 20.0
INCLUDES:
- Systems and circuits tolerance and adjustments
C
0.4
0.4
0.4
2
090903
1ST CROSSMEMBER SUBSTITUTION (*)
3.0
3.0
3.0
3
090904
ENGINE REAR BRACKET SUBSTITUTION (ONE)
2.0
2.0
2.0
FRONT FRAME BRACKET SUBSTITUTION (ONE) (*)
2.0
2.0
2.0
RADIATOR BRACKET SUBSTITUTION (ONE) (*)
3.0
3.0
3.0
4
090905
5
090906
INCLUDES:
- Cooling circuit level and adjustment
6
090907
FRONT STRUT PIN SUBSTITUTION (ONE)
2.1
2.1
2.1
7
090908
INSTRUMENT PANEL FRONT BRACKET SUBSTITUTION
(ONE) (*)
1.0
1.0
1.0
8
090909
INSTRUMENT PANEL BRACKET ASSEMBLY SUBSTITUTION
(ONE)(*)
1.5
1.5
1.5
9
090910
ENGINE BRACKET ASSEMBLY SUBSTITUTION (ONE)
3.0
3.0
3.0
(SEPARATED ENGINE)
10
090911
BOX Nº 1 BRACKET ASSEMBLY SUBSTITUTION (ONE) (*)
1.5
1.5
1.5
11
090912
BOX Nº 2 BRACKET ASSEMBLY SUBSTITUTION (ONE) (*)
1.0
1.0
1.0
12
090913
REAR SPRING BRACKET ASSEMBLY SUBSTITUTION (ONE) (*)
3.5
3.5
3.5
13
090914
FRAME BRACKET SUBSTITUTION (ONE) (*)
0.5
0.5
0.5
(SEPARATED FUEL TANK)
14
090915
REAR STRUT BRACKET ASSEMBLY SUBSTITUTION (ONE)
2.0
2.0
2.0
15
090916
REAR SPRING BRACKET ASSEMBLY SUBSTITUTION (ONE)
(*)
3.0
3.0
3.0
(*) WITH TOTAL OR PARTIAL SEPARATED BODY
09-09
09-09
09-09
COMPONENTS
POS
COMPONENTS
POS
COMPONENTS
POS
Frame assembly
1
12
Muffler bracket
23
1st crossmember
2
Frame bracket
13
Rear muffler bracket
24
Engine rear bracket
3
Rear strut bracket assembly
14
Fuel tank bracket assembly
25
Front frame bracket assembly
4
15
LSPV fixed bracket
26
5
Rear box bracket assembly
16
6th crossmember assembly
27
Front strut pin
6
Crossmember 6th reinforcement
17
Rear towing hook
28
Instrument panel front bracket
7
Front spring bracket assembly
18
Side abutment bracket assembly
29
Instrument panel bracket assembly
8
Front cushion bracket assembly
19
2nd crossmember
30
Engine bracket assembly
9
Front towing hook
20
3rd crossmember
31
10
Hose brake flexible bracket
21
4th crossmember
32
11
Join coupling plate assembly
22
BASIC
POS OPERATION
CODE
C/V
MODEL CODES AND
REPAIR TIME
09-09. CHASSIS FRAME ASSEMBLY
AL01 AL02 AL03
16
090917
REAR BOX BRACKET ASSEMBLY SUBSTITUTION (ONE) (*)
0.5
0.5
0.5
17
090918
CROSSMEMBER 6TH REINFORCEMENT SUBSTITUTION
(ONE)(*)
0.5
0.5
0.5
18
090919
FRONT SPRING BRACKET ASSEMBLY SUBSTITUTION (ONE)
3.0
3.0
3.0
19
090920
FRONT CUSHION BRACKET ASSEMBLY SUBSTITUTION
(ONE)
2.0
2.0
2.0
20
090921
FRONT TOWING HOOK SUBSTITUTION (ONE)
0.8
0.8
0.8
21
090922
HOSE BRAKE FLEXIBLE BRACKET SUBSTITUTION (ONE)
1.0
1.0
1.0
22
090923
JOIN COUPLING PLATE ASSEMBLY SUBSTITUTION
2.0
2.0
2.0
23
090924
MUFFLER BRACKET SUBSTITUTION (ONE)
2.0
2.0
2.0
24
090925
REAR MUFFLER BRACKET SUBSTITUTION
1.5
1.5
1.5
25
090926
FUEL TANK BRACKET ASSEMBLY SUBSTITUTION (ONE) (*)
0.5
0.5
0.5
2.0
2.0
2.0
26
090927
LSPV FIXED BRACKET SUBSTITUTION (ONE) (*)
INCLUDES:
- Drain and measures
27
090928
6TH CROSSMEMBER ASSEMBLY SUBSTITUTION (*)
4.0
4.0
4.0
28
090929
REAR TOWING HOOK SUBSTITUTION
0.8
0.8
0.8
29
090930
SIDE ABUTMENT BRACKET ASSEMBLY SUBSTITUTION
(ONE)
1.2
1.2
1.2
30
090931
2ND CROSSMEMBER SUBSTITUTION (*)
3.0
3.0
3.0
(SEPARATED GEAR BOX AND ENGINE)
31
090932
3RD CROSSMEMBER SUBSTITUTION (*)
3.0
3.0
3.0
32
090933
4TH CROSSMEMBER SUBSTITUTION (*)
3.0
3.0
3.0
090900
OTHER
(*) WITH TOTAL OR PARTIAL SEPARATED BODY
* * *
Prepared by
SANTANA MOTOR S.A.
After-Sales Service Department
1st Ed. October 2002
Printed in Spain
Printed: October 2002

Repair Time Manual PS

Transcription

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