engine

engine
LIGHT DUTY VEHICLE
(TF* & UC* - NEW CAB MODEL)
LABOR TIME GUIDE
FOREWORD
These Labor Time allowances are published by ISUZU for the purpose of implementing the terms of the current Warranty Claim Processing Manual and are
intended for the purpose of computing the compensation payable by ISUZU
MOTORS LIMITED for the performance of warranty, policy and campaign adjustments and other work authorized and performed for the account of ISUZU. The
use of these allowances for any other purposes will be at the discretion of each
dealer. All time allowances are subject to change at any time by ISUZU based on
time studies by ISUZU related to improved methods, techniques or equipment or
other advances in the industry.
ISUZU MOTORS LIMITED
Publication No. L1G-LE-03D1
Printed in Japan
INTRODUCTION
This Labor Time Guide is designed for more
convenient and accurate use. The guide is identical in page format to all Labor Time Guides produced by ISUZU. In addition to the uniform page
layout, the Operation Description and Numbering
System is now standard for all ISUZU vehicles.
PAGE LAYOUT
To aid in the use of the Time Guide, the
layout has been structured in reading sequence.
Reading from left to right are the “Operation
Description” and its qualifiers, followed by the
“Operation Numbers”. On the right hand side of
the page is an area designating the vehicles by
series with their appropriate times.
POLICY CODES
The policy codes applicable to any labor
operation(s) are noted under the major operation
description (if they apply to all operations) or to
the left of a particular operation if the operations
listed under a major labor operation description
have different policy requirements. Each letter
indicates a policy as it applies to an Operation.
Below is a listing of the Policy Codes and
Descriptions used in this publication.
P–
A–
T–
E–
Power train
Requires Authorization
Towing Allowed
Emission Related Operation
OPERATION DESCRIPTION
MAJOR OPERATIONS
Operations having a labor operation number
(A1234) are classified as Major Operations. A
major operation time allowance is sufficient to do
the work described as a single operation.
Operations within each section are generally
arranged in the following manner – Front to
Rear, Top to Bottom, Right to Left. Sitting in the
driver’s seat, Right-Hand components are to the
Driver’s Right, Left-Hand to the Driver’s Left.
ADD CONDITIONS
Additional time allowances which may be
required for performing a Major Operation or supplement a Major Operation are included in the
“ADD” sections under vehicle designation. Each
“add” is preceded by a letter designation (A, B,
C, ~) which should be placed on the dealer repair
order under the 5-Position Major Operation Number if the “ADD” is performed. These letters are
not to appear on the Warranty Claim.
ACTION WORDS
Each labor operation description has been
revised to clearly identify the repair that is
allowable on that component. These notations,
plus the description of same, are provided below:
REPLACE (as a single action word)
The “REPLACE” notation is used when the
part or an assembly is subject to replacement
only. A part is required on the warranty claim.
R&R (as a single action word)
“R&R” notation indicates the part or assembly is repairable and can be removed, repaired,
and reinstalled. All labor operations so noted are
followed by “ADD” statements which cover all
possible repair conditions. This can be a labor
only operation.
REPAIR
ALIGN (as a single action word)
ADJUST
TIGHTEN
The above notation indicate the work (repair)
to be performed. This can be a labor only operation.
REPAIR OR REPLACE
R&R OR REPLACE
The above notations indicate the part or
assembly can be repaired, aligned or adjusted on
the vehicle or removed, repaired, and/or
reinstalled or replaced, depending on the extent
of failure. This can be a labor only operation
when no part or assembly is required.
RECONDITION
When this term is used with a Major Operation, it means to remove an assembly from the
vehicle, disassemble, clean and inspect all parts,
rebuild the assembly with the same or new parts,
reinstall and adjust. When this term is used in an
ADD Operation, it does not include Remove and
Reinstall but only that work necessary to recondition an assembly once it is removed from the
vehicle.
INCLUDES
The Includes which follow some of the
descriptions are provided to assist in knowing
whether or not certain items or functions are
included within the operation. These are not all
encompassing because to place all such data in
the Guide would make it difficult to use. If there
are any questions as to whether something is
included or not, the Request for Review form may
be used to question or recommend changes.
NOTES
Throughout the Time Guide, various notes
will be inserted to assist in the use of the Guide.
TIME ALLOWANCES
Some repair operation time allowances are
developed from data which indicates that most
repairs can be performed in the published time. It
is reasonable to assume that additional time may
be required when unusual conditions are encountered. An authorization is required for the additional time.
DIAGNOSIS TIME
“Repair diagnosis” time is included in all
established labor time operations where it is
required of the technician to perform the operation. It is the responsibility of qualified supervisory personnel to assist technicians in “customer
problem analysis” and “symptom diagnosis”.
Service personnel should be contacted for
assistance in circumstances requiring extensive
diagnosis. Time for extensive diagnosis will
require authorization if deemed allowable.
Following are definitions of the terms used in
the preceding statement:
“Customer Problem Analysis” – The process
of translating the customer’s problems to a
symptom. Examples are: A/C insufficient cooling,
brakes pull, engine diesels, hesitates, surges, etc.
It also includes those failures which are readily
apparent to the normal senses of sight, touch,
sound and smell. Defining these is the duty of the
dealership service management and/or service
writer.
All time allowances as indicated in hours and
tenths of hours published in this guide (except
for a few Repair Operations) are based on studies
of the actual time required to complete the
operation. No connection with technicians’
wages is implied since they are dependent upon
the dealer technician pay plan in use.
“Symptom Diagnosis” – The process of
finding the source of a problem based on a
detailed symptom. Symptom diagnosis is complete when the problem has been found.
The time allowances published have been
determined by performing the operation a sufficient number of times to establish an average
time or to determine that a fair and equitable time
has been developed. Standard technicians’ hand
tools and dealer essential and available tools are
used in performing time studies. No power operated wrenches are used for time studies. Procedures outlined in Service Manuals, other Service Publications and good shop practices are
used as a guide when performing the work
necessary to establish time allowances.
Examples Are:
The time allowance includes the actual time
required to perform the operation plus an additional allowance to provide for operating variables. Time allowances do not include time to
remove and replace special equipment other than
manufacturer options and accessories.
“Repair Diagnosis” – The checks, tests and
measurements needed in the repair to find the
cause of failure, or identify faulty parts.
● cleaning and inspection of all parts such
as gears and clutch plates;
● use of common testers such as an ohmmeter, voltampere meter or timing light that are
included in the service manual procedure.
REQUEST FOR REVIEW
Any questions relating to suggested new or
existing operations and/or time allowances in this
time guide should be submitted on a “Request
for Review” form. These forms can be found at
the end of this Manual. When completing this
form, it is important that vehicle identification
data affecting or influencing the operation in
question be provided. It is also important to submit a complete (detailed) description of the work
performed. The statement “followed Shop Manual
Procedure” is generally not a sufficient explanation of the procedure followed. Generally, a technician performs the steps of an operation in a
sequence which is comfortable to him/her and it
is their procedure which we would like to review
and compare with ours. The “Request for
Review” form is primarily intended for your use
to inform us of a problem affecting the ability of
technicians to perform an operation within the
published time allowance. The request should be
forwarded to the address indicated on the form.
All inquiries received at the home office will
be acknowledged and reviewed. A review will be
conducted of the Labor Time Guide text and procedure as outlined by the model year service
manual and dealer bulletins, restudies will be
conducted as required.
VEHICLES MODEL YEAR
Refer to below illustrations for vehicles model.
'03 Cab Model
'12 Cab Model
VEHICLE AND ENGINE IDENTIFICATION
The Engine Code designation from the Vehicle Identification Number (VIN) is used to identify the appropriate engine mechanical sections
within this publication. Refer to the VIN chart for
engine identification codes.
ABBREVIATIONS
Abbreviations will be used through the Labor Time Guide. Below is a list of
abbreviations and their meaning.
Abbreviations
Description
Abbreviations
Description
A/C
Air Conditioning
EXC
Except
ADD
Addition
INC
Includes
ADJ
Adjust
I/P
Instrument Panel
AIR
Air Injector Reactor
MAN
Manual
ASSY
Assembly
NEC
Necessary
AUTO
Automatic
OHC
Overhead Camshaft
CONT’D
Continued
P/S
Power Steering
CV-JOINT
Constant Velosity
R&R
Remove and Reinstall
CYL
Cylinder
TRANS
Transmission
D&C
Disconnect And Connect
TPS
Throttle Position Sensor
DIFF
Differential
TURBO
Turbocharger
DOHC
Double Overhead Camshaft
T.V.
Throttle Valve
ECM
Electronic Control Module
VIN
Vehicle Identification Number
EFE
Early Fuel Evaporation
W/
With
EGR
Exhaust Gas Recirculation
W/O
Without
WITH A
Technicians Comments:
Other — (Describe in Technicians Comments section)
Operation Description is incorrect
(Record you suggestion in tech comments)
Published Time is insufficient
(Completion of step by step labor description on
reverse side is required)
A New Labor Operation description is recommended
(Record your suggestion in technicians comments)
IS REQUESTED BECAUSE:
OPERATION DESCRIPTION OF
NUMBER
A REVIEW OF LABOR OPERATION
SIGNATURE
Does the labor listed on the reverse side follow
the Isuzu Service Manual?
Is the repairing technician Isuzu trained?
Did you verify the availability/condition of the
essential tools required for this repair?
Did you review this request with both the
technician and service manager?
SIGNATURE
recommendation/comments:
YES NO
DISTRIBUTOR USE ONLY
SERVICE MGR. SIGNATURE:
SUBMITTED BY:
ISUZU DEALER CODE:
FRANCHISE NAME:
DEALERSHIP INFORMATION
REQUEST FOR REVIEW FORM
LABOR OP #
OPERATION DESCRIPTION
STEP
NO.
DESCRIPTION OF BASIC STEPS
TIME
IN MIN.
STEP
NO.
DESCRIPTION OF BASIC STEPS
The actual time required to perform this labor operation in our shop is
hr.
Vehicle Information
VIN #
Engine Family
Trans #
Rear Axle #
Body Type
Special Equip.
Additional Comments:
TIME
IN MIN.
TROUBLE CODES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
BROKEN
BROKEN WELD
STRIPPED
TORN OR PUNCTURED
CRACKED
WORN
SCORED OR SCRATCHED
POOR METAL FINISH
CHIPPED
SOILED OR STAINED
BENT
FOREIGN MATERIAL
OVERHEATED
BURNED
SEIZED
PAINT - DIRT OR FOREIGN
MATERIAL
PAINT - DRY SPRAY, MOTTLING
SAGS,
OFF-COLOR, ROUGH
PAINT - FILM MARRED OR
SCRATCHED
PAINT - THIN OR RUBBED THROUGH
PAINT - CORROSION, CRAZING,
CRACKING, CHALKING
PAINT - POOR REPAIR
PAINT - FILM SPOTTED
PAINT - FINISH COMES OFF
CHROME PLATING DEFECTIVE
MISALIGNED
MISADJUSTED
LOOSE
PART OMITTED
POROSITY
POOR MACHINING
GLASS - POOR VISION
WEAK
OUT OF BALANCE
OUT OF ROUND
VIBRATES
POOR ENGAGEMENT
DOES NOT SEAT
GRABS
NOISY
CHATTERS
LEAKS
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
78
79
81
82
83
84
85
93
95
96
SHIFTS HARD
SLIPS OUT OF GEAR
WIND NOISE
FLOODS
FLAT SPOT OR HESITATES
DISCOLORED
PITTED
ELECTRICAL FAILURES
NOT CONNECTED
BINDS, STICKS
NOT DRILLED
WRONG PART
POOR FIT
INOPERATIVE
REGISTERS INCORRECTLY
PART IMPROPERLY INSTALLED
PULLS
ENGINE PING
INCORRECT PRESSURE
IMPROPER CLEARANCE
FADE OR HARD PEDAL
GLAZED
SLIPS
COLLAPSED
EXCESSIVE LUBRICATION OR OIL
SOAKED
INSUFFICIENT LUBRICATION
POOR OIL MILEAGE
POOR GASOLINE MILEAGE
PULLED LOOSE
SPLIT SEAMS
IMPROPERLY PADDED
FUMES
RUSTED OR CORRODED
WRINKLED
CARBON DEPOSIT
POOR RELEASE
HARD RIDE
SURGE
HARD STARTING (COLD)
HARD STARTING (HOT)
SHEARED
DISCHARGED
SPECIAL POLICY
CAMPAIGN
A PAINT
A
PAINT A - 3
PAINT EXTERIOR
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
NOTE: All paint operations are ST (straight time) operation which requires
time documentation as detailed in the claims processing manual.
Authorization request is required beyond 1.5 hours.
BUMPER, FRONT
COLOR COAT; ONE PIECE
A0028
ST
ST
COLOR COAT
A0260
ST
ST
COLOR COAT; COMPLETE
A0347
ST
ST
COLOR COAT
A0420
ST
ST
COLOR COAT; RIGHT
A0650
ST
ST
COLOR COAT; LEFT
A0651
ST
ST
ALLIGATOR TYPE HOOD; COLOR COAT; RIGHT
A0680
ST
ST
ALLIGATOR TYPE HOOD; COLOR COAT; LEFT
A0681
ST
ST
COLOR COAT; RIGHT
A0800
ST
ST
COLOR COAT; LEFT
A0801
ST
ST
COLOR COAT
A0880
ST
ST
GRILLE
INC: R&R grille, emblem and headlight bezels.
HOOD
PANEL, SHROUD UPPER AND/OR VENT GRILLE
WHEEL OPENING EXTENSION, FRONT
FENDER, FRONT COMPLETE
DOES NOT INC: Fender extension.
PILLAR, WINDSHIELD
ROOF
POLICY: A
Except SPOT REPAIR
A - 4 PAINT
PAINT EXTERIOR
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
PILLAR, CENTER
COLOR COAT; RIGHT
A1020
ST
ST
COLOR COAT; LEFT
A1021
ST
ST
COLOR COAT; RIGHT
A1040
ST
ST
COLOR COAT; LEFT
A1041
ST
ST
COLOR COAT; RIGHT
A1100
ST
ST
COLOR COAT; LEFT
A1101
ST
ST
COLOR COAT; RIGHT
A1220
ST
ST
COLOR COAT; LEFT
A1221
ST
ST
COLOR COAT
A1360
ST
-
COLOR COAT; RIGHT
A1400
ST
ST
COLOR COAT; LEFT
A1401
ST
ST
COLOR COAT; RIGHT
A1403
ST
-
COLOR COAT; LEFT
A1404
ST
-
COLOR COAT; RIGHT
A1520
ST
ST
COLOR COAT; LEFT
A1521
ST
ST
ROCKER
FRAME, FRONT DOOR WINDOW
DOOR, FRONT
INC: Door window frame, R&R mirror.
DOES NOT INC: Drivers vent. On aluminum tilt series,
use spot repair for vent.
PANEL, CAB BACK
POLICY: A
Except SPOT REPAIR
FRAME, REAR DOOR WINDOW
FRAME, SIDE ACCESS PANEL WINDOW
DOOR, REAR
PAINT A - 5
PAINT EXTERIOR
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
DOOR, SIDE ACCESS PANEL
COLOR COAT; RIGHT
A1523
ST
-
COLOR COAT; LEFT
A1524
ST
-
COLOR COAT; RIGHT
A2180
ST
ST
COLOR COAT; LEFT
A2181
ST
ST
COLOR COAT
A2410
ST
-
COLOR COAT; RIGHT
A2500
ST
ST
COLOR COAT; LEFT
A2501
ST
ST
COLOR COAT
A2920
ST
-
COLOR COAT
A3240
ST
ST
COLOR COAT; RIGHT FRONT
A3300
ST
-
COLOR COAT; LEFT FRONT
A3301
ST
-
COLOR COAT; RIGHT REAR
A3320
ST
-
COLOR COAT; LEFT REAR
A3321
ST
-
QUARTER (COMPLETE)
LOAD FLOOR
WHEEL OPENING EXTENSION, REAR
TAILGATE, COMPLETE
REAR BUMPER
WHEELS
B BODY EXTERIOR
B
BUMPERS, DOORS AND EXTERIOR TRIM B - 7
BUMPER AND FRONT END
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
BUMPER ASSEMBLY, FRONT - REPLACE
B0048
.4
.4
BAR, FRONT BUMPER FACE - REPLACE
B0210
.4
.4
REINFORCEMENT ASSEMBLY, FRONT BUMPER - REPLACE
B0215
.4
.4
BAR, IMPACT, FRONT - REPLACE
B0230
.4
.4
BUMPER ASSEMBLY, FRONT - ALIGN
B0260
.2
.2
BAR, REAR BUMPER FACE - REPLACE
B0800
.4
.4
SHEET, NONSLIP, REAR BUMPER - REPLACE
B0850
.6
-
.2
-
ADD:
A - To Replace Bumper Back Bar (Either Right or Left)......................................................
BUMPER ASSEMBLY, REAR - ALIGN
B0860
.5
.5
BUMPER AND/OR STEP ASSEMBLY, REAR - REPLACE
B0880
.4
.4
.2
-
B0890
.4
.4
RIGHT
B0891
.2
-
LEFT
B0892
.2
-
ONE PIECE
B1308
.2
.2
HOOD ASSEMBLY, ENGINE - R&R OR REPLACE
B1490
.3
.3
HOOD ASSEMBLY - ALIGN
B1500
.3
.3
ADD:
A - For Steel Bumper Type..................................................................................................
REINFORCEMENT ASSEMBLY, REAR BUMPER - REPLACE
SIDE GUARD, BUMPER, REAR - REPLACE
GRILLE ASSEMBLY - REPLACE
INC; Adjust bumper and/or latch.
B - 8 BUMPERS, DOORS AND EXTERIOR TRIM
BUMPER AND FRONT END
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
INSULATION, ENGINE HOOD - REPLACE
B1510
.3
.3
LATCH, HOOD - R&R OR REPLACE
B1540
.4
.4
SUPPORT, HOOD LATCH - REPLACE
B1550
.4
.4
ROD, HOOD SUPPORT - REPLACE
B1600
.2
.2
CABLE, HOOD LATCH - R&R OR REPLACE
B1630
.6
.6
BUMPERS, HOOD - REPLACE
B1650
.2
.2
RIGHT
B1710
.3
.3
LEFT
B1711
.3
.3
BOTH
B1717
.5
.5
RIGHT
B1860
.3
.5
A - For Wagon Model..........................................................................................................
.2
-
B - Fitted 2012 Cab Model...................................................................................................
.2
-
.3
.5
A - For Wagon Model..........................................................................................................
.2
-
B - Fitted 2012 Cab Model...................................................................................................
.2
-
.6
.9
A - For Wagon Model..........................................................................................................
.3
-
B - Fitted 2012 Cab Model...................................................................................................
.3
-
HINGE, HOOD - REPLACE
SKIRT, FRONT FENDER INNER - REPLACE
ADD:
LEFT
B1861
ADD:
BOTH
B1867
ADD:
FENDER, FRONT - R&R OR REPLACE
RIGHT
B1870
.7
.7
LEFT
B1871
.7
.7
.2
-
ADD:
A - Fitted 2012 Cab Model...................................................................................................
BUMPERS, DOORS AND EXTERIOR TRIM B - 9
BUMPER AND FRONT END
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
FENDER, FRONT - ALIGN
RIGHT
B1880
.3
.3
LEFT
B1881
.3
.3
RIGHT
B1890
.2
.2
LEFT
B1891
.2
.2
BOTH
B1897
.3
.3
A - To Replace Front Bumper Extension One.....................................................................
.2
.2
B - To Replace Front Bumper Extension Two.....................................................................
.4
.4
.3
.4
A - For Wagon Model..........................................................................................................
.1
-
B - Fitted 2012 Cab Model...................................................................................................
.2
-
.3
.4
A - For Wagon Model..........................................................................................................
.1
-
B - Fitted 2012 Cab Model...................................................................................................
.2
-
WHEEL OPENING EXTENSION, FRONT - REPLACE
ADD:
SKIRT, REAR FENDER INNER - REPLACE
RIGHT
B1901
ADD:
LEFT
B1902
ADD:
PLATE, SKID - REPLACE
FRONT
B1905
.3
-
REAR
B1906
.3
-
B1932
.5
.5
.3
-
CROSSMEMBER, TRANSMISSION MOUNTING - R&R OR REPLACE
ADD:
A - Fitted 2012 Cab Model...................................................................................................
STEP ASSEMBLY, BODY SIDE - REPLACE
RIGHT
B1940
.5
.5
LEFT
B1941
.5
.5
B - 10 BUMPERS, DOORS AND EXTERIOR TRIM
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
DOOR ASSEMBLY, FRONT - ALIGN
RIGHT
B4000
.6
.6
LEFT
B4001
.6
.6
RIGHT
B4005
1.2
1.2
LEFT
B4006
1.2
1.2
RIGHT UPPER
B4012
.4
.4
LEFT UPPER
B4013
.4
.4
RIGHT LOWER
B4014
.4
.4
LEFT LOWER
B4015
.4
.4
RIGHT
B4070
.4
.4
LEFT
B4071
.4
.4
RIGHT
B4120
.1
.3
A - Fitted 2003 Cab Model...................................................................................................
.2
-
B - With Passive Entry and Start System............................................................................
.2
-
C - Diagnosis Time..............................................................................................................
.3
-
.1
.3
.2
-
.7
.8
.1
-
DOOR ASSEMBLY, FRONT - R&R
HINGE, FRONT DOOR (BOLT ON) - REPLACE
INC: Adjust door lock striker plate and door assembly to door opening.
CHECK ASSEMBLY, FRONT DOOR - REPLACE
HANDLE, FRONT DOOR OUTSIDE - REPLACE
ADD:
LEFT
B4121
ADD:
A - Fitted 2003 Cab Model...................................................................................................
CYLINDER SET, LOCK - REPLACE
B4170
ADD:
A - For Wagon Model..........................................................................................................
CYLINDER, FRONT DOOR LOCK - R&R OR REPLACE
RIGHT
B4180
.3
.3
LEFT
B4181
.3
.3
BUMPERS, DOORS AND EXTERIOR TRIM B - 11
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
STRIKER, FRONT DOOR LOCK - REPLACE
DOES NOT INC: Aligning door assembly to door opening.
RIGHT
B4240
.2
.2
LEFT
B4241
.2
.2
RIGHT
B4260
.6
.6
LEFT
B4261
.6
.6
RIGHT
B4280
.2
.2
LEFT
B4281
.2
.2
RIGHT
B4340
.3
.3
LEFT
B4341
.3
.3
RIGHT
B4350
.2
.2
LEFT
B4351
.2
.2
RIGHT
B4360
.6
.6
LEFT
B4361
.6
.6
RIGHT
B4390
.2
.2
LEFT
B4391
.2
.2
RIGHT
B4400
.3
.3
LEFT
B4401
.3
.3
LOCK, FRONT DOOR - R&R OR REPLACE
HANDLE, FRONT DOOR INSIDE OPENING - R&R OR REPLACE
CHECK ASSEMBLY, REAR DOOR - REPLACE
KNOB, FRONT DOOR INSIDE LOCKING - REPLACE
ROD, FRONT DOOR INSIDE LOCKING - R&R OR REPLACE
DOOR OPENING EXTENSION, REAR - REPLACE
DOOR ASSEMBLY, REAR - ALIGN
B - 12 BUMPERS, DOORS AND EXTERIOR TRIM
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
DOOR ASSEMBLY, REAR - R&R
RIGHT
B4405
1.2
1.2
LEFT
B4406
1.2
1.2
RIGHT UPPER
B4412
.4
.4
LEFT UPPER
B4413
.4
.4
RIGHT LOWER
B4414
.4
.4
LEFT LOWER
B4415
.4
.4
RIGHT
B4520
.1
.4
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.4
-
B - For Wagon Model..........................................................................................................
.3
-
.1
.4
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.4
-
B - For Wagon Model..........................................................................................................
.3
-
HINGE, REAR DOOR (BOLT ON) - REPLACE
HANDLE, REAR DOOR OUTSIDE - REPLACE
ADD:
LEFT
B4521
ADD:
STRIKER, REAR DOOR LOCK - REPLACE
RIGHT
B4640
.2
.2
LEFT
B4641
.2
.2
RIGHT
B4660
.4
.4
.1
-
.4
.4
.1
-
LOCK, REAR DOOR - R&R OR REPLACE
ADD:
A - For Pick Up Model..........................................................................................................
LEFT
B4661
ADD:
A - For Pick Up Model..........................................................................................................
HANDLE, REAR DOOR INSIDE OPENING - R&R OR REPLACE
RIGHT
B4700
.2
.2
LEFT
B4701
.2
.2
BUMPERS, DOORS AND EXTERIOR TRIM B - 13
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
KNOB, REAR DOOR INSIDE LOCKING - REPLACE
RIGHT
B4720
.2
.2
LEFT
B4721
.2
.2
RIGHT
B4730
.4
.4
.1
-
.4
.4
.1
-
ROD, REAR DOOR INSIDE LOCKING - R&R OR REPLACE
ADD:
A - For Pick Up Model..........................................................................................................
LEFT
B4731
ADD:
A - For Pick Up Model..........................................................................................................
PANEL ASSEMBLY, SIDE ACCESS - ALIGN
RIGHT
B4800
.3
-
LEFT
B4801
.3
-
RIGHT
B4803
1.4
-
LEFT
B4804
1.4
-
RIGHT UPPER
B4806
.4
-
LEFT UPPER
B4807
.4
-
RIGHT LOWER
B4808
.4
-
LEFT LOWER
B4809
.4
-
RIGHT
B4812
.2
-
LEFT
B4813
.2
-
RIGHT UPPER
B4815
.3
-
LEFT UPPER
B4816
.3
-
RIGHT LOWER
B4817
.5
-
LEFT LOWER
B4818
.5
-
PANEL ASSEMBLY, SIDE ACCESS - R&R
HINGE, SIDE ACCESS PANEL - REPLACE
STRIKER, SIDE ACCESS PANEL LOCK - REPLACE
LOCK, SIDE ACCESS PANEL - R&R OR REPLACE
B - 14 BUMPERS, DOORS AND EXTERIOR TRIM
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
HANDLE, SIDE ACCESS PANEL INSIDE OPENING - R&R OR REPLACE
RIGHT
B4821
.7
-
LEFT
B4822
.7
-
RIGHT
B4824
.7
-
LEFT
B4825
.7
-
B5300
.7
-
RIGHT
B5450
.2
.2
LEFT
B5451
.2
.2
BOTH
B5457
.3
.3
TAILGATE ASSEMBLY, REAR BODY - ALIGN
B5700
.2
-
TAILGATE ASSEMBLY, REAR BODY - REPLACE
B5705
.5
-
RIGHT
B5710
.2
-
LEFT
B5711
.2
-
RIGHT
B5720
.2
-
LEFT
B5721
.2
-
BOTH
B5727
.2
-
RIGHT
B5820
.2
-
LEFT
B5821
.2
-
BOTH
B5827
.2
-
B5830
.3
-
ROD, SIDE ACCESS PANEL INSIDE LOCKING - R&R OR REPLACE
BOX, PICKUP - ALIGN AND/OR R&R
SUPPORT, REAR COMPARTMENT LID AND/OR TAILGATE COUNTERBALANCE
(GAS TUBE) - REPLACE
HINGE, TAILGATE, REAR BODY - REPLACE
LINK ASSY, TAILGATE, REAR BODY - R&R OR REPLACE
STRIKER, TAILGATE LOCK, REAR BODY - R&R OR REPLACE
LOCK, TAILGATE, REAR BODY - R&R OR REPLACE
BUMPERS, DOORS AND EXTERIOR TRIM B - 15
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
B5835
.3
-
B5850
.2
-
B6000
.2
.2
ONE PIECE
B6108
.6
.6
RIGHT
B6112
.5
.5
LEFT
B6113
.5
.5
OUTSIDE
B6160
.3
.3
B6180
.2
.2
B6191
.2
.2
LOCK, BACK DOOR - R&R OR REPLACE
B6197
.3
.3
LID, FUEL FILLER - REPLACE
B6701
.2
.2
CABLE, RELEASE, FUEL FILLER LID - REPLACE
B6702
.9
1.0
.1
-
.1
.3
.2
-
HANDLE ASSEMBLY, TAIL GATE, OUTSIDE - REPLACE
RUBBER, BUMPER, SIDEGATE AND/OR TAILGATE - REPLACE
ONE OR ALL
DOOR ASSEMBLY, BACK DOOR - ALIGN
DOOR ASSEMBLY, BACK DOOR - R&R
HINGE, BACK DOOR - REPLACE
HANDLE, BACK DOOR - REPLACE
CYLINDER, BACK DOOR LOCK - R&R OR REPLACE
STRIKER, BACK DOOR LOCK - REPLACE
CENTER
ADD:
A - For Wagon Model..........................................................................................................
KNOB, RELEASE CABLE, FUEL FILLER LID - REPLACE
B6703
ADD:
A - Fitted 2003 Cab Model...................................................................................................
B - 16 BUMPERS, DOORS AND EXTERIOR TRIM
DOORS AND REAR COMPARTMENT
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
WHEEL OPENING EXTENSION, REAR - REPLACE
RIGHT
B6710
.2
.2
LEFT
B6711
.2
.2
BOTH
B6717
.3
.3
BUMPERS, DOORS AND EXTERIOR TRIM B - 17
EXTERIOR TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
B7100
.2
.2
B7390
.2
.2
B7790
.2
.3
A - Additional Each Moulding...............................................................................................
.2
.2
B - For Wagon Model..........................................................................................................
.1
-
.2
.2
.2
.2
EMBLEM, GRILLE - REPLACE
INC: R&R grille if necessary.
PLATE, MODEL DESIGNATION - REPLACE
ONE
MOULDING, ROOF - REPLACE
ADD:
MOULDING, DOOR - REPLACE
B7795
ADD:
A - Additional Each Moulding...............................................................................................
C BODY INTERIOR
C
C - 10 GLASS, INTERIOR TRIM AND SEATS
GLASS AND ATTACHING PARTS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
C0020
.5
.5
C0034
1.2
1.2
C0040
.2
.2
RIGHT
C0100
.5
.5
LEFT
C0101
.5
.5
RIGHT
C0110
.4
.4
LEFT
C0111
.4
.4
RIGHT
C0114
.4
.4
LEFT
C0115
.4
.4
RIGHT
C0120
.2
.2
LEFT
C0121
.2
.2
RIGHT
C0130
.2
.2
LEFT
C0131
.2
.2
GLASS, WINDSHIELD - RESEAL
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
INC: Water test.
GLASS, WINDSHIELD - REPLACE
INC: Water test and extra man's assistance.
ONE PIECE
MIRROR, INSIDE REAR VIEW - REPLACE
GLASS, FRONT DOOR - ALIGN
GLASS, FRONT DOOR - R&R
INC: Necessary lubrication and adjustments.
GLASS, FRONT DOOR - REPLACE
INC: Necessary lubrication and adjustments.
WAIST SEAL AND/OR RETAINER, FRONT DOOR WINDOW INNER R&R OR REPLACE
WAIST SEAL, FRONT DOOR WINDOW OUTER - R&R OR REPLACE
GLASS, INTERIOR TRIM AND SEATS C - 11
GLASS AND ATTACHING PARTS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CHANNEL, FRONT DOOR WINDOW RUN - R&R OR REPLACE
INC: R&R door glass as necessary.
RIGHT
C0140
.5
.5
LEFT
C0141
.5
.5
RIGHT
C0160
.5
.5
LEFT
C0161
.5
.5
RIGHT
C0170
.2
-
LEFT
C0171
.2
-
RIGHT
C0180
.5
-
LEFT
C0181
.5
-
RIGHT
C0182
.5
.5
LEFT
C0183
.5
.5
RIGHT
C0300
.3
.3
LEFT
C0301
.3
.3
RIGHT
C0310
.5
.6
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.2
-
B - For Wagon Model..........................................................................................................
.1
-
.5
.6
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.2
-
B - For Wagon Model..........................................................................................................
.1
-
EXTENSION, FRONT DOOR WINDOW CHANNEL (AT REAR) - R&R OR REPLACE
HANDLE, FRONT DOOR WINDOW REGULATOR - REPLACE
REGULATOR, FRONT DOOR WINDOW (MANUAL) - R&R OR REPLACE
INC: D&C glass, prop in up position and transfer motor where necessary.
REGULATOR, FRONT DOOR WINDOW (POWER) - R&R OR REPLACE
INC: D&C glass, prop in up position and transfer motor where necessary.
GLASS, REAR DOOR - ALIGN
GLASS, REAR DOOR - R&R
ADD:
LEFT
C0311
ADD:
C - 12 GLASS, INTERIOR TRIM AND SEATS
GLASS AND ATTACHING PARTS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.5
.6
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.2
-
B - For Wagon Model..........................................................................................................
.1
-
.5
.6
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.2
-
B - For Wagon Model..........................................................................................................
.1
-
GLASS, REAR DOOR - REPLACE
RIGHT
C0314
ADD:
LEFT
C0315
ADD:
WAIST SEAL, REAR DOOR WINDOW INNER - R&R OR REPLACE
RIGHT
C0320
.2
.2
LEFT
C0321
.2
.2
RIGHT
C0330
.2
.2
LEFT
C0331
.2
.2
RIGHT
C0340
.5
.5
.2
-
.5
.5
.2
-
WAIST SEAL, REAR DOOR WINDOW OUTER - R&R OR REPLACE
CHANNEL, REAR DOOR WINDOW RUN - R&R OR REPLACE
ADD:
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
LEFT
C0341
ADD:
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
HANDLE, REAR DOOR WINDOW REGULATOR - REPLACE
RIGHT
C0370
.2
-
LEFT
C0371
.2
-
RIGHT
C0380
.7
-
LEFT
C0381
.7
-
REGULATOR, REAR DOOR WINDOW (MANUAL) - R&R OR REPLACE
GLASS, INTERIOR TRIM AND SEATS C - 13
GLASS AND ATTACHING PARTS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.4
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.4
-
B - For Wagon Model..........................................................................................................
.1
-
.3
.4
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.4
-
B - For Wagon Model..........................................................................................................
.1
-
REGULATOR, REAR DOOR WINDOW (POWER) - R&R OR REPLACE
RIGHT
C0382
ADD:
LEFT
C0383
ADD:
GLASS, REAR DOOR STATIONARY - REPLACE
RIGHT
C0430
.7
.7
LEFT
C0431
.7
.7
RIGHT
C0440
.3
-
LEFT
C0441
.3
-
RIGHT
C0443
.4
-
LEFT
C0444
.4
-
RIGHT
C0446
.4
-
LEFT
C0447
.4
-
RIGHT
C0449
.3
-
LEFT
C0450
.3
-
RIGHT
C0494
.7
.7
LEFT
C0495
.7
.7
GLASS, SIDE ACCESS PANEL - ALIGN
GLASS, SIDE ACCESS PANEL - R&R
GLASS, SIDE ACCESS PANEL - REPLACE
LATCH, SIDE ACCESS PANEL GLASS - REPLACE
CHANNEL, QUARTER STATIONARY GLASS (RUBBER) - REPLACE
C - 14 GLASS, INTERIOR TRIM AND SEATS
GLASS AND ATTACHING PARTS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
GLASS, QUARTER STATIONARY - RESEAL
RIGHT
C0500
.7
.7
LEFT
C0501
.7
.7
RIGHT
C0510
.7
.7
LEFT
C0511
.7
.7
RIGHT
C0530
.7
-
LEFT
C0531
.7
-
RIGHT UPPER
C0540
.7
-
LEFT UPPER
C0541
.7
-
RIGHT LOWER
C0544
.7
-
LEFT LOWER
C0545
.7
-
.1
-
GLASS, QUARTER STATIONARY - R&R OR REPLACE
GLASS, QUARTER SWING OUT - REPLACE
INC: Transfer necessary parts.
HINGE, QUARTER GLASS SWING OUT - REPLACE
ADD:
A - To Replace Both............................................................................................................
LATCH, QUARTER GLASS SWING OUT - REPLACE
RIGHT
C0550
.8
-
LEFT
C0551
.8
-
C0650
.5
.5
C0660
.4
.8
.4
-
GLASS, BACK WINDOW - RESEAL
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
INC: Water test.
GLASS, BACK WINDOW - REPLACE
INC: R&R rubber channel where nec, water test and extra man's
assistance.
ADD:
A - For Wagon Model..........................................................................................................
GLASS, INTERIOR TRIM AND SEATS C - 15
WEATHER STRIPS AND FINISHER
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
WEATHER STRIP, FRONT DOOR - ALIGN OR REPLACE
RIGHT
C1060
.3
.3
LEFT
C1061
.3
.3
RIGHT
C1120
.2
.3
.1
-
.2
.3
.1
-
WEATHER STRIP, REAR DOOR - ALIGN OR REPLACE
ADD:
A - For Wagon Model..........................................................................................................
LEFT
C1121
ADD:
A - For Wagon Model..........................................................................................................
WEATHER STRIP, SIDE ACCESS PANEL - ALIGN OR REPLACE
RIGHT
C1130
.5
-
LEFT
C1131
.5
-
RIGHT
C1133
.3
-
LEFT
C1134
.3
-
RIGHT
C1240
.7
-
LEFT
C1241
.7
-
C1345
.2
.2
RIGHT
C1603
.3
.3
LEFT
C1604
.3
.3
RIGHT
C1610
.2
.3
.1
-
WEATHER STRIP, SIDE ACCESS PANEL GLASS - ALIGN OR REPLACE
WEATHER STRIP, QUARTER WINDOW (SWING OUT) - ALIGN OR REPLACE
WEATHER STRIP, BACK DOOR (BODY SIDE OPENING SURROUND)
- ALIGN OR REPLACE
FINISHER, FRONT DOOR - ALIGN OR REPLACE
FINISHER, REAR DOOR - ALIGN OR REPLACE
ADD:
A - For Wagon Model..........................................................................................................
(CONTINUED)
C - 16 GLASS, INTERIOR TRIM AND SEATS
INTERIOR TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.3
.1
-
(CONT'D)
LEFT
C1611
ADD:
A - For Wagon Model..........................................................................................................
SUNSHADE AND/OR SUPPORT - R&R OR REPLACE
RIGHT
C2020
.2
.2
LEFT
C2021
.2
.2
C2100
.2
.2
.3
.3
C2120
.2
.2
C2160
.2
.2
C2200
.2
.2
REAR RIGHT
C2250
.2
.2
REAR LEFT
C2251
.2
.2
C2350
.2
.2
C2361
.2
.3
.1
-
C2362
.2
.2
C2470
.2
.4
.2
-
LOCK, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE
ADD:
A - To Code Cylinder...........................................................................................................
HINGE AND/OR STRIKER, GLOVE COMPARTMENT INSTRUMENT
PANEL - ADJUST OR REPLACE
BOX, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE
INC: D&C door assembly.
ASH TRAY, INSTRUMENT PANEL - R&R OR REPLACE
ASH TRAY, DOOR TRIM PAD - R&R OR REPLACE
TRIM COVER, INSTRUMENT, LOWER (DRIVER) - REPLACE
KNEE BOLSTER - REPLACE
DRIVER
ADD:
A - For Wagon Model..........................................................................................................
PASSENGER
CLUSTER, CENTER, INSTRUMENT PANEL - R&R OR REPLACE
ADD:
A - Fitted 2003 Cab Model...................................................................................................
GLASS, INTERIOR TRIM AND SEATS C - 17
INTERIOR TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
2.4
2.8
.4
-
C2480
.5
.5
INSTRUMENT PANEL ASSEMBLY - R&R
C2500
1.9
1.9
DOOR AND/OR PAD, CONSOLE COMPARTMENT - R&R OR REPLACE
C2740
.2
.2
FRONT
C2860
.2
.2
REAR
C2861
.2
.2
ONE PIECE
C3098
.5
.5
ONE PIECE
C3108
.7
1.5
A - To Replace Headlining for Crew Cab.............................................................................
.5
-
B - To Replace Headlining for Extend Cab..........................................................................
.2
-
C - For Wagon Model..........................................................................................................
.5
-
D - Fitted 2003 Cab Model...................................................................................................
.3
-
PAD, INSTRUMENT PANEL COVER - REPLACE
C2475
INC: R&R instrument panel assembly, and transfer ducts, harnesses,
reinforcement, SRS infrator and other parts as necessary.
ADD:
A - Fitted 2003 Cab Model...................................................................................................
PAD, INSTRUMENT PANEL COVER - REPAIR
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
CONSOLE ASSEMBLY - R&R OR REPLACE
HEADLINING ASSEMBLY - REPAIR
HEADLINING ASSEMBLY - R&R
ADD:
TRIM ASSEMBLY, A-PILLAR - R&R OR REPLACE
RIGHT
C3220
.2
.2
LEFT
C3221
.2
.2
C - 18 GLASS, INTERIOR TRIM AND SEATS
INTERIOR TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
TRIM ASSEMBLY, FRONT DOOR - R&R OR REPLACE
RIGHT; ONE PIECE
C3348
.2
.2
LEFT; ONE PIECE
C3358
.2
.2
.1
-
ADD:
A - For Window Manual Type..............................................................................................
PLATE AND/OR INSERT, FRONT DOOR SILL - REPLACE
RIGHT
C3360
.2
.2
LEFT
C3361
.2
.2
C3370
.2
-
RIGHT
C3380
.2
.2
LEFT
C3381
.2
.2
RIGHT
C3400
.2
.2
LEFT
C3401
.2
.2
RIGHT
C3420
.3
.3
LEFT
C3421
.3
.3
RIGHT
C3450
.3
.3
LEFT
C3451
.3
.3
RIGHT
C3540
.2
.2
LEFT
C3541
.2
.2
RIGHT
C3543
.2
-
LEFT
C3544
.2
-
REST, FOOT - R&R OR REPLACE
TRIM COVER, KICKING PLATE - REPLACE
GARNISH, DOOR MIRROR, FRONT - REPLACE
SHEET, WATERPROOF, FRONT DOOR - REPLACE
SHEET, WATERPROOF, REAR DOOR - REPLACE
TRIM ASSEMBLY, REAR DOOR - R&R OR REPLACE
TRIM ASSEMBLY, SIDE ACCESS PANEL - R&R OR REPLACE
GLASS, INTERIOR TRIM AND SEATS C - 19
INTERIOR TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
PLATE AND/OR INSERT, REAR DOOR SILL - REPLACE
RIGHT
C3560
.2
.2
LEFT
C3561
.2
.2
UPPER RIGHT
C4020
.3
.3
UPPER LEFT
C4021
.3
.3
LOWER RIGHT
C4025
.2
.2
LOWER LEFT
C4026
.2
.2
RIGHT
C4030
.4
.5
LEFT
C4031
.4
.5
A - For Regular Cab.............................................................................................................
.2
-
B - With Center Jack Cover.................................................................................................
.1
-
C - For Extend Cab (Fitted 2003 Cab Model)......................................................................
.2
-
D - For Wagon Model..........................................................................................................
.1
-
TRIM ASSEMBLY, BC-PILLAR - R&R OR REPLACE
TRIM ASSEMBLY, QUARTER UPPER - R&R OR REPLACE
ADD:
TRIM ASSEMBLY, QUARTER LOWER - R&R OR REPLACE
RIGHT
C4035
.4
.4
LEFT
C4036
.4
.4
A - For Regular Cab.............................................................................................................
.1
-
B - With Center Jack Cover.................................................................................................
.1
-
.3
-
.1
-
.2
.2
ADD:
TRIM COVER, CAB BACK - R&R OR REPLACE
C4050
ADD:
A - For Regular Cab.............................................................................................................
TRIM ASSEMBLY, BACK DOOR (SINGLE DOOR TYPE) - R&R OR REPLACE
C4080
C - 20 GLASS, INTERIOR TRIM AND SEATS
INTERIOR TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.8
1.0
A - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
1.2
-
B - For Wagon Model..........................................................................................................
.2
-
C - For Crew Cab Model (Fitted 2012 Cab Model)..............................................................
.6
-
CARPET OR VINYL MAT - REPLACE
FRONT
C4202
ADD:
LUGGAGE
C4203
1.3
1.3
ONE
C4300
.2
.2
ONE OR ALL
C4350
.2
.2
ONE OR ALL
C4400
.2
.2
ASSIST GRIP, FRONT - R&R OR REPLACE
ASSIST GRIP, REAR - R&R OR REPLACE
COAT HANGER, FRONT AND/OR REAR - R&R OR REPLACE
GLASS, INTERIOR TRIM AND SEATS C - 21
SEATS AND SEAT TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
C4710
.2
-
BUCKET SEAT, ONE SIDE; PASSENGER
C6010
.3
.3
BUCKET SEAT, ONE SIDE; DRIVER
C6011
.3
.3
.1
.1
COVER ASSEMBLY, JACK STORAGE - REPLACE
SLIDE ADJUSTER ASSEMBLY, FRONT SEAT MANUAL - R&R OR REPLACE
ADD:
A - To Replace Both Sides Same Seat................................................................................
RECLINING ADJUSTER ASSEMBLY, FRONT SEAT MANUAL - R&R OR REPLACE
BUCKET SEAT ; PASSENGER
C6110
.3
.3
BUCKET SEAT ; DRIVER
C6111
.3
.3
PASSENGER
C6690
.2
.2
DRIVER
C6691
.2
.2
BUCKET SEAT; PASSENGER
C6820
.2
.2
BUCKET SEAT; DRIVER
C6821
.2
.2
C6830
.3
-
BUCKET SEAT; PASSENGER
C6870
1.0
1.0
BUCKET SEAT; DRIVER
C6871
1.1
1.1
BUCKET SEAT; PASSENGER
C7050
.7
.7
BUCKET SEAT; DRIVER
C7051
.7
.7
RIGHT
C7230
.2
.2
LEFT
C7231
.2
.2
HEADREST, FRONT SEAT - R&R OR REPLACE
SEAT ASSEMBLY, FRONT - REPLACE
BENCH SEAT ASSEMBLY, FRONT - REPLACE
COVER AND/OR PAD, FRONT SEAT, CUSHION - R&R OR REPLACE
COVER AND/OR PAD, FRONT SEAT, BACK - R&R OR REPLACE
HEADREST, REAR SEAT - R&R OR REPLACE
C - 22 GLASS, INTERIOR TRIM AND SEATS
SEATS AND SEAT TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.0
1.0
.2
-
C7253
.2
-
C7260
.6
1.0
A - For Crew Cab.................................................................................................................
.5
-
B - For Wagon Model..........................................................................................................
.4
-
.6
-
.5
-
C7700
.3
-
C7809
.3
-
RIGHT
C7910
.4
.4
LEFT
C7911
.4
.4
C7920
.4
.4
.3
.3
COVER AND/OR PAD, REAR SEAT, CUSHION - R&R OR REPLACE
C7250
ADD:
A - For Pick Up Model..........................................................................................................
CUSHION; 1 PIECE TYPE
COVER AND/OR PAD, REAR SEAT, BACK - R&R OR REPLACE
INC: Replace frame as necessary.
ADD:
COVER AND/OR PAD, REAR SEAT, BACK - R&R OR REPLACE
INC: Replace frame as necessary.
BACK; 1 PIECE TYPE
C7278
ADD:
A - For Crew Cab.................................................................................................................
SEAT ASSEMBLY, REAR BENCH - R&R OR REPLACE
SEAT ASSEMBLY, REAR BENCH - R&R OR REPLACE
CUSHION 1 PIECE/BACK 1 OR 2 PIECE TYPE
SLIDE ADJUSTER ASSEMBLY, REAR SEAT - REPLACE
CONTROL CABLE, REAR SEAT DEVICE - REPLACE
ADD:
A - Additional Each Control Cable.......................................................................................
RECLINING ADJUSTER ASSEMBLY, REAR SEAT - REPLACE
COVER AND/OR PAD, 3RD SEAT, CUSHION - REPLACE (BENCH TYPE)
RIGHT
C7950
1.1
1.1
LEFT
C7951
1.1
1.1
C8350
.6
.6
GLASS, INTERIOR TRIM AND SEATS C - 23
SEATS AND SEAT TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
COVER AND/OR PAD, 3RD SEAT, BACK - REPLACE (BENCH TYPE)
C8351
.6
.6
HINGE, 3RD SEAT - REPLACE (BENCH TYPE)
C8355
.8
.8
C9020
.2
.3
.1
-
.2
.3
.1
-
.2
-
.1
-
.4
.4
.2
-
.4
.4
.2
-
.6
.6
.3
-
.2
.4
.2
-
.2
.4
.2
-
.2
-
SEAT BELT, FRONT BUCKLE SIDE - REPLACE
RIGHT
ADD:
A - For Wagon Model..........................................................................................................
LEFT
C9021
ADD:
A - For Wagon Model..........................................................................................................
CENTER
C9022
ADD:
A - For Bucket Seat Type....................................................................................................
SEAT BELT, FRONT RETRACTOR SIDE - R&R OR REPLACE
RIGHT
C9040
ADD:
A - For Regular Cab or Extend Cab (Fitted 2003 Cab Model).............................................
LEFT
C9041
ADD:
A - For Regular Cab or Extend Cab (Fitted 2003 Cab Model).............................................
BOTH
C9047
ADD:
A - For Regular Cab or Extend Cab (Fitted 2003 Cab Model).............................................
GUIDE AND/OR COVER, SEAT BELT - R&R OR REPLACE
RIGHT
C9050
ADD:
A - For Wagon Model..........................................................................................................
LEFT
C9051
ADD:
A - For Wagon Model..........................................................................................................
SEAT BELT, FRONT CENTER - REPLACE
C9100
C - 24 GLASS, INTERIOR TRIM AND SEATS
SEATS AND SEAT TRIM
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
SEAT BELT, REAR (BUCKLE SIDE) - REPLACE
RIGHT
C9190
.3
.3
LEFT
C9191
.3
.3
CENTER
C9192
.2
.2
.1
-
C9193
.2
.2
C9200
.5
.7
A - For Regular Cab.............................................................................................................
.1
-
B - For Wagon Model..........................................................................................................
.2
-
.5
.7
A - For Regular Cab.............................................................................................................
.1
-
B - For Wagon Model..........................................................................................................
.2
-
ADD:
A - For Pick Up Model (C9192 Only)...................................................................................
SEAT BELT, REAR (TONGUE SIDE) - REPLACE
SEAT BELT, REAR (RETRACTOR SIDE) - REPLACE
RIGHT
ADD:
LEFT
C9201
ADD:
CENTER
C9202
.3
-
RIGHT
C9230
.2
.2
LEFT
C9231
.2
.2
SEAT BELT, 3RD (TONGUE SIDE) - REPLACE
C9235
.2
.2
BOLTS, FASTENERS AND FITTINGS - TIGHTEN
C9990
.2
.2
SEAT BELT, 3RD (BUCKLE SIDE) - REPLACE
NOTE: This operation is to be used on body items only. For chassis
items refer to operation number E1990 of the frame section.
D HEATING AND AIR CONDITIONING
D
HEATING AND AIR CONDITIONING D – 3
D - 4 HEATING AND AIR CONDITIONING
HEATING AND AIR CONDITIONING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
FOR THOSE OPERATIONS IN THIS SECTION WHICH HAVE AN "ADD"
FOR DISCHARGE/CHARGE OF THE A/C SYSTEM, THIS "ADD" CAN
ONLY BE USED ONCE PER REPAIR ORDER.
CONTROL ASSEMBLY - REPLACE
HEATER ONLY
D0360
.7
-
WITH A/C
D0362
.3
.5
A - Fitted 2003 Cab Pick Up Model (D0362 Only)...............................................................
.4
-
B - For Wagon Model..........................................................................................................
.2
-
ADD:
AUTO A/C
D0363
.2
-
HEATER (NON A/C) AIR INLET
D0436
.7
-
HEATER (NON A/C) TEMPERATURE
D0437
.7
-
HEATER DEFROSTER
D0438
.7
.7
AIR CONDITIONING TEMPERATURE
D0447
.7
.7
AIR SOURCE SELECT
D0448
.5
.5
D0500
.2
-
HEATER ONLY
D1000
.2
-
WITH A/C
D1002
.2
.2
D1010
.2
-
D1027
.2
.2
D1100
.2
-
CABLES, AIR DISTRIBUTION - R&R OR REPLACE
INC: Fabricate new cable and adjust.
ACTUATOR, AIR DISTRIBUTION - REPLACE
RESISTOR, BLOWER MOTOR - REPLACE
FILTER, BLOWER UNIT - REPLACE
RELAY, A/C - REPLACE
A/C
SENSOR, SUN - REPLACE
HEATING AND AIR CONDITIONING D - 5
HEATING AND AIR CONDITIONING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
.5
.5
.4
.4
.5
.5
SWITCH, COMPRESSOR CUT-OFF - REPLACE
DUAL PRESSURE
D1116
ADD:
A - Discharge/Charge A/C. System.....................................................................................
SWITCH, THERMOSTATIC CONTROL - REPLACE
D1140
ADD:
A - Discharge/Charge A/C. System.....................................................................................
MOTOR AND/OR FAN - R&R OR REPLACE
BLOWER (HEATER ONLY)
D1320
.2
-
BLOWER (WITH A/C)
D1322
.2
.2
A/C CONDENSER
D1323
.6
.6
RIGHT
D1420
1.9
1.9
LEFT
D1421
1.9
1.9
CENTER
D1426
2.0
2.0
RIGHT
D1440
.2
.2
LEFT
D1441
.2
.2
2.0
-
NOZZLE ASSEMBLY, DEFROSTER - REPLACE
DEFLECTOR (GRILLE), AIR - REPLACE
ADD:
A - Fitted 2012 Cab Model...................................................................................................
RIGHT CENTER
D1442
.3
.3
LEFT CENTER
D1443
.3
.3
RIGHT
D1520
2.1
2.1
LEFT
D1521
2.1
2.1
CENTER
D1526
2.1
2.1
REAR
D1528
.7
.7
DUCT ASSEMBLY, VENTILATION - REPLACE
D - 6 HEATING AND AIR CONDITIONING
HEATING AND AIR CONDITIONING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CASE, HEATER - REPLACE
INC: R&R instrument panel assembly and cross beam.
HEATER ONLY
D2220
1.9
-
WITH A/C
D2222
2.0
2.0
.5
.5
.3
.3
.5
.5
ADD:
A - Discharge/Charge A/C. System.....................................................................................
CASE, EVAPORATOR - R&R OR REPLACE
D2510
ADD:
A - Discharge/Charge A/C. System.....................................................................................
HOSES, HEATER (WITHOUT AIR CONDITIONING) - REPLACE
ONE
D2746
.5
-
BOTH
D2747
.6
-
ALL HOSES
D2787
.6
.6
HEATER ONLY
D2800
1.9
-
WITH A/C
D2802
2.0
2.0
.5
.5
HOSES, HEATER (WITH AIR CONDITIONING) - REPLACE
CORE, HEATER - R&R
ADD:
A - Discharge/Charge A/C. System.....................................................................................
CORE, HEATER - REPLACE
HEATER ONLY
D2820
1.9
-
WITH A/C
D2822
2.0
2.0
.5
.5
.3
.3
ADD:
A - Discharge/Charge A/C. System.....................................................................................
A/C SYSTEM - LEAK TEST DISCHARGED SYSTEM
NOTE: This labor operation to be used when necessary to partially
charge 1 lb. max. the A/C system to locate a leak. Other labor hours
not allowed with this labor operation. This operation may only be
claimed in conjunction with a failed part operation.
D3000
HEATING AND AIR CONDITIONING D - 7
HEATING AND AIR CONDITIONING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
SEALS, REFRIGERANT O-RING - REPLACE
COMPRESSOR MANIFOLD
D3040
.3
.3
CONDENSER
D3041
.2
.2
CONDENSER OUTLET PIPE
D3042
.2
.2
EXPANSION VALVE
D3043
.3
.3
EVAPORATOR
D3044
.3
.3
FILTER DRYER
D3048
.2
.2
.5
.5
ADD:
A - Discharge/Charge A/C. System.....................................................................................
HOSES AND/OR LINES, REFRIGERANT - REPLACE
INC: Assemble service hose as necessary.
COMPRESSOR DISCHARGE
D3082
.3
.3
COMPRESSOR SUCTION
D3089
.3
.3
FILTER DRYER OUTLET
D3097
.3
.3
CONDENSOR OUTLET
D3098
.7
-
.5
.5
.7
1.7
A - Discharge/Charge A/C. System.....................................................................................
.5
.5
B - With Intercooler (Fitted 2003 Cab Model)......................................................................
.9
.9
C - With Condenser Fan Moter............................................................................................
.1
.1
D - For Wagon Model..........................................................................................................
1.0
-
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.6
-
F - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.3
-
.3
.3
.5
.5
.3
.3
.5
.5
ADD:
A - Discharge/Charge A/C. System.....................................................................................
CONDENSER - REPLACE
D3140
ADD:
VALVE, EXPANSION - REPLACE
D3220
ADD:
A - Discharge/Charge A/C. System.....................................................................................
DRYER, IN-LINE FILTER - REPLACE
D3250
ADD:
A - Discharge/Charge A/C. System.....................................................................................
D - 8 HEATING AND AIR CONDITIONING
HEATING AND AIR CONDITIONING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.4
.4
.5
.5
D4020
.3
.3
D4237
.5
.5
D4240
.6
.6
A - Discharge/Charge A/C. System.....................................................................................
.5
.5
B - 6V*1 Engine...................................................................................................................
.8
.8
C - C24*E Engine................................................................................................................
.1
.1
.4
.4
A - Discharge/Charge A/C. System.....................................................................................
.5
.5
B - 6V*1 Engine...................................................................................................................
.8
.8
C - C24*E Engine................................................................................................................
.1
.1
CORE, EVAPORATOR - REPLACE
D3320
ADD:
A - Discharge/Charge A/C. System.....................................................................................
PULLEY IDLER, A/C - R&R
BRACKET (S) , COMPRESSOR MOUNTING - R&R OR REPLACE
ALL
CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR - REPLACE
INC. R&R compressor assembly.
ADD:
COMPRESSOR ASSEMBLY - REPLACE
D4440
ADD:
DRAIN HOSE, REAR COOLER - REPLACE
D5000
.4
.4
DUCTS, AIR VENTILATION, REAR COOLER - REPLACE
D5010
1.6
1.6
CORE, EVAPORATOR, REAR COOLER - REPLACE
D5020
1.8
1.8
VALVE, EXPANSION, REAR COOLER - REPLACE
D5030
1.6
1.6
GRILLES, AIR DUCT, REAR COOLER (ONE OR ALL) - REPLACE
D5050
1.5
1.5
KNOB, BLOWER SWITCH, REAR COOLER - REPLACE
D5060
.2
.2
BLOWER MOTOR ASSEMBLY, REAR COOLER - REPLACE
D5070
1.5
1.5
HEATING AND AIR CONDITIONING D - 9
HEATING AND AIR CONDITIONING
OPERATION DESCRIPTION
PIPE (1), HIGH OR LOW PRESSURE LINE, REAR COOLER - REPLACE
OPERATION
NUMBER
D5080
CAB STYLE
VIN CODE
TF*
UC*
1.2
1.2
.2
.2
ADD:
A - Each Additional..............................................................................................................
RESISTER, REAR COOLER - REPLACE
D5090
.4
.4
REAR COOLER UNIT - R&R
D5100
1.5
1.5
SWITCH, BLOWER, REAR COOLER - REPLACE
D5110
.2
.2
E WHEELS, SUSPENSION, STEERING
E
E – 2 STEERING, SUSPENSION, WHEELS AND TIRES
STEERING, SUSPENSION, WHEELS AND TIRES E – 5
E – 6 STEERING, SUSPENSION, WHEELS AND TIRES
STEERING, SUSPENSION, WHEELS AND TIRES E – 7
E - 8 STEERING, SUSPENSION, WHEELS AND TIRES
WHEELS AND TIRES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
COVER, WHEEL - REPLACE
FRONT
E0022
.2
.2
REAR
E0023
.2
.2
ALL
E0027
.3
.3
ONE
E0200
.4
.4
TWO
E0201
.6
.6
THREE
E0202
.8
.8
FOUR
E0203
1.0
1.0
ONE
E0411
.5
.5
TWO
E0412
.7
.7
THREE
E0413
.9
.9
FOUR
E0414
1.1
1.1
ONE
E0420
.3
.3
TWO
E0421
.4
.4
THREE
E0422
.5
.5
FOUR
E0423
.6
.6
RIGHT FRONT
E0474
.5
.5
LEFT FRONT
E0475
.5
.5
A - To Replace Additional Two Bolts...................................................................................
.2
.2
B - To Replace Additional Four Bolts...................................................................................
.4
.4
C - To Replace All Bolts.......................................................................................................
.6
.6
D - With ABS.......................................................................................................................
.2
.2
WHEEL - BALANCE
INC: R&R wheel and tire.
WHEEL OR TIRE - REPLACE
NOTE: Include separate tire from wheel, and wheel balance (static).
WHEEL W/TIRE - R&R OR REPLACE
INC: R&R wheel to hub.
NOTE: Does not include wheel balance (static).
BOLT, WHEEL MOUNTING - REPLACE
INC: R&R wheel and hub as an assembly.
ADD:
(CONTINUED)
STEERING, SUSPENSION, WHEELS AND TIRES E - 9
WHEELS AND TIRES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.1
.1
(CONT'D)
E - For 4x4 Model................................................................................................................
RIGHT REAR
E0484
1.3
1.3
LEFT REAR
E0485
1.3
1.3
A - To Replace Additional Two Bolts...................................................................................
.2
.2
B - To Replace Additional Four Bolts...................................................................................
.4
.4
C - To Replace All Bolts.......................................................................................................
.6
.6
ADD:
HANGER ASSY(HOLD DOWN), SPARE TIRE - R&R OR REPLACE
E0600
.2
.2
JACK AND/OR HANDLE - REPLACE
E0620
.2
.2
E - 10 STEERING, SUSPENSION, WHEELS AND TIRES
FRAME
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.5
.5
A - To Replace Additional Two Cushions............................................................................
.1
.1
B - To Replace Additional Four Cushions............................................................................
.2
.2
C - Replace All Cushions.....................................................................................................
.3
.3
E1760
.5
.5
E1770
.5
.5
E1860
.5
.5
E1990
.2
.2
CUSHION, PAD AND/OR BOLT, BODY - R&R OR REPLACE
MOUNT POSITION ONE
E1106
ADD:
CROSSMEMBER, FRAME - REPAIR
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
CROSSMEMBER, FRAME - REPLACE
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
FRAME ASSEMBLY - REPAIR
NOTE: This is a st (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
BOLTS, FASTENERS AND FITTINGS - TIGHTEN
NOTE: This operation is to be used on chassis items only. For body
items refer to operation C9990 of the seats section.
STEERING, SUSPENSION, WHEELS AND TIRES E - 11
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
TOE-IN, FRONT SUSPENSION - ADJUST
E2000
.4
.4
FRONT SUSPENSION - CHECK AND/OR ALIGN
E2020
.9
.9
RIGHT
E2140
.3
.3
LEFT
E2141
.3
.3
BOTH
E2147
.4
.4
E2160
.6
.6
INSULATOR AND/OR BRACKET, FRONT STABILIZER SHAFT AT FRAME - REPLACE
E2180
.4
.4
NUT, FRONT WHEEL HUB - REPLACE
E2200
.4
.4
A - To Replace Both............................................................................................................
.3
.3
B - For 4x4 Model................................................................................................................
.1
.1
INC: Adjust camber, caster, toe-in and trim height where applicable.
LINK AND/OR LINK BUSHINGS OR BUSHING AND/OR BRACKET,
FRONT STABILIZER SHAFT AT CONTROL ARM - R&R OR REPLACE
POLICY: P
(Except Bushing)
NOTE: Maximum time not to exceed operation number E2147.
SHAFT, FRONT STABILIZER - REPLACE
POLICY: P
INC: R&R links and bushings.
ADD:
BEARING, FRONT WHEEL - ADJUST
RIGHT
E2220
.4
.4
LEFT
E2221
.4
.4
BOTH
E2227
.6
.6
.1
.1
ADD:
A - For 4x4 Model................................................................................................................
CAP, FRONT WHEEL HUB DUST - REPLACE
RIGHT
E2230
.2
.2
LEFT
E2231
.2
.2
BOTH
E2237
.2
.2
E - 12 STEERING, SUSPENSION, WHEELS AND TIRES
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
BEARING, FRONT WHEEL - REPLACE
POLICY: T, P
INC: R&R wheel, clean and pack inner and outer bearings, replace seal, fill oiler cap.
NOTE: Maximum time not to exceed operation number E2267 & E2268.
INNER RIGHT (4 x 2)
E2240
.7
.7
INNER LEFT (4 x 2)
E2241
.7
.7
INNER RIGHT (4 x 4)
E2242
.9
.9
INNER LEFT (4 x 4)
E2243
.9
.9
INNER BOTH (4 x 2)
E2247
1.0
1.0
INNER BOTH (4 x 4)
E2248
1.4
1.4
OUTER RIGHT (4 x 2)
E2250
.7
.7
OUTER LEFT (4 x 2)
E2251
.7
.7
OUTER RIGHT (4 x 4)
E2252
.9
.9
OUTER LEFT (4 x 4)
E2253
.9
.9
OUTER BOTH (4 x 2)
E2257
1.0
1.0
OUTER BOTH (4 x 4)
E2258
1.4
1.4
INNER AND OUTER RIGHT (4 x 2)
E2260
.7
.7
INNER AND OUTER LEFT (4 x 2)
E2261
.7
.7
INNER AND OUTER RIGHT (4 x 4)
E2262
.9
.9
INNER AND OUTER LEFT (4 x 4)
E2263
.9
.9
INNER AND OUTER BOTH (4 x 2)
E2267
1.1
1.1
INNER AND OUTER BOTH (4 x 4)
E2268
1.5
1.5
RIGHT (4 x 2)
E2280
.6
.6
LEFT (4 x 2)
E2281
.6
.6
RIGHT (4 x 4)
E2282
.8
.8
LEFT (4 x 4)
E2283
.8
.8
BOTH (4 x 2)
E2287
1.0
1.0
BOTH (4 x 4)
E2291
1.3
1.3
SEAL, FRONT WHEEL BEARING - REPLACE
POLICY: P
INC: Clean, inspect and repack inner and outer bearings. Replace bearings if necessary.
STEERING, SUSPENSION, WHEELS AND TIRES E - 13
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.9
1.0
A - For 4x4 Model................................................................................................................
.2
.2
B - With ABS........................................................................................................................
.2
.2
C - For Wagon Model..........................................................................................................
.1
-
.9
1.0
A - For 4x4 Model................................................................................................................
.2
.2
B - With ABS........................................................................................................................
.2
.2
C - For Wagon Model..........................................................................................................
.1
-
1.7
1.8
A - For 4x4 Model................................................................................................................
.3
.3
B - With ABS........................................................................................................................
.2
.2
C - For Wagon Model..........................................................................................................
.1
-
HUB ASSEMBLY, FRONT WHEEL - REPLACE
INC: R&R wheel, clean and pack inner and outer bearings, replace seal, fill oiler cap.
RIGHT
E2320
ADD:
LEFT
E2321
ADD:
BOTH
E2327
ADD:
AUTO LOCKING HUB - REPLACE
RIGHT
E2360
.5
-
LEFT
E2361
.5
-
BOTH
E2367
.8
-
.3
-
ADD:
A - To Replace Manual Locking Hub...................................................................................
KNUCKLE ASSEMBLY, STEERING - REPLACE
POLICY: T
INC: R&R wheel, hub and steering knuckle.
Adjust and lubricate front wheel bearings and set toe-in.
RIGHT (4 x 2)
E2520
1.2
1.2
LEFT (4 x 2)
E2521
1.2
1.2
RIGHT (4 x 4)
E2522
1.4
1.4
LEFT (4 x 4)
E2523
1.4
1.4
BOTH (4 x 2)
E2527
2.0
2.0
BOTH (4 x 4)
E2528
2.3
2.3
E - 14 STEERING, SUSPENSION, WHEELS AND TIRES
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
BEARING, KNUCKLE - REPLACE
RIGHT
E2530
1.7
1.7
LEFT
E2531
1.7
1.7
BOTH
E2535
2.8
2.8
RIGHT
E2551
1.5
1.5
LEFT
E2552
1.5
1.5
BOTH
E2557
2.3
2.3
LOWER RIGHT
E2830
.2
.2
LOWER LEFT
E2831
.2
.2
LOWER BOTH
E2837
.3
.3
UPPER RIGHT
E2920
.5
1.3
UPPER LEFT
E2921
.5
1.3
.8
-
.8
2.4
1.6
-
SEAL, KNUCKLE OIL - REPLACE
DUMPER, CONTROL ARM - REPLACE
NOTE: Maximum time not to exceed operation number E2837.
BALL JOINT, CONTROL ARM - REPLACE
POLICY: T
ADD:
A - Fitted 2003 Cab Model...................................................................................................
UPPER BOTH
E2927
ADD:
A - Fitted 2003 Cab Model...................................................................................................
LOWER RIGHT
E2930
.4
1.2
LOWER LEFT
E2931
.4
1.2
A - Fitted 2003 Cab Model...................................................................................................
.8
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.6
-
.7
2.2
A - Fitted 2003 Cab Model...................................................................................................
1.5
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
1.1
-
ADD:
LOWER BOTH
E2937
ADD:
STEERING, SUSPENSION, WHEELS AND TIRES E - 15
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
SPRING, FRONT COIL - REPLACE
POLICY: A, T
RIGHT
E3020
.8
-
LEFT
E3021
.8
-
A - Fitted 2012 Cab Model...................................................................................................
.3
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.4
-
1.4
-
A - Fitted 2012 Cab Model...................................................................................................
.6
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.8
-
E3300
.3
.3
RIGHT
E3320
.7
.7
LEFT
E3321
.7
.7
BOTH
E3327
1.1
1.1
.2
.2
ADD:
BOTH
E3027
ADD:
BAR, FRONT TORSION - ADJUST
NOTE: Use operation E2020 instead of this one, if front end alignment is necessary.
BAR, FRONT TORSION - REPLACE
INC: Adjust trim height.
ADD:
A - With Skid Plate...............................................................................................................
ARM, TORSION BAR PIVOT - REPLACE
INC: Adjust trim height.
RIGHT
E3330
.7
.7
LEFT
E3331
.7
.7
BOTH
E3337
1.1
1.1
.2
.2
ADD:
A - With Skid Plate...............................................................................................................
ARM ASSEMBLY, FRONT CONTROL - REPLACE
UPPER RIGHT
E3520
.6
1.7
UPPER LEFT
E3521
.6
1.7
1.1
-
ADD:
A - Fitted 2003 Cab Model...................................................................................................
(CONTINUED)
E - 16 STEERING, SUSPENSION, WHEELS AND TIRES
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.1
3.0
1.9
-
(CONT'D)
UPPER BOTH
E3527
ADD:
A - Fitted 2003 Cab Model...................................................................................................
LOWER RIGHT
E3530
.8
1.5
LOWER LEFT
E3531
.8
1.5
A - Fitted 2003 Cab Model...................................................................................................
.7
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.1
-
1.4
2.7
A - Fitted 2003 Cab Model...................................................................................................
1.3
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.2
-
ADD:
LOWER BOTH
E3537
ADD:
BUSHINGS AND/OR SHAFT, FRONT CONTROL ARM - REPLACE
POLICY: T
UPPER RIGHT
E3540
.9
2.0
UPPER LEFT
E3541
.9
2.0
1.1
-
1.4
3.3
1.9
-
ADD:
A - Fitted 2003 Cab Model...................................................................................................
UPPER BOTH
E3547
ADD:
A - Fitted 2003 Cab Model...................................................................................................
LOWER RIGHT
E3550
1.1
1.8
LOWER LEFT
E3551
1.1
1.8
A - Fitted 2003 Cab Model...................................................................................................
.7
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.1
-
1.7
3.0
A - Fitted 2003 Cab Model...................................................................................................
1.3
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.2
-
ADD:
LOWER BOTH
E3557
ADD:
STEERING, SUSPENSION, WHEELS AND TIRES E - 17
FRONT SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.3
A - Fitted 2003 Cab 4x2 Model (EXC. High Ride Suspension.)...........................................
.5
-
B - Fitted 2012 Cab 4x2 Model............................................................................................
.8
-
C - Fitted 2012 Cab 4x4 Model............................................................................................
.9
-
.3
.3
A - Fitted 2003 Cab 4x2 Model (EXC. High Ride Suspension.)...........................................
.5
-
B - Fitted 2012 Cab 4x2 Model............................................................................................
.8
-
C - Fitted 2012 Cab 4x4 Model............................................................................................
.9
-
.5
.5
A - Fitted 2003 Cab 4x2 Model (EXC. High Ride Suspension.)...........................................
.9
-
B - Fitted 2012 Cab 4x2 Model............................................................................................
1.5
-
C - Fitted 2012 Cab 4x4 Model............................................................................................
1.7
-
SHOCK ABSORBER, FRONT - REPLACE
POLICY: A
RIGHT
E3800
ADD:
LEFT
E3801
ADD:
BOTH
E3807
ADD:
COVER, FRONT SHOCK ABSORBER - REPLACE
RIGHT
E3830
.8
-
LEFT
E3831
.8
-
A - Fitted 2012 Cab 4x2 Model............................................................................................
.3
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.4
-
1.4
-
A - Fitted 2012 Cab 4x2 Model............................................................................................
.6
-
B - Fitted 2012 Cab 4x4 Model............................................................................................
.8
-
ADD:
BOTH
E3837
ADD:
E - 18 STEERING, SUSPENSION, WHEELS AND TIRES
REAR SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
E4160
.5
-
RIGHT
E4180
.2
-
LEFT
E4181
.2
-
BOTH
E4187
.3
-
RIGHT
E4400
.3
.3
LEFT
E4401
.3
.3
BOTH
E4407
.4
.4
RIGHT
E5100
.8
.8
LEFT
E5101
.8
.8
BOTH
E5107
1.5
1.5
RIGHT
E5130
.7
.7
LEFT
E5131
.7
.7
BOTH
E5137
1.3
1.3
RIGHT
E5140
.9
.9
LEFT
E5141
.9
.9
BOTH
E5147
1.7
1.7
BAR, REAR STABILIZER - REPLACE
INSULATOR AND/OR SUPPORT, REAR STABILIZER BAR - REPLACE
DUMPER, AXLE - REPLACE
BOLT, REAR LEAF SPRING CENTER - REPLACE
POLICY: T
INC: D&C spring to axle and align spring leaves.
DOES NOT INC: Rebushing.
SPRING ASSEMBLY, REAR LEAF - REPLACE
POLICY: A, T
INC: D&C spring at both hangers and axle.
DOES NOT INC: Rebushing.
LEAVES, REAR SPRING - REPLACE
INC: Remove, disassemble, clean, replace leaves as necessary.
DOES NOT INC: Rebushing.
STEERING, SUSPENSION, WHEELS AND TIRES E - 19
REAR SUSPENSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
BUSHING, REAR LEAF SPRING EYE - REPLACE
RIGHT
E5180
.8
.8
LEFT
E5181
.8
.8
BOTH
E5185
1.5
1.5
RIGHT
E5200
.4
.4
LEFT
E5201
.4
.4
BOTH
E5207
.6
.6
RIGHT
E5220
.4
.4
LEFT
E5221
.4
.4
BOTH
E5227
.5
.5
RIGHT
E5240
.3
.3
LEFT
E5241
.3
.3
BOTH
E5247
.4
.4
RIGHT
E5260
.5
.5
LEFT
E5261
.5
.5
BOTH
E5267
.7
.7
RIGHT
E5800
.2
.2
LEFT
E5801
.2
.2
BOTH
E5807
.3
.3
SHACKLE AND/OR BUSHING, REAR LEAF SPRING - REPLACE
POLICY: T
U-BOLT OR RETAINING BOLT, REAR LEAF SPRING - REPLACE
POLICY: T
INC: Both U-bolts or retaining bolts.
BOLT, REAR LEAF SPRING EYE OR LINK - REPLACE
POLICY: T
BRACKET, REAR SHOCK ABSORBER AND LEAF SPRING MOUNTING - REPLACE
SHOCK ABSORBER, REAR - REPLACE
POLICY: A
E - 20 STEERING, SUSPENSION, WHEELS AND TIRES
STEERING
OPERATION DESCRIPTION
OPERATION
NUMBER
WHEEL, STEERING - ALIGN
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
.2
.2
E7010
.2
.2
E7020
.2
.2
.2
.2
E7000
ADD:
A - With SRS.......................................................................................................................
EMBLEM AND/OR PAD, HORN BUTTON - REPLACE
INC: Transfer parts.
WHEEL, STEERING - REPLACE
ADD:
A - With SRS.......................................................................................................................
HORN CONTACT - REPLACE
E7100
.2
.2
CYLINDER, IGNITION LOCK - R&R OR REPLACE
E7200
.4
.4
.2
.2
.2
.2
.1
.1
E7660
.9
.9
E7782
.2
1.0
.8
-
.6
1.0
.4
-
POLICY: T
ADD:
A - With SRS.......................................................................................................................
COVER, LOCK HOUSING - REPLACE
E7220
ADD:
A - With SRS.......................................................................................................................
COLUMN ASSEMBLY, STEERING - R&R
UNIVERSAL JOINT, STEERING SHAFT - R&R OR REPLACE
UPPER
ADD:
A - Fitted 2003 Cab Model...................................................................................................
LOWER
E7783
ADD:
A - Fitted 2003 Cab Model...................................................................................................
STEERING, SUSPENSION, WHEELS AND TIRES E - 21
STEERING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
TIE ROD, INNER - REPLACE
POLICY: T
INC: Check and adjust toe-in R&R rack and pinion gear assembly as necessary.
RIGHT
E8040
1.3
1.3
LEFT
E8041
1.3
1.3
BOTH
E8047
1.5
1.5
RIGHT
E8060
.6
.6
LEFT
E8061
.6
.6
BOTH
E8067
1.1
1.1
CAP, POWER STEERING PUMP RESERVOIR - REPLACE
E8300
.2
.2
PULLEY, POWER STEERING PUMP - REPLACE
E8360
.5
-
E8380
.8
-
E8440
.8
.8
.3
.3
TIE ROD END AND/OR ADJUST SLEEVE - REPLACE
POLICY: T
INC: Check and adjust toe-in.
POLICY: T
SEAL, POWER STEERING PUMP SHAFT, OIL - REPLACE
POLICY: T
VALVE, POWER STEERING PUMP FLOW CONTROL - REPLACE
POLICY: T
ADD:
A - Diagnosis Time..............................................................................................................
HOSES, POWER STEERING HYDRAULIC - REPLACE
POLICY: T
INC: Check and add fluid.
PRESSURE
E8622
.5
.5
RETURN
E8623
.4
.4
E - 22 STEERING, SUSPENSION, WHEELS AND TIRES
STEERING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
-
.2
-
.5
1.1
A - To Replace Reservoir and/or Hose................................................................................
.3
.3
B - To Recondition (EXC. 4JJ1/4JK1 Engine).....................................................................
.6
-
C - To Recondition (4JJ1/4JK1 Engine)..............................................................................
.3
.3
D - To Replace Mounting Bracket........................................................................................
.2
-
E - 6V*1 Engine...................................................................................................................
.2
-
F - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)...................................................................
.6
-
G - Diagnosis Time..............................................................................................................
.3
.3
H - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.3
-
.6
1.2
A - 6V*1 Engine...................................................................................................................
.2
-
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.6
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
.3
.3
SWITCH, PRESSURE, POWER STEERING - R&R OR REPLACE
E8700
NOTE: Include flush power steering system.
ADD:
A - 6V*1 Engine...................................................................................................................
PUMP ASSEMBLY, POWER STEERING - R&R
E9040
POLICY: T
INC: Bleed hydraulic system.
ADD:
PUMP ASSEMBLY, POWER STEERING - REPLACE
E9050
POLICY: T
INC: Bleed hydraulic system.
ADD:
RESERVOIR ASSEMBLY, POWER STEERING FLUID REMOTE - REPLACE
POLICY: T
INC: Bleed hydraulic system.
E9100
STEERING, SUSPENSION, WHEELS AND TIRES E - 23
STEERING
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.2
1.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - For 4x4 Model................................................................................................................
.2
.2
1.2
1.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - For 4x4 Model................................................................................................................
.2
.2
E9750
.3
-
ONE
E9880
.6
.6
BOTH
E9882
.9
.9
GEAR ASSEMBLY, POWER STEERING - R&R
E9720
POLICY: T
INC: R&R steering gear assembly, drain and refill, bleed hydraulic system.
ADD:
GEAR ASSEMBLY, POWER STEERING - REPLACE
E9740
POLICY: T
ADD:
BELT, POWER STEERING PUMP DRIVE - REPLACE
DUST COVER, RACK AND PINION - REPLACE
Inc. Adjust Set Toe-in.
F AXLE AND DIFFERENTIAL
F
F – 2 AXLE AND DIFFERENTIAL
AXLE AND DIFFERENTIAL F - 3
AXLE AND DIFFERENTIAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
F0040
.6
.6
FRONT
F1002
1.0
1.0
REAR
F1003
1.0
1.0
INTERMEDIATE
F1004
1.0
1.0
F1010
.6
1.0
.4
-
BEARING, CENTER SUPPORT - REPLACE
POLICY: T, P
INC: D&C front and intermediate U-joints. R&R center bearing support
to frame. R&R propeller shaft and hanger bearing to shaft.
UNIVERSAL JOINT, PROPELLER SHAFT - REPLACE
YOKE, PROPELLER SHAFT - REPLACE
ADD:
A - For Wagon Model..........................................................................................................
PROPELLER SHAFT ASSEMBLY - R&R OR REPLACE
POLICY: P, T
ONE PIECE TYPE
F1280
.4
-
TWO PIECE TYPE
F1281
.4
.4
FRONT DRIVE (4x4)
F1288
.4
.4
LEFT
F1300
4.6
4.6
RIGHT
F1301
3.5
-
RIGHT OUTER
F1400
1.9
1.9
RIGHT INNER
F1401
1.7
1.7
RIGHT BOTH
F1402
1.9
1.9
LEFT OUTER
F1403
1.9
1.9
LEFT INNER
F1404
1.7
1.7
LEFT BOTH
F1405
1.9
1.9
INNER SHAFT, FRONT OUTPUT - REPLACE
DUST COVER, FRONT DRIVE SHAFT - REPLACE
INC: Adjust set toe-in.
F - 4 AXLE AND DIFFERENTIAL
AXLE AND DIFFERENTIAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
3.2
4.4
1.2
-
3.2
4.5
1.3
-
3.3
4.6
1.3
-
3.2
4.4
A - For Wagon Model..........................................................................................................
.1
-
B - Fitted 2003 Cab Model...................................................................................................
1.1
-
3.2
4.5
A - For Wagon Model..........................................................................................................
.1
-
B - Fitted 2003 Cab Model...................................................................................................
1.2
-
3.3
4.6
A - For Wagon Model..........................................................................................................
.1
-
B - Fitted 2003 Cab Model...................................................................................................
1.2
-
3.4
4.6
1.2
-
.5
.5
SHAFT, FRONT OUTPUT - REPLACE
POLICY: P
RIGHT
F1420
ADD:
A - Fitted 2003 Cab Model...................................................................................................
LEFT
F1421
ADD:
A - Fitted 2003 Cab Model...................................................................................................
BOTH
F1427
ADD:
A - Fitted 2003 Cab Model...................................................................................................
SEALS, FRONT OUTPUT SHAFT - REPLACE
POLICY: P
RIGHT
F1440
ADD:
LEFT
F1441
ADD:
BOTH
F1447
ADD:
INNER SHAFT
F1445
ADD:
A - Fitted 2003 Cab Model...................................................................................................
ACTUATOR ASSEMBLY (ELECTRIC TYPE), SHIFT ON THE FLY - REPLACE
F1504
AXLE AND DIFFERENTIAL F - 5
AXLE AND DIFFERENTIAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
SHAFT, REAR AXLE - REPLACE
POLICY: P, T
RIGHT
F1530
1.3
1.3
LEFT
F1531
1.3
1.3
BOTH
F1537
2.5
2.5
F1550
3.0
4.3
1.3
-
AXLE ASSEMBLY, FRONT DRIVE (COMPLETE) - R&R
ADD:
A - Fitted 2003 Cab Model...................................................................................................
SEAL, AXLE SHAFT OIL, REAR AXLE - REPLACE
POLICY: P
RIGHT
F1610
1.3
1.3
LEFT
F1611
1.3
1.3
BOTH
F1617
2.5
2.5
RIGHT
F1620
.9
.9
LEFT
F1621
.9
.9
BOTH
F1627
1.4
1.4
RIGHT
F1650
1.3
1.3
LEFT
F1651
1.3
1.3
BOTH
F1657
2.5
2.5
FRONT DIFFERENTIAL
F2022
.6
.6
REAR DIFFERENTIAL
F2023
.6
.6
SEAL, AXLE SHAFT OIL, INNER, REAR AXLE - REPLACE
BEARING, AXLE SHAFT, REAR AXLE - REPLACE
POLICY: P, T
SEAL, PINION SHAFT OIL - REPLACE
POLICY: P
F - 6 AXLE AND DIFFERENTIAL
AXLE AND DIFFERENTIAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
FLANGE, PINION SHAFT - REPLACE
POLICY: P
INC: Reset bearing preload. Pinion seal and add lubricant.
FRONT DIFFERENTIAL
F2042
.5
.5
REAR DIFFERENTIAL
F2043
.5
.5
F2122
4.0
5.3
A - To Replace Pinion Shaft and/or Side and Pinion Gears................................................
.5
.5
B - To Replace Side Bearings.............................................................................................
.4
.4
C - To Replace Pinion Bearings..........................................................................................
.4
.4
D - To Replace Ring Gear and Pinion.................................................................................
.7
.7
E - To Replace Case...........................................................................................................
.5
.5
F - To Replace Carrier.........................................................................................................
.8
.8
G - To Recondition Carrier Complete..................................................................................
1.4
1.4
H - Fitted 2003 Cab Model...................................................................................................
1.3
-
2.4
2.4
A - To Replace Pinion Shaft and/or Side and Pinion Gears................................................
.5
.5
B - To Replace Side Bearings.............................................................................................
.4
.4
C - To Replace Pinion Bearings..........................................................................................
.4
.4
D - To Replace Ring Gear and Pinion.................................................................................
.7
.7
E - To Replace Case...........................................................................................................
.5
.5
F - To Replace Carrier.........................................................................................................
.8
.8
G - To Recondition Carrier Complete..................................................................................
1.4
1.4
H - To Replace Disc & Spring (LSD.)...................................................................................
.5
.5
3.8
3.8
CARRIER ASSEMBLY, FRONT AXLE - R&R OR REPLACE
POLICY: A, P, T
ADD:
CARRIER ASSEMBLY, REAR AXLE - R&R OR REPLACE
F2123
POLICY: A, P, T
ADD:
HOUSING ASSEMBLY, REAR AXLE - REPLACE
POLICY: P, T
INC: R&R propeller shaft, transfer all parts,
bleed brakes and make all necessary adjustments.
F3023
AXLE AND DIFFERENTIAL F - 7
AXLE AND DIFFERENTIAL
OPERATION DESCRIPTION
OPERATION
NUMBER
HOUSING ASSEMBLY, FRONT AXLE - REPLACE
F3060
CAB STYLE
VIN CODE
TF*
UC*
4.2
5.5
1.3
-
ADD:
A - Fitted 2003 Cab Model...................................................................................................
DRAIN OR REFILL PLUG AND/OR GASKET, FRONT OR REAR AXLE - REPLACE
VENTILATOR, AXLE - REPLACE
INC: Hose assembly.
FRONT AXLE
F3080
.2
.2
REAR AXLE
F3082
.2
.2
F3270
.3
.3
H BRAKES
H
BRAKES H – 1
H – 2 BRAKES
BRAKES H – 3
H – 4 BRAKES
BRAKES H - 5
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
H0042
.6
.6
FRONT RIGHT
H0080
.5
.5
FRONT LEFT
H0081
.5
.5
.3
.3
.7
.7
A - To Recondition Caliper Assembly (One)........................................................................
.3
.3
B - To Recondition Caliper Assembly (All)...........................................................................
.5
.5
PADS, DISC BRAKE - R&R OR REPLACE
BOTH FRONT
CALIPER ASSEMBLY - R&R
POLICY: T
INC: R&R brake pads from caliper. Clean and inspect caliper and bleed brakes.
ADD:
A - To Recondition Caliper Assembly (One)........................................................................
FRONT BOTH
H0087
ADD:
CALIPER ASSEMBLY - REPLACE
POLICY: T
INC: R&R brake pads from caliper. Clean and inspect caliper
and bleed brakes.
FRONT RIGHT
H0100
.6
.6
FRONT LEFT
H0101
.6
.6
FRONT BOTH
H0107
.8
.8
FRONT RIGHT (4x2)
H0120
.7
.7
FRONT LEFT (4x2)
H0121
.7
.7
FRONT RIGHT (4x4)
H0122
.9
.9
FRONT LEFT (4x4)
H0123
.9
.9
FRONT BOTH (4x2)
H0127
1.2
1.2
FRONT BOTH (4x4)
H0128
1.5
1.5
A - To Reface Disc (One)....................................................................................................
.4
.4
B - To Reface Disc (Two).....................................................................................................
.7
.7
C - With ABS.......................................................................................................................
.2
.2
DISC ASSEMBLY - R&R OR REPLACE
INC: D&C caliper assembly and visually inspect. Check rotor lateral runout and parallelism.
Transfer seals, bearings and races. Clean and repack wheel bearing as necessary.
ADD:
H - 6 BRAKES
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
SHIELD, FRONT BRAKE DUST - R&R OR REPLACE
RIGHT
H0160
.6
.6
LEFT
H0161
.6
.6
.1
.1
1.2
1.2
.2
.2
ADD:
A - For 4x4 Model................................................................................................................
BOTH
H0167
ADD:
A - For 4x4 Model................................................................................................................
DRUM, BRAKE - R&R OR REPLACE
INC: Adjust wheel bearings when necessary to remove hub, adjust brake shoes.
DOES NOT INC: Replace hub, bearings or oil seal. Adjust brake shoes on opposite wheels.
REAR RIGHT
H0200
.3
.3
REAR LEFT
H0201
.3
.3
REAR BOTH
H0207
.4
.4
A - To Reface Drum (One)...................................................................................................
.4
.4
B - To Reface Drum (Two)...................................................................................................
.7
.7
ADD:
SHOES AND LININGS, DRUM BRAKE - R&R OR REPLACE
INC: R&R wheel, hub, drum and brake shoes. Clean shoes and drum.
Clean and lubricate anchor pins and cam. Adjust wheel bearings and brake shoes.
DOES NOT INC: Reline brake shoes.
REAR RIGHT
H0250
.5
.5
REAR LEFT
H0251
.5
.5
REAR BOTH
H0257
.8
.8
REAR RIGHT
H0290
.5
.5
REAR LEFT
H0291
.5
.5
REAR BOTH
H0297
.8
.8
REAR RIGHT
H0340
.5
.5
REAR LEFT
H0341
.5
.5
REAR BOTH
H0347
.8
.8
SPRINGS, BRAKE SHOE RETURN AND/OR HOLD DOWN - REPLACE
SELF ADJUSTER, BRAKE - R&R OR REPLACE
BRAKES H - 7
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CYLINDER, BRAKE WHEEL - R&R OR REPLACE
POLICY: T
INC: Time to recondition, adjust bearings, bleed brakes.
REAR RIGHT
H0370
.7
.7
REAR LEFT
H0371
.7
.7
REAR BOTH
H0377
1.2
1.2
DRUM, RIGHT
H0400
1.1
1.3
.2
-
1.1
1.3
.2
-
1.9
2.5
.6
-
H0615
.5
.5
H0620
.4
.4
H0640
.4
.4
H0700
.4
.4
SHIELD, REAR BRAKE DUST - R&R OR REPLACE
ADD:
A - For Wagon Model..........................................................................................................
DRUM, LEFT
H0401
ADD:
A - For Wagon Model..........................................................................................................
DRUM, BOTH
H0407
ADD:
A - For Wagon Model..........................................................................................................
RESERVOIR, BRAKE MASTER CYLINDER - REPLACE
INC: Air bleed brake system.
CYLINDER ASSEMBLY, BRAKE MASTER - R&R
INC: Air bleed brake system.
CYLINDER ASSEMBLY, BRAKE MASTER - REPLACE
POLICY: T
INC: Air bleed brake system.
BRAKE SYSTEM - BLEED
H - 8 BRAKES
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
HOSE, BRAKE - REPLACE
POLICY: T
INC: Air bleed brake system.
FRONT RIGHT
H0720
.5
.5
FRONT LEFT
H0721
.5
.5
FRONT BOTH
H0727
.6
.6
REAR CENTER
H0739
.4
.4
VALVE, LOAD SENSING PROPORTIONING, BRAKE - R&R OR REPLACE
H0775
1.3
1.3
VALVE, LOAD SENSING PROPORTIONING, BRAKE - ADJUST
H0777
.9
.9
VALVE, BRAKE COMBINATION - REPLACE
H0780
.5
.5
SWITCH, LOW BRAKE FLUID WARNING - REPLACE
H0785
.5
.5
MASTER CYL TO CONNECTOR
H0800
.7
.7
CONNECTOR TO FRONT WHEEL FLEX HOSE; RIGHT
H0880
.7
.7
CONNECTOR TO FRONT WHEEL FLEX HOSE; LEFT
H0881
.7
.7
AXLE HOUSING JUNCTION TO REAR WHEEL; RIGHT
H0910
.5
.5
AXLE HOUSING JUNCTION TO REAR WHEEL; LEFT
H0911
.5
.5
H0960
.2
.2
.3
-
.7
.7
A - To Recondition Booster..................................................................................................
ST
ST
B - Fitted 2012 Cab Model...................................................................................................
.7
-
PIPE, BRAKE - REPLACE
POLICY: T
INC: Air bleed brake system.
VACUUM TANK - REPLACE
ADD:
A - For Two Batteries Specification.....................................................................................
BOOSTER ASSEMBLY, VACUUM POWER BRAKE - R&R
POLICY: T
INC: Air bleed brake system.
MASTER VAC MODEL
H1100
ADD:
BRAKES H - 9
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.7
.7
.7
-
H1240
.2
.2
FRONT RIGHT
H2410
.3
.3
FRONT LEFT
H2411
.3
.3
FRONT BOTH
H2412
.4
.4
REAR BOTH
H2417
.4
.4
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.6
.6
A - For 4x4 Model................................................................................................................
.1
.1
B - For Pick Up Model..........................................................................................................
.1
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.6
.6
A - For 4x4 Model................................................................................................................
.1
.1
B - For Pick Up Model..........................................................................................................
.1
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
1.2
1.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
1.2
1.2
.3
.3
BOOSTER ASSEMBLY, VACUUM POWER BRAKE - REPLACE
H1120
POLICY: T
ADD:
A - Fitted 2012 Cab Model...................................................................................................
VALVE, FILTER, HOSE AND/OR PIPE, VACUUM POWER BRAKE - REPLACE
SPEED SENSOR, ABS - R&R
ADD:
RING, EXCITOR, ABS - R&R
FRONT RIGHT
H2450
ADD:
FRONT LEFT
H2451
ADD:
REAR RIGHT
H2453
ADD:
REAR LEFT
H2454
ADD:
A - Diagnosis Time..............................................................................................................
(CONTINUED)
H - 10 BRAKES
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.5
-
.4
.4
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
.4
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
.4
A - For Pick Up Model..........................................................................................................
.1
-
B - Diagnosis Time..............................................................................................................
.3
.3
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.5
1.2
.7
-
(CONT'D)
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
HYDRAULIC UNIT, ABS - R&R
H2480
INC: R&R battery, time to bleed brakes.
ADD:
G-SENSOR, ABS - R&R
H2495
INC: R&R center console assembly.
ADD:
CONTROL MODULE, ABS ELECTRONIC BRAKE - R&R
H2506
ADD:
PEDAL AND/OR BUSHING, BRAKE - R&R OR REPLACE
H2640
ADD:
A - Fitted 2003 Cab Model...................................................................................................
PAD, BRAKE PEDAL - REPLACE
H2660
.2
.2
SPRING, BRAKE PEDAL RETURN - REPLACE
H2680
.5
1.2
.7
-
ADD:
A - Fitted 2003 Cab Model...................................................................................................
PARKING BRAKE - ADJUST
H2800
.3
.3
LEVER AND/OR SUPPORT, PARKING BRAKE ASSEMBLY - R&R OR REPLACE
H2860
.3
.3
1.7
-
ADD:
A - For Stick (T-Handle) Type..............................................................................................
BRAKES H - 11
BRAKES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CABLE, PARKING BRAKE - REPLACE
FRONT SECTION
H2885
.5
.5
REAR SECTION (1 PIECE)
H2886
.8
.8
REAR SECTION (2 PIECE)
H2887
1.3
1.3
J ENGINE
J
J - 30 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
MANIFOLD AND/OR GASKET, EXHAUST - REPLACE
POLICY: P, E
NOTE: For HFV6 engine.
RIGHT BANK
J0100
1.5
-
LEFT BANK
J0102
1.6
-
4J
J0103
1.3
2.2
A - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.5
-
B - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.9
-
C - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.5
.5
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.7
-
E - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.9
-
F - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)................
.5
-
G - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
H - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.9
-
1.1
-
A - 6V*1 Engine, Left...........................................................................................................
.8
-
B - 6V*1 Engine for 4x4 Model, Right..................................................................................
.5
-
MANIFOLD AND/OR GASKET, EXHAUST - REPLACE
POLICY: P, E
NOTE: EXC. HFV6 engine.
ADD:
6V
J0107
ADD:
C24*E
J0111
.6
-
4J
J0203
1.1
1.8
A - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
B - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.6
-
C - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.8
-
E - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
.3
-
F - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
G - 4JJ1/4JK1 Engine..........................................................................................................
.7
-
MANIFOLD AND/OR GASKET, INTAKE - REPLACE
POLICY: P
ADD:
(CONTINUED)
ENGINE J - 31
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
C24*E
J0210
1.6
-
6V
J0220
1.4
-
HFV6
J0221
.6
-
HFV6
J0224
.9
-
DIESEL
J0240
.7
1.6
A - With A/C. (EXC. 4JJ1/4JK1 Engine)..............................................................................
.3
-
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.5
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.6
-
J0245
.3
-
J0250
.2
.2
.2
.2
J0260
.2
.2
J0290
.2
.2
COMMON CHAMBER AND/OR GASKET, INLET - REPLACE
MANIFOLD, INTAKE UPPER - R&R OR REPLACE
POLICY:P
MANIFOLD, INTAKE LOWER - R&R OR REPLACE
POLICY:P
PUMP AND/OR GASKET, VACUUM - REPLACE
ADD:
FLEXIBLE PIPE, VACUUM PUMP - REPLACE
DIESEL
HOSE (ONE), VACUUM - REPLACE
ADD:
A - To Replace Hose (One Additional)................................................................................
TANK, VACUUM - REPLACE
ONE
COVER, ENGINE - REPLACE
J - 32 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.2
-
A - Right Bank......................................................................................................................
.2
-
B - Clean Rocker Cover Assembly......................................................................................
.1
-
.3
.6
A - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.3
-
B - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.7
-
C - Clean Rocker Cover Assembly......................................................................................
.1
.1
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.7
-
F - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)...................................................................
.3
-
G - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
1.0
-
A - 6V*1 Engine, Right.........................................................................................................
.6
-
B - Clean Rocker Cover Assembly......................................................................................
.1
-
.3
-
.1
-
7.2
-
.3
-
.6
3.0
A - 4JJ1/4JK1 Engine..........................................................................................................
2.4
-
B - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.3
-
C - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
D - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.7
-
E - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
COVER AND/OR GASKET, ROCKER - R&R OR REPLACE
POLICY: P
HFV6
J0302
ADD:
4J
J0303
ADD:
6V
J0307
ADD:
C24*E
J0311
ADD:
A - Clean Rocker Cover Assembly......................................................................................
ROCKER ARM - REPLACE
POLICY: P, T
INC: R&R rocker cover and install new gasket.
HFV6
J0352
ADD:
A - Left Bank........................................................................................................................
4J
J0353
ADD:
(CONTINUED)
ENGINE J - 33
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
C24*E
J0361
.7
-
4J
J0423
.5
1.1
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.6
-
B - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.3
-
C - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.9
-
E - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.7
-
F - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
VALVE LASH - ADJUST
ADD:
6V
J0427
3.3
-
HFV6
J0502
8.7
-
A - With A/C. for Wagon Model...........................................................................................
.4
-
B - Right Bank......................................................................................................................
.4
-
C - Both Bank......................................................................................................................
1.0
-
3.4
6.7
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
3.3
-
B - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
C - With A/C. for Pick Up Model..........................................................................................
.3
-
D - With A/C. for Wagon Model...........................................................................................
.4
.4
E - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
F - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)...................................................................
3.4
-
G - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
7.0
-
H - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
.8
-
J - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model)......................................
.6
-
K - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
GASKET, CYLINDER HEAD - REPLACE
POLICY: P, T
INC: R&R rocker cover, loosen rocker arms (diesel only) and remove push
rods (diesel only), D&C exhaust pipe and make all necessary adjustments.
ADD:
4J
J0503
ADD:
(CONTINUED)
J - 34 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
3.9
-
A - 6V*1 Engine, Right.........................................................................................................
2.2
-
B - With A/C. for Wagon Model...........................................................................................
.4
-
(CONT'D)
6V
J0507
ADD:
C24*E
J0508
3.5
-
HFV6
J0512
10.4
-
A - With A/C. for Wagon Model...........................................................................................
.4
-
B - Left Bank........................................................................................................................
.4
-
C - Both Bank......................................................................................................................
2.7
-
5.6
9.9
A - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
4.3
-
C - With A/C. for Pick Up Model..........................................................................................
.3
-
D - With A/C. for Wagon Model...........................................................................................
.4
.4
E - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
F - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)...................................................................
4.8
-
G - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
8.4
-
H - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
.8
-
J - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model)......................................
.6
-
K - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
7.4
-
A - 6V*1 Engine, Right.........................................................................................................
.7
-
B - 6V*1 Engine, Both..........................................................................................................
3.7
-
C - With A/C. for Wagon Model...........................................................................................
.4
-
5.0
-
HEAD, CYLINDER - REPLACE
POLICY: P, T
INC: R&R rocker cover, loosen rocker arms (diesel only) and remove push
rods (diesel only) D&C exhaust pipe and make all necessary adjustments.
ADD:
4J
J0513
ADD:
6V
J0517
ADD:
C24*E
J0518
ENGINE J - 35
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
10.2
-
A - To Recondition Valves One Cyl. (Right Bank)...............................................................
.4
-
B - To Recondition All Valves (Right Bank).........................................................................
2.6
-
C - To Recondition All Valves (Left Bank)...........................................................................
2.3
-
D - To Recondition All Valves (Both Bank)..........................................................................
4.9
-
E - With A/C. for Wagon Model...........................................................................................
.4
-
4.2
7.5
A - To Recondition All Valves (4JJ1/4JK1 Engine)..............................................................
2.3
2.3
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
3.3
-
C - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
D - With A/C. for Pick Up Model..........................................................................................
.3
-
E - With A/C. for Wagon Model...........................................................................................
.4
.4
F - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)...........................................
.3
.3
G - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
4.3
-
H - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
7.9
-
J - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)................
.8
-
K - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.6
-
L - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
M - To Recondition All Valves (4JA1/4JH1 Engine).............................................................
1.3
-
9.9
-
.4
-
B - To Recondition All Valves (6V*1 Engine; The Same Cyl. Head)....................................
.8
-
C - 6V*1 Engine, Right.........................................................................................................
.7
-
D - 6V*1 Engine, Both..........................................................................................................
3.7
-
E - With A/C. for Wagon Model...........................................................................................
.4
-
VALVE - RECONDITION OR REPLACE
POLICY: P
INC: R&R rocker cover, rocker arms, push rods, cylinder head, recondition
valve seat and replace valve seal and make all necessary adjustments.
ONE CYL; HFV6
J0522
ADD:
ONE CYL; 4J
J0523
ADD:
ONE CYL; 6V
J0527
ADD:
A - To Recondition Valves One Additional Cyl. (6V*1 Engine; The Same Cyl. Head).........
INC: Replace valves as necessary.
(CONTINUED)
J - 36 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
4.4
-
A - To Recondition All Valves..............................................................................................
1.5
-
B - With A/C. for Wagon Model...........................................................................................
.4
-
7.6
-
A - To Replace Springs, Caps and/or Seals One Additional Cyl.........................................
.4
-
B - To Replace Springs, Caps and/or Seals Two Additional Cyl.........................................
.8
-
C - To Recondition All Springs, Caps and/or Seals.............................................................
2.5
-
D - Left Bank........................................................................................................................
.3
-
.6
3.1
A - To Replace Springs, Caps and/or Seals One Additional Cyl. (4JJ1/4JK1 Engine)........
.3
.3
B - To Replace Springs, Caps and/or Seals Two Additional Cyl. (4JJ1/4JK1 Engine)........
.5
.5
C - To Replace All Springs, Caps and/or Seals (4JJ1/4JK1 Engine)..................................
.7
.7
D - To Recondition All Springs, Caps and/or Seals (4JJ1/4JK1 Engine).............................
1.0
1.0
E - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
F - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)...................................................................
2.5
-
G - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
H - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
2.8
-
J - To Replace Springs, Caps and/or Seals One Additional Cyl..........................................
.1
-
K - To Replace Springs, Caps and/or Seals Two Additional Cyl. .......................................
.2
-
L - To Replace All Springs, Caps and/or Seals...................................................................
.3
-
M - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.6
-
N - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
4.0
-
A - To Replace Springs, Caps and/or Seals One Additional Cyl.........................................
.3
-
B - To Replace Springs, Caps and/or Seals Two Additional Cyl. .......................................
.5
-
C - To Replace All Springs, Caps and/or Seals...................................................................
.7
-
D - 6V*1 Engine, Right.........................................................................................................
1.7
-
(CONT'D)
ONE CYL; C24*E
J0528
ADD:
SPRING, CAP AND/OR SEAL, VALVE - REPLACE
POLICY: T, P
INC; R&R Cylinder head assy. (6V*1, C24*E)
ONE CYL; HFV6
J0542
ADD:
ONE CYL; 4J
J0543
ADD:
ONE CYL; 6V
J0547
ADD:
(CONTINUED)
ENGINE J - 37
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
4.3
-
A - To Replace Springs, Caps and/or Seals One Additional Cyl.........................................
.4
-
B - To Replace Springs, Caps and/or Seals Two Additional Cyl.........................................
.8
-
C - To Replace All Springs, Caps and/or Seals...................................................................
1.1
-
7.3
-
A - To Replace Left Bank Adjuster......................................................................................
.2
-
B - To Replace Both Bank Adjuster.....................................................................................
.5
-
.6
-
A - To Replace All Push Rods.............................................................................................
.1
-
B - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
C - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.6
-
D - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
6.1
-
A - With A/C.........................................................................................................................
.3
-
B - 4x4 Model.......................................................................................................................
.9
-
C - To Replace All Lifters.....................................................................................................
.2
-
D - For A/T...........................................................................................................................
.8
-
E - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.7
-
(CONT'D)
ONE CYL; C24*E
J0548
ADD:
ADJUSTER, VALVE LASH - REPLACE
POLICY: P, T
HFV6
J0560
ADD:
PUSH ROD - REPLACE
POLICY: P, T
ONE CYL; 4J
J0583
ADD:
LIFTER, VALVE - REPLACE
POLICY: P, T
ONE CYL; 4J
J0623
ADD:
J - 38 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
A - To Adjust All belts..........................................................................................................
.1
.1
B - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
.2
-
.1
-
.2
.2
.1
-
.3
.3
A - C24*E Engine.................................................................................................................
.3
-
B - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.1
-
J0667
.2
-
J0680
.2
-
.1
-
BELT, DRIVE - ADJUST
NOTE: EXC. serpentine type.
ONE; 4J
J0653
ADD:
ONE; C24*E
J0659
ADD:
A - To Adjust All belts..........................................................................................................
BELT, DRIVE - REPLACE
POLICY: T
A/C
J0660
ADD:
A - C24*E Engine.................................................................................................................
FAN GENERATOR
J0663
ADD:
SERPENTINE
TENSIONER, SERPENTINE BELT - REPLACE
ADD:
A - HFV6 engine..................................................................................................................
PULLEY, CRANKSHAFT - REPLACE
POLICY: P, T
C24*E
J0700
.7
-
HFV6
J0702
2.5
-
4J
J0703
.6
.6
A - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.3
-
B - 4JA1/4JH1 Engine.........................................................................................................
.1
-
1.3
-
ADD:
6V
J0707
ENGINE J - 39
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
SPROCKET, CAMSHFT TIMING - REPLACE
POLICY: P, T
NOTE: For HFV6 engine.
RIGHT BANK, INLET
J0731
7.0
-
RIGHT BANK, EXHAUST
J0732
7.0
-
LEFT BANK , INLET
J0733
7.2
-
LEFT BANK, EXHAUST
J0734
7.2
-
6V
J0747
1.9
-
HFV6
J0752
2.6
-
4J
J0753
.7
.7
A - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.3
-
B - 4JA1/4JH1 Engine.........................................................................................................
.4
-
SEAL, CRANKCASE FRONT COVER - REPLACE (BELT TYPE)
POLICY: P
SEAL, TIMING COVER OIL - REPLACE (GEAR TYPE)
POLICY: P
INC: R&R harmonic balancer.
ADD:
TENSIONER AND/OR SHOE AND/OR GUIDE, TIMING CHAIN - REPLACE
POLICY: P, T
NOTE: For HFV6 engine.
RIGHT BANK SECONDLY
J0761
6.9
-
LEFT BANK SECONDLY
J0762
7.1
-
PRIMARILY
J0763
7.0
-
RIGHT BANK SECONDLY
J0764
7.0
-
LEFT BANK SECONDLY
J0765
7.2
-
PRIMARILY
J0766
7.1
-
CHAIN, TIMING - REPLACE
POLICY: P, T
NOTE: For HFV6 engine.
J - 40 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
COVER AND/OR GASKET, TIMING - REPLACE
POLICY: P
C24*E
J0780
1.1
-
HFV6
J0782
6.6
-
4J
J0783
1.5
2.0
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.5
-
B - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.7
-
ADD:
6V
J0787
1.3
-
4J
J0793
6.4
10.8
A - With A/C.........................................................................................................................
.3
.3
B - For 4x4 Model................................................................................................................
.9
.9
C - For A/T...........................................................................................................................
.8
.8
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
E - 4JJ1/4JK1 Engine..........................................................................................................
4.4
-
F - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
6.4
-
G - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.6
-
H - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
J - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
K - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
2.3
-
1.6
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Model................................................................................................................
.9
-
C - For A/T...........................................................................................................................
.8
-
HOUSING AND/OR GASKET, TIMING PULLEY - REPLACE
INC: R&R engine assembly. (4J** Engine)
ADD:
C24*E
J0799
ADD:
BELT, CAMSHAFT DRIVE - REPLACE
POLICY: P, T
INC: Adjust.
C24*E
J0800
1.1
-
6V
J0807
1.6
-
ENGINE J - 41
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
PULLEY IDLER TIMING - REPLACE
POLICY: P, T
6V
J0817
1.6
-
6V
J0818
1.6
-
C24*E
J0828
1.1
-
4J
J0823
1.5
2.0
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.5
-
B - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.7
-
TENSIONER ASSEMBLY, TIMING BELT - REPLACE
GEAR, IDLER TIMING - REPLACE
ADD:
GEAR, CRANKSHAFT TIMING - REPLACE
POLICY: P, T
HFV6
J0832
7.1
-
4J
J0833
1.6
2.3
A - 4JJ1/4JK1 Engine .........................................................................................................
.7
-
B - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
5.5
-
ADD:
GEAR, CAMSHAFT TIMING - REPLACE
POLICY: P, T
4J
J0843
1.6
-
4J
J0853
6.0
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Model................................................................................................................
.9
-
C - To Replace All Valve Lifter.............................................................................................
.1
-
CAMSHAFT - REPLACE
POLICY: P, T
NOTE: EXC. 4JJ1/4JK1 and HFV6 engines.
INC: R&R radiator, harmonic balancer, cover and seal.
Replace camshaft gear if necessary. Adjust valves.
ADD:
(CONTINUED)
J - 42 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
D - For A/T...........................................................................................................................
.8
-
E - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.9
-
1.2
-
A - With A/C.........................................................................................................................
.3
-
B - For A/T...........................................................................................................................
.8
-
1.3
-
A - With A/C.........................................................................................................................
.3
-
B - For A/T...........................................................................................................................
.8
-
3.6
-
A - With A/C.........................................................................................................................
.3
-
B - For A/T...........................................................................................................................
.8
-
1.4
-
A - 6V*1 Engine...................................................................................................................
.7
-
B - To Replace Second Camshaft Oil Seal..........................................................................
.2
-
7.1
-
.2
-
7.1
-
.2
-
(CONT'D)
6V(LEFT)
J0857
ADD:
6V(RIGHT)
J0858
ADD:
C24*E
J0860
ADD:
SEAL, CAMSHAFT OIL - REPLACE
J0861
ADD:
CAMSHAFT, INTAKE - REPLACE
POLICY: P, T
HFV6
J0862
ADD:
A - To Replace Left Bank Intake Camshaft ........................................................................
CAMSHAFT, EXHAUST - REPLACE
POLICY: P, T
HFV6
J0863
ADD:
A - To Replace Left Bank Exhaust Camshaft......................................................................
ENGINE J - 43
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.5
1.5
A - To Replace Intake Camshaft..........................................................................................
.4
.4
B - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
C - Fitted 2012 Cab Model...................................................................................................
.4
-
.6
.6
A - With A/C.........................................................................................................................
.2
.2
B - Fitted 2012 Cab Model...................................................................................................
.2
-
2.7
2.7
A - With A/C.........................................................................................................................
.2
.2
B - To Replace Sprocket, Cam Drive...................................................................................
.2
.2
C - To Replace Sprocket, Supply Pump..............................................................................
.1
.1
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
2.7
2.7
A - With A/C.........................................................................................................................
.2
.2
B - To Replace Guide..........................................................................................................
.2
.2
C - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
CAMSHAFT, EXHAUST - REPLACE
4JJ1/4JK1
J0864
ADD:
TENSIONER ASSEMBLY, AND/OR GASKET TIMING CHAIN - REPLACE
4JJ1/4JK1
J0865
ADD:
CHAIN, TIMING - REPLACE
4JJ1/4JK1
J0866
ADD:
LEVER, TIMING CHAIN - REPLACE
4JJ1/4JK1
J0867
ADD:
CAP, OIL FILLER - REPLACE
J0900
.2
.2
TUBE, DIPSTICK - REPLACE
J0930
.2
.2
A - 4JA1/4JH1 Engine ........................................................................................................
.2
-
B - HFV6 Engine..................................................................................................................
.2
-
ADD:
J - 44 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
FILTER, OIL - REPLACE
C24*E
J0950
.2
-
HFV6
J0952
.2
-
4J
J0953
.3
.3
6V
J0957
.4
-
J0961
.5
-
A - 6V*1 Engine...................................................................................................................
1.0
-
B - 4JA1/4JH1 Engine ........................................................................................................
.3
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.9
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
3.7
-
E - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
.5
-
.4
.4
.4
-
ADAPTER, OIL FILTER - REPLACE
ADD:
PAN AND/OR GASKET OIL - REPLACE
4J
J0992
ADD:
A - 4JA1/4JH1 Engine ........................................................................................................
6V
J0996
.8
-
C24*E
J0998
4.1
-
HFV6
J0999
9.5
-
A - With Auto Trans.............................................................................................................
2.0
-
B - For 4x4 Model................................................................................................................
.9
-
4.6
12.0
A - With A/C.........................................................................................................................
.3
.3
B - For A/T. Pick Up Model..................................................................................................
.8
-
C - For A/T. Wagon Model...................................................................................................
1.1
1.1
D - For 4x4 Pick Up Model (4JJ1/4JK1 Engine)..................................................................
1.1
-
E - For 4x4 Wagon Model (4JJ1/4JK1 Engine)...................................................................
.8
.8
ADD:
CRANKCASE OR MAIN PAN AND/OR GASKET, OIL - REPLACE
POLICY: P
INC: R&R engine assembly or front axle case assembly,
clean oil pump screen.
4J
J1003
ADD:
(CONTINUED)
ENGINE J - 45
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
F - For 4x4 Model (4JA1/4JH1 Engine )..............................................................................
2.9
-
G - 4JJ1/4JK1 Engine..........................................................................................................
7.4
-
H - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
J - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger)........................................
9.4
-
K - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
L - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
M - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
2.3
-
3.6
-
A - With A/C.........................................................................................................................
.3
-
B - For A/T. Wagon Model...................................................................................................
1.1
-
C - For 4x4 Model................................................................................................................
3.9
-
6.5
-
A - For 4x4 Model................................................................................................................
.5
-
B - For A/T...........................................................................................................................
.8
-
C - For Wagon Model..........................................................................................................
.1
-
7.2
-
.1
-
1.9
2.0
A - For 4x4 Model (4JA1/4JH1 Engine )..............................................................................
2.9
-
B - With A/C.........................................................................................................................
.3
.3
C - For A/T. (4JA1/4JH1 Engine )........................................................................................
.8
-
D - 4JA1/4JH1 Engine ........................................................................................................
2.9
-
E - For Wagon Model..........................................................................................................
.1
-
4.1
-
A - For 4x4 Model................................................................................................................
3.0
-
B - For A/T...........................................................................................................................
.8
-
(CONT'D)
6V
J1009
ADD:
PUMP, ENGINE OIL - REPLACE
POLICY: P, T
NOTE : 4J (EXC.4JJ1/4JK1), 6V - Inc. R&R engine assembly, and R&R oil pan.
C24*E
J1020
ADD:
HFV6
J1022
ADD:
A - For Wagon Model..........................................................................................................
4J
J1023
ADD:
6V
J1027
ADD:
(CONTINUED)
J - 46 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.1
-
3.3
-
3.9
-
.9
12.0
A - With A/C. (4JJ1/4JK1 Engine).......................................................................................
.3
.3
B - 4JJ1/4JK1 Engine..........................................................................................................
11.1
-
C - For 4x4 Model (4JJ1/4JK1 Engine)................................................................................
.8
.8
D - For A/T. (4JJ1/4JK1 Engine)..........................................................................................
1.1
1.1
E - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
F - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
13.1
-
5.6
-
A - For 4x4 Model................................................................................................................
.5
-
B - With A/C. (Engine Remove Work only)..........................................................................
.3
-
9.5
-
A - With A/C. (Engine Remove Work only)..........................................................................
.3
-
B - For 4x4 Model................................................................................................................
.9
-
C - With Auto Trans.............................................................................................................
2.0
-
J1040
3.6
-
J1090
1.0
1.0
(CONT'D)
C - For Wagon Model..........................................................................................................
STRAINER, OIL - REPLACE
6V
J1030
ADD:
A - For 4x4 Model................................................................................................................
4J
J1034
ADD:
C24*E
J1036
ADD:
HFV6
J1037
ADD:
OIL GALLERY - REPLACE
6V
KIT, OIL CATCH TANK - INSTALL
POLICY: A
ENGINE J - 47
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
2.7
-
A - For 4x4 Model................................................................................................................
.8
-
B - For A/T. Pick Up Model..................................................................................................
.4
-
C - For A/T. Wagon Model...................................................................................................
.9
-
10.1
-
A - For 4x4 Model................................................................................................................
.9
-
B - With Auto Trans.............................................................................................................
2.0
-
3.1
3.1
A - For 4x4 Model ...............................................................................................................
.8
.8
B - For A/T. Pick Up Model (Fitted 2003 Cab Model)..........................................................
.4
-
C - For A/T. Wagon Model...................................................................................................
.9
.9
D - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.8
-
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.9
-
F - For 4x4 Model (4JJ1/4JK1 Engine Fitted 2012 Cab Model)...........................................
1.1
-
G - For A/T. Model (4JJ1/4JK1 Engine Fitted 2012 Cab Model).........................................
1.0
-
H - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.1
-
J - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
1.5
-
K - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
L - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
2.3
-
4.4
-
A - For 4x4 Model................................................................................................................
.8
-
B - For A/T. Pick Up Model..................................................................................................
.4
-
C - For A/T. Wagon Model...................................................................................................
.9
-
SEALS, CRANKSHAFT REAR MAIN - REPLACE
POLICY: P
INC: R&R transmission.
C24*E
J1120
ADD:
HFV6
J1122
ADD:
4J
J1123
ADD:
6V
J1127
ADD:
J - 48 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
9.1
-
A - To Replace Main Bearings (One Additional)..................................................................
.2
-
B - To Replace Main Bearings (Two Additional)..................................................................
.4
-
C - To Replace All Main Bearings........................................................................................
.8
-
D - To Replace Connecting Rod Bearings (One Additional)................................................
.2
-
E - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
-
F - To Replace All Connecting Rod Bearings......................................................................
.5
-
G - For 4x4 Pick Up Model...................................................................................................
.9
-
H - For 4x4 Wagon Model....................................................................................................
.8
-
J - For A/T. Pick Up Model...................................................................................................
.8
-
K - For A/T. Wagon Model...................................................................................................
1.1
-
L - For Pick Up Model with A/C. (Engine Remove Work only).............................................
.3
-
M - For Wagon Model with A/C. (Engine Remove Work only).............................................
.4
-
N - For 4x4 Model................................................................................................................
2.9
-
13.5
-
A - To Replace Main Bearings (One Additional)..................................................................
.2
-
B - To Replace Main Bearings (Two Additional)..................................................................
.4
-
C - To Replace All Main Bearings........................................................................................
.8
-
D - To Replace Connecting Rod Bearings (One Additional)................................................
.2
-
E - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
-
F - To Replace All Connecting Rod Bearings......................................................................
.5
-
G - For 4x4 Pick Up Model...................................................................................................
.9
-
H - For 4x4 Wagon Model....................................................................................................
.8
-
J - For Pick Up Model with A/C. (Engine Remove Work only).............................................
.3
-
K - For Wagon Model with A/C. (Engine Remove Work only).............................................
.4
-
L - For 4x4 Model.................................................................................................................
2.9
-
M - With Auto Trans.............................................................................................................
2.0
-
7.5
13.6
.2
.2
BEARING, CRANKSHAFT MAIN - REPLACE
POLICY: P, T
INC; R&R engine assembly, oil pan and flywheel housing,
plastic type gauge bearing.
ONE BEARING; C24*E
J1150
ADD:
ONE BEARING; HFV6
J1152
ADD:
ONE BEARING; 4J
J1153
ADD:
A - To Replace Main Bearings (One Additional)..................................................................
(CONTINUED)
ENGINE J - 49
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
B - To Replace Main Bearings (Two Additional)..................................................................
.4
.4
C - To Replace All Main Bearings........................................................................................
.8
.8
D - To Replace Connecting Rod Bearings (One Additional)................................................
.2
.2
E - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
.3
F - To Replace All Connecting Rod Bearings......................................................................
.5
.5
G - For 4x4 Model (4JJ1/4JK1 Engine)................................................................................
.8
.8
H - For A/T. Pick Up Model..................................................................................................
.8
-
J - For A/T. Wagon Model....................................................................................................
1.1
1.1
K - For Pick Up Model with A/C. (Engine Remove Work only)............................................
.3
-
L - For Wagon Model with A/C. (Engine Remove Work only)..............................................
.4
.4
M - 4JJ1/4JK1 Engine..........................................................................................................
6.1
-
N - For 4x4 Model (4JA1/4JH1 Engine)...............................................................................
2.9
-
P - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
Q - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
8.1
-
R - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.5
-
S - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
T - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
U - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
2.3
-
8.6
-
A - To Replace Main Bearings (One Additional)..................................................................
.2
-
B - To Replace Main Bearings (Two Additional)..................................................................
.4
-
C - To Replace All Main Bearings........................................................................................
.8
-
D - To Replace Connecting Rod Bearings (One Additional)................................................
.2
-
E - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
-
F - To Replace All Connecting Rod Bearings......................................................................
.5
-
G - For 4x4 Pick Up Model...................................................................................................
.9
-
H - For 4x4 Wagon Model....................................................................................................
.8
-
J - For A/T. Pick Up Model...................................................................................................
.8
-
K - For A/T. Wagon Model...................................................................................................
1.1
-
L - For Pick Up Model with A/C. (Engine Remove Work only).............................................
.3
-
M - For Wagon Model with A/C. (Engine Remove Work only).............................................
.4
-
N - For 4x4 Model................................................................................................................
2.9
-
(CONT'D)
ONE BEARING; 6V
J1157
ADD:
J - 50 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
5.6
-
A - To Replace Connecting Rod Bearings (One Additional)................................................
.2
-
B - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
-
C - To Replace All Connecting Rod Bearings......................................................................
.5
-
D - For 4x4 Pick Up Model...................................................................................................
.9
-
E - For 4x4 Wagon Model....................................................................................................
.8
-
F - For A/T. Pick Up Model..................................................................................................
.8
-
G - For A/T. Wagon Model...................................................................................................
1.1
-
H - For Pick Up Model with A/C. (Engine Remove Work only)............................................
.3
-
J - For Wagon Model with A/C. (Engine Remove Work only)..............................................
.4
-
12.2
-
A - To Replace Connecting Rod Bearings (One Additional)................................................
.2
-
B - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
-
C - To Replace All Connecting Rod Bearings......................................................................
.5
-
D - For 4x4 Wagon Model....................................................................................................
.8
-
E - For A/T. Pick Up Model..................................................................................................
.8
-
F - For A/T. Wagon Model...................................................................................................
1.1
-
G - For Pick Up Model with A/C. (Engine Remove Work only)............................................
.3
-
H - For Wagon Model with A/C. (Engine Remove Work only).............................................
.4
-
J - With Auto Trans..............................................................................................................
2.0
-
K - For 4x4 Model................................................................................................................
.9
-
5.2
12.2
A - To Replace Connecting Rod Bearings (One Additional)................................................
.2
.2
B - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
.3
C - To Replace All Connecting Rod Bearings......................................................................
.5
.5
D - For 4x4 Model (4JA1/4JH1 Engine)...............................................................................
2.9
-
E - For 4x4 Pick Up Model (4JJ1/4JK1 Engine)...................................................................
.9
-
F - For 4x4 Wagon Model (4JJ1/4JK1 Engine)....................................................................
.8
.8
BEARING, CONNECTING ROD - REPLACE
POLICY: P, T
INC: R&R oil pan, oil pump, plastic type gauge bearings ,
clean and inspect oil pump and pan.
: 6V - R&R front axle housing complete.
ONE BEARING; C24*E
J1180
ADD:
ONE BEARING; HFV6
J1182
ADD:
ONE BEARING; 4J
J1183
ADD:
(CONTINUED)
ENGINE J - 51
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
G - For A/T. Pick Up Model..................................................................................................
.8
-
H - For A/T. Wagon Model...................................................................................................
1.1
1.1
J - For Pick Up Model with A/C. (Engine Remove Work only).............................................
.3
-
K - For Wagon Model with A/C. (Engine Remove Work only).............................................
.4
.4
L - 4JJ1/4JK1 Engine...........................................................................................................
7.0
-
M - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
N - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
9.0
-
P - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
Q - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
.9
-
R - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
2.3
-
7.2
-
A - To Replace Connecting Rod Bearings (One Additional)................................................
.2
-
B - To Replace Connecting Rod Bearings (Two Additional)................................................
.3
-
C - To Replace All Connecting Rod Bearings......................................................................
.5
-
D - For 4x4 Wagon Model....................................................................................................
.8
-
E - For A/T. Pick Up Model..................................................................................................
.8
-
F - For A/T. Wagon Model...................................................................................................
1.1
-
G - For Pick Up Model with A/C. (Engine Remove Work only)............................................
.3
-
H - For Wagon Model with A/C. (Engine Remove Work only).............................................
.4
-
9.4
-
A - For Pick Up Model with A/C...........................................................................................
.3
-
B - For Wagon Model with A/C............................................................................................
.4
-
C - To Replace Rod and/or Pin Only (One).........................................................................
.3
-
D - To Replace Rod and/or Pin Only (Two).........................................................................
.6
-
E - To Replace Rod and/or Pin Only (All)............................................................................
.9
-
F - To Replace Cylinder Head.............................................................................................
4.6
-
G - To Recondition or Replace All Valve.............................................................................
1.7
-
H - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
-
(CONT'D)
ONE BEARING; 6V
J1187
ADD:
CRANKSHAFT - REPLACE
POLICY: P, T
INC: R&R engine assembly R&R cylinder head assembly, oil pan and flywheel
housing, plastic type gauge bearings.
C24*E
J1200
ADD:
(CONTINUED)
J - 52 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
J - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
-
K - To Replace Piston, Rod and/or Rings (All)....................................................................
.9
-
L - For A/T. Pick Up Model...................................................................................................
.8
-
M - For A/T. Wagon Model..................................................................................................
1.1
-
N - For 4x4 Pick Up Model...................................................................................................
.9
-
P - For 4x4 Wagon Model....................................................................................................
.8
-
7.5
13.7
A - For Pick Up Model with A/C...........................................................................................
.3
-
B - For Wagon Model with A/C............................................................................................
.4
.4
C - For 4x4 Model (4JA1/4JH1 Engine)...............................................................................
2.9
-
D - To Replace Rod and/or Pin Only (One).........................................................................
.3
.3
E - To Replace Rod and/or Pin Only (Two).........................................................................
.6
.6
F - To Replace Rod and/or Pin Only (All)............................................................................
.9
.9
G - To Replace Cylinder Head.............................................................................................
1.2
1.2
H - To Recondition or Replace All Valve.............................................................................
1.7
1.7
J - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
.3
K - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
.6
L - To Replace Piston, Rod and/or Rings (All).....................................................................
.9
.9
M - To Replace Cylinder Liner (One)...................................................................................
.5
-
N - To Replace Cylinder Liner (Two)...................................................................................
1.0
-
P - To Replace Cylinder Liner (All)......................................................................................
1.6
-
Q - 4JJ1/4JK1 Engine..........................................................................................................
6.2
-
R - For A/T. Pick Up Model..................................................................................................
.8
-
S - For A/T. Wagon Model...................................................................................................
1.1
1.1
T - For 4x4 Wagon Model (4JJ1/4JK1 Engine)....................................................................
.8
.8
U - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
V - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
8.2
-
W - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)......
1.5
-
X - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
Y - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
2.3
-
Z - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.5
-
8.6
-
.3
-
(CONT'D)
4J
J1203
ADD:
6V
J1207
ADD:
A - For Pick Up Model with A/C...........................................................................................
(CONTINUED)
ENGINE J - 53
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
B - For Wagon Model with A/C............................................................................................
.4
-
C - For 4x4 Model................................................................................................................
2.9
-
D - To Replace Rod and/or Pin Only (One).........................................................................
.3
-
E - To Replace Rod and/or Pin Only (Two).........................................................................
.6
-
F - To Replace Cylinder Head.............................................................................................
1.2
-
G - To Recondition or Replace All Valve.............................................................................
1.7
-
H - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
-
J - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
-
K - For A/T. Pick Up Model..................................................................................................
.8
-
L - For A/T. Wagon Model...................................................................................................
1.1
-
M - To Replace Rod and/or Pin only (All) (6V*1 Engine).....................................................
1.3
-
N - To Replace Piston Rod and/or Rings (All) (6V*1 Engine)..............................................
1.4
-
P - For 4x4 Pick Up Model...................................................................................................
.9
-
Q - For 4x4 Wagon Model...................................................................................................
.8
-
14.6
-
A - To Replace Rod and/or Pin Only (One).........................................................................
.3
-
B - To Replace Rod and/or Pin Only (Two).........................................................................
.6
-
C - To Replace Rod and/or Pin Only (All)............................................................................
.9
-
D - To Replace Cylinder Head (One Bank)..........................................................................
1.7
-
E - To Replace Cylinder Head (Both Bank).........................................................................
3.4
-
F - To Recondition or Replace All Valve..............................................................................
7.5
-
G - To Replace Piston, Rod and/or Rings (One).................................................................
.3
-
H - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
-
J - To Replace Piston, Rod and/or Rings (All).....................................................................
.9
-
K - With Auto Trans.............................................................................................................
2.0
-
L - For 4x4 Model.................................................................................................................
.9
-
(CONT'D)
HFV6
J1210
ADD:
J - 54 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
13.5
-
A - To Recondition or Replace All Valves............................................................................
4.9
-
B - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
-
C - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
-
D - To Replace Piston, Rod and/or Rings (All)....................................................................
.9
-
E - To Replace Cylinder Head (One Bank)..........................................................................
1.7
-
F - To Replace Cylinder Head (Both Bank).........................................................................
3.4
-
G - With Auto Trans.............................................................................................................
2.0
-
H - For 4x4 Model................................................................................................................
.9
-
8.6
12.3
A - To Recondition or Replace All Valves............................................................................
1.7
1.7
B - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
.3
C - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
.6
D - To Replace Piston, Rod and/or Rings (All)....................................................................
.9
.9
E - To Replace Cylinder Liner (One)....................................................................................
.5
-
F - To Replace Cylinder Liner (Two)....................................................................................
1.0
-
G - To Replace Cylinder Liner (All)......................................................................................
1.6
-
H - To Replace Cylinder Head.............................................................................................
1.2
1.2
J - 4JJ1/4JK1 Engine...........................................................................................................
3.7
-
K - For 4x4 Model (4JA1/4JH1 Engine)...............................................................................
2.9
-
L - For 4x4 Pick Up Model...................................................................................................
.9
-
M - For 4x4 Wagon Model (4JJ1/4JK1 Engine)...................................................................
.8
.8
N - For A/T. Pick Up Model..................................................................................................
.8
-
P - For A/T. Wagon Model...................................................................................................
1.1
1.1
Q - For Pick Up Model with A/C...........................................................................................
.3
-
R - For Wagon Model with A/C............................................................................................
.4
.4
S - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
T - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
5.7
-
U - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
PISTON, ROD AND/OR RINGS - REPLACE
POLICY: P, T
POLICY: A (EXC. UC* MODEL)
INC: R&R oil pan and cylinder head, R&R piston and rod assembly.
: 6V - R&R front axle housing complete.
ONE CYL; HFV6
J1302
ADD:
ONE CYL; 4J
J1303
ADD:
(CONTINUED)
ENGINE J - 55
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
V - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
W - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
2.3
-
9.0
-
A - To Recondition or Replace All Valves............................................................................
1.7
-
B - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
-
C - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
-
D - To Replace Cylinder Head.............................................................................................
1.2
-
E - For 4x4 Model................................................................................................................
2.9
-
F - For 4x4 Pick Up Model...................................................................................................
.9
-
G - For 4x4 Wagon Model...................................................................................................
.8
-
H - For A/T. Pick Up Model..................................................................................................
.8
-
J - For A/T. Wagon Model....................................................................................................
1.1
-
K - For Pick Up Model with A/C...........................................................................................
.3
-
L - For Wagon Model with A/C.............................................................................................
.4
-
M - To Replace Piston, Rod and/or Rings (All) (6V*1 Engine).............................................
1.9
-
7.6
-
A - To Recondition or Replace All Valves............................................................................
1.7
-
B - To Replace Piston, Rod and/or Rings (One)..................................................................
.3
-
C - To Replace Piston, Rod and/or Rings (Two)..................................................................
.6
-
D - To Replace Piston, Rod and/or Rings (All)....................................................................
.9
-
E - To Replace Cylinder Head.............................................................................................
4.6
-
F - For 4x4 Pick Up Model...................................................................................................
.9
-
G - For 4x4 Wagon Model...................................................................................................
.8
-
H - For A/T. Pick Up Model..................................................................................................
.8
-
J - For A/T. Wagon Model....................................................................................................
1.1
-
K - For Pick Up Model with A/C...........................................................................................
.3
-
L - For Wagon Model with A/C.............................................................................................
.4
-
2.9
2.9
A - For 4x4 Pick Up Model (Fitted 2003 Cab Model)...........................................................
.9
-
B - For 4x4 Wagon Model....................................................................................................
.8
.8
(CONT'D)
ONE CYL; 6V
J1307
ADD:
ONE CYL; C24*E
J1309
ADD:
FLYWHEEL (AUTOMATIC TRANSMISSION) - REPLACE
J1401
POLICY: P
ADD:
(CONTINUED)
J - 56 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
C - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.3
-
D - HFV6 Engine..................................................................................................................
2.8
-
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.7
-
F - For 4x4 Model (4JJ1/4JK1 Engine Fitted 2012 Cab Model)...........................................
1.1
-
G - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
3.0
-
H - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.4
-
2.6
-
A - To Replace Clutch Pilot Bearing....................................................................................
.2
-
B - To Replace Ring Gear...................................................................................................
.5
-
C - For 4x4 Model................................................................................................................
.8
-
D - For Pick Up Model.........................................................................................................
.5
-
3.8
-
A - To Replace Clutch Pilot Bearing....................................................................................
.2
-
B - To Replace Ring Gear...................................................................................................
.5
-
C - For 4x4 Model................................................................................................................
.9
-
3.0
3.0
A - To Replace Clutch Pilot Bearing....................................................................................
.2
.2
B - To Replace Ring Gear...................................................................................................
.5
.5
C - For 4x4 Model (Fitted 2003 Cab Model)........................................................................
.8
.8
D - For Pick Up Model (Fitted 2003 Cab Model)..................................................................
.5
-
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.8
-
F - For 4x4 Model (4JJ1/4JK1 Engine Fitted 2012 Cab Model)...........................................
1.1
-
G - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.0
-
H - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
4.1
-
A - To Replace Clutch Pilot Bearing....................................................................................
.2
-
B - To Replace Ring Gear...................................................................................................
.5
-
(CONT'D)
FLYWHEEL (MANUAL TRANSMISSION) - REPLACE
POLICY: P
INC: R&R transmission.
C24*E
J1420
ADD:
HFV6
J1422
ADD:
4J
J1423
ADD:
6V
J1427
ADD:
(CONTINUED)
ENGINE J - 57
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
C - For 4x4 Model................................................................................................................
.8
-
D - For Pick Up Model.........................................................................................................
.5
-
.4
1.2
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.8
-
B - HFV6 Engine..................................................................................................................
.6
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.7
-
D - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
E - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.3
-
F - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
1.5
-
.4
1.2
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.8
-
B - HFV6 Engine..................................................................................................................
1.6
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.4
-
D - For 4x4 Model (Fitted 2012 Cab Model)........................................................................
.3
-
E - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.2
-
F - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
1.2
-
(CONT'D)
MOUNT, ENGINE - REPLACE
POLICY: P
FRONT RIGHT
J1500
ADD:
FRONT LEFT
J1501
ADD:
6V FRONT RIGHT
J1502
1.7
-
6V FRONT LEFT
J1503
1.7
-
FRONT BOTH
J1507
.6
1.4
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.8
-
B - HFV6 Engine..................................................................................................................
2.0
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
2.4
-
D - For 4x4 Model (Fitted 2012 Cab Model)........................................................................
.2
-
E - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
3.0
-
F - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)................
1.8
-
G - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
1.7
-
3.2
-
ADD:
6V FRONT BOTH
J1508
J - 58 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
J1600
.4
.4
J1643
4.0
4.0
A - Fitted 2012 Cab Model...................................................................................................
1.5
-
B - For 4x4 Model (Fitted 2012 Cab Model).........................................................................
1.1
-
C - For A/T. Model (Fitted 2012 Cab Model)........................................................................
1.0
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.7
-
E - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
F - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
G - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
2.3
-
10.7
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Pick Up Model...................................................................................................
.9
-
C - For 4x4 Wagon Model....................................................................................................
.8
-
D - To Boring.......................................................................................................................
ST
-
E - To Replace Cylinder Head.............................................................................................
1.2
-
F - To Recondition or Replace All Valves............................................................................
1.7
-
G - For A/T. Model...............................................................................................................
.8
-
15.5
-
A - For 4x4 Pick Up Model...................................................................................................
.9
-
B - For 4x4 Wagon Model....................................................................................................
.8
-
C - To Boring.......................................................................................................................
ST
-
D - To Replace Cylinder Head (One Bank)..........................................................................
1.7
-
PLUG, EXPANSION - REPLACE
POLICY: P
NOTE: Add appropriate labor operation time(s) for removal of necessary
components to gain access to plug to regular labor hours column.
PLUG, OIL GALLERY - REPLACE
POLICY: P
INC: R&R flywheel.
4J
ADD:
BLOCK, ENGINE FITTED - R&R OR REPLACE
POLICY: P, T
INC: R&R engine assembly.
C24*E
J1800
ADD:
HFV6
J1802
ADD:
(CONTINUED)
ENGINE J - 59
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
E - To Replace Cylinder Head (Both Bank).........................................................................
3.4
-
F - To Recondition or Replace All Valves............................................................................
7.5
-
G - For A/T. Model...............................................................................................................
.8
-
H - With Auto Trans.............................................................................................................
2.0
-
10.5
14.7
A - With A/C.........................................................................................................................
.3
.3
B - For 4x4 Pick Up Model...................................................................................................
.9
-
C - For 4x4 Wagon Model....................................................................................................
.8
.8
D - To Boring.......................................................................................................................
ST
ST
E - To Replace Cylinder Head.............................................................................................
1.2
-
F - To Replace Cylinder Head (4JJ1/4JK1 Engine).............................................................
3.1
3.1
G - To Recondition or Replace All Valves...........................................................................
1.7
1.7
H - 4JJ1/4JK1 Engine..........................................................................................................
4.2
-
J - For A/T. Model................................................................................................................
.8
.8
K - With EGR. Cooler (4JA1/4JH1 Engine).........................................................................
.4
-
L - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)...........................................
.3
.3
M - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
6.2
-
N - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
P - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
Q - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
2.3
-
R - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.8
-
11.6
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Pick Up Model...................................................................................................
.9
-
C - For 4x4 Wagon Model....................................................................................................
.8
-
D - To Boring.......................................................................................................................
ST
-
E - To Replace Cylinder Head.............................................................................................
1.2
-
F - To Recondition or Replace All Valves............................................................................
1.7
-
G - For A/T. Model...............................................................................................................
.8
-
(CONT'D)
4J
J1803
ADD:
6V
J1807
ADD:
J - 60 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
8.2
-
A - With A/C.........................................................................................................................
.3
-
B - To Recondition or Replace All Valves............................................................................
1.7
-
C - To Replace Cyl. Head....................................................................................................
1.7
-
D - For 4x4 Pick Up Model...................................................................................................
.9
-
E - For 4x4 Wagon Model....................................................................................................
.8
-
F - For A/T. Pick Up Model..................................................................................................
.8
-
11.7
-
A - To Recondition or Replace All Valves............................................................................
7.5
-
B - To Replace Cylinder Head (One Bank)..........................................................................
1.7
-
C - To Replace Cylinder Head (Both Bank).........................................................................
3.4
-
D - For 4x4 Pick Up Model...................................................................................................
.9
-
E - For 4x4 Wagon Model....................................................................................................
.8
-
F - With Auto Trans.............................................................................................................
2.0
-
8.7
13.1
A - With A/C.........................................................................................................................
.3
.3
B - To Recondition or Replace All Valves............................................................................
1.7
1.7
C - To Replace Cylinder Head.............................................................................................
1.2
-
D - To Replace Cylinder Head (4JJ1/4JK1 Engine).............................................................
3.1
3.1
E - For 4x4 Pick Up Model...................................................................................................
.9
-
F - For 4x4 Wagon Model....................................................................................................
.8
.8
G - For A/T. Pick Up Model..................................................................................................
.8
-
H - For A/T. Wagon Model...................................................................................................
1.1
1.1
J - 4JJ1/4JK1 Engine...........................................................................................................
4.4
-
K - With EGR. Cooler (4JA1/4JH1 Engine).........................................................................
.4
-
L - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)...........................................
.3
.3
M - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
6.4
-
N - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
1.5
-
P - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
Q - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger).......
2.3
-
ENGINE PARTIAL/BASIC - REPLACE
POLICY: A, P, T
INC: R&R engine assembly.
C24*E
J1820
ADD:
HFV6
J1822
ADD:
4J
J1823
ADD:
(CONTINUED)
ENGINE J - 61
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.8
-
10.3
-
A - With A/C.........................................................................................................................
.3
-
B - To Recondition or Replace All Valves............................................................................
1.7
-
C - To Replace Cylinder Head.............................................................................................
1.2
-
D - For 4x4 Pick Up Model...................................................................................................
.9
-
E - For 4x4 Wagon Model....................................................................................................
.8
-
F - For A/T. Pick Up Model..................................................................................................
.8
-
G - For A/T. Wagon Model...................................................................................................
1.1
-
8.7
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Model................................................................................................................
.9
-
C - With Auto Trans.............................................................................................................
.8
-
4.9
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Pick Up Model...................................................................................................
.9
-
C - For 4x4 Wagon Model....................................................................................................
.8
-
D - For A/T. Pick Up Model..................................................................................................
.8
-
E - For A/T. Wagon Model...................................................................................................
1.1
-
6.1
-
A - For 4x4 Pick Up Model...................................................................................................
.9
-
B - For 4x4 Wagon Model....................................................................................................
.8
-
C - With Auto Trans.............................................................................................................
2.0
-
(CONT'D)
R - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
6V
J1827
ADD:
ENGINE UNIVERSAL - REPLACE
POLICY: P, T
INC: R&R engine assembly.
6V
J1840
ADD:
ENGINE ASSEMBLY - REPLACE
POLICY: A, P, T
C24*E
J1880
ADD:
HFV6
J1882
ADD:
(CONTINUED)
J - 62 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
4.2
5.1
A - With A/C.........................................................................................................................
.3
.3
B - 4JJ1/4JK1 Engine..........................................................................................................
.9
-
C - For 4x4 Pick Up Model...................................................................................................
.9
-
D - For 4x4 Wagon Model....................................................................................................
.8
.8
E - For A/T. Pick Up Model..................................................................................................
.8
-
F - For A/T. Wagon Model...................................................................................................
1.1
1.1
G - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
H - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.9
-
J - For 4x4 M/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
1.5
-
K - For 4x2 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
.9
-
L - For 4x4 A/T. Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)........
2.3
-
M - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.8
-
5.8
-
A - With A/C.........................................................................................................................
.3
-
B - For 4x4 Pick Up Model...................................................................................................
.9
-
C - For 4x4 Wagon Model....................................................................................................
.8
-
D - For A/T. Pick Up Model..................................................................................................
.8
-
E - For A/T. Wagon Model...................................................................................................
1.1
-
J3020
.2
.2
J3040
.3
.3
J3080
.4
.7
A - 6V*1 Engine...................................................................................................................
.3
-
B - 4JA1/4JH1 Engine ........................................................................................................
.2
-
C - 4JJ1/4JK1 Engine..........................................................................................................
.3
-
D - HFV6 Engine..................................................................................................................
.5
-
(CONT'D)
4J
J1883
ADD:
6V
J1887
ADD:
CAP, RADIATOR FILLER - REPLACE
INC: Diagnosis to pressure test cap.
COCK OF PLUG, RADIATOR DRAIN - REPLACE
INC: Drain and refill.
RADIATOR ASSEMBLY - R&R
ADD:
ENGINE J - 63
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.4
.7
A - 6V*1 Engine...................................................................................................................
.3
-
B - 4JA1/4JH1 Engine ........................................................................................................
.2
-
C - 4JJ1/4JK1 Engine..........................................................................................................
.3
-
D - HFV6 Engine..................................................................................................................
.5
-
.8
3.7
A - To Repair Core...............................................................................................................
1.0
-
B - To Replace Core............................................................................................................
1.0
-
C - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
2.9
-
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
2.4
-
F - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
4.8
-
G - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
.5
-
J3180
.2
.2
ONE PIECE
J3247
.2
.2
TWO PIECE TYPE; UPPER
J3248
.2
.2
TWO PIECE TYPE; LOWER
J3249
.4
.4
TWO PIECE TYPE; BOTH
J3250
.4
.4
.1
-
.2
.2
RADIATOR ASSEMBLY - REPLACE
J3100
POLICY: T
INC: Drain and refill.
ADD:
COOLER, ENGINE OIL - REPLACE
POLICY: P, T
INC: Drain and refill.
4J
J3123
ADD:
TUBE, OVERFLOW - REPLACE
SHROUD, RADIATOR FAN - REPLACE
ADD:
A - Fitted 2012 Cab Model...................................................................................................
RESERVOIR, RADIATOR COOLANT - REPLACE
J3260
J - 64 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
A - To Replace Clamp (One Additional)..............................................................................
.1
.1
B - To Replace Clamp (Two Additional)...............................................................................
.2
.2
C - To Replace Clamp (Three Additional)............................................................................
.3
.3
D - To Replace Clamp (Four Additional)..............................................................................
.4
.4
CLAMP, RADIATOR HOSE - REPLACE
ONE
J3340
ADD:
HOSE, ENGINE COOLANT - REPLACE
POLICY: T
INC: Drain and refill radiator as necessary.
UPPER
J3362
.2
.2
LOWER
J3363
.3
.3
.1
-
.4
.4
.1
-
.3
.6
A - 6V*1 Engine...................................................................................................................
.2
-
B - C24*E Engine.................................................................................................................
.3
-
C - 4JJ1/4JK1 Engine .........................................................................................................
.3
-
D - HFV6 Engine..................................................................................................................
.4
-
E - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.3
-
.3
.6
A - 6V*1 Engine...................................................................................................................
.2
-
B - C24*E Engine.................................................................................................................
.3
-
C - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.3
-
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.5
-
E - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.3
-
ADD:
A - HFV6 Engine..................................................................................................................
BOTH
J3367
ADD:
A - 4JH1 or 6V*1 Engine......................................................................................................
COOLING FAN - REPLACE
J3380
POLICY: T
INC: R&R fan clutch assembly if any.
ADD:
CLUTCH ASSEMBLY, COOLING FAN - REPLACE
J3390
ADD:
ENGINE J - 65
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.5
A - 6V*1 Engine...................................................................................................................
.2
-
B - C24*E Engine.................................................................................................................
.3
-
C - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.2
-
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.5
-
E - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.3
-
1.2
-
A - With A/C.........................................................................................................................
.1
-
B - For Pick Up Model..........................................................................................................
.3
-
PULLEY, COOLANT PUMP - REPLACE
J3420
POLICY: P, T
NOTE: Applicable for both "w/fan clutch" and "w/o fan clutch" models.
INC: Adjust belt tension.
ADD:
PUMP AND/OR GASKET, COOLANT - REPLACE
POLICY: P, T
INC: Drain and refill radiator as necessary.
C24*E
J3480
ADD:
HFV6
J3482
.5
-
4J
J3483
.7
.7
A - With A/C.........................................................................................................................
.1
.1
B - Fitted 2003 Cab Pick Up Model.....................................................................................
.3
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
D - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.1
-
1.9
-
A - With A/C.........................................................................................................................
.1
-
B - For Pick Up Model..........................................................................................................
.3
-
.4
.4
ADD:
6V
J3487
ADD:
THERMOSTAT, OUTLET AND/OR GASKET - REPLACE
POLICY: P
NOTE: EXC. 6V*1 and HFV6 engines
INC: Drain and refill radiator as necessary and test thermostat.
J3500
J - 66 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
-
2.0
-
.4
-
.4
-
J3540
.8
.8
J4020
.4
.7
A - 6V*1 Engine...................................................................................................................
.3
-
B - 4JA1/4JH1 Engine with A/C...........................................................................................
.6
-
C - 4JJ1/4JK1 Engine .........................................................................................................
.3
-
.9
.9
.3
-
.8
.8
.3
-
1.0
1.0
.3
-
THERMOSTAT, INLET AND/OR GASKET - REPLACE
J3505
POLICY: P
NOTE: For 6V*1 and HFV6 engines.
INC: Drain and refill radiator as necessary and test thermostat.
ADD:
A - HFV6 Engine..................................................................................................................
HOUSING AND/OR GASKET, THERMOSTAT - REPLACE
J3520
POLICY: P
ADD:
A - 4JA1/4JH1 Engine ........................................................................................................
COOLING SYSTEM - FLUSH
INC: Drain cooling system, R&R thermostat, flush with clear water
and test coolant.
PULLEY AND/OR FAN, GENERATOR - REPLACE
POLICY: T
ADD:
BEARING, GENERATOR - REPLACE
INC: R&R generator, separate end frame, and R&R rotor.
FRONT
J4042
ADD:
A - With A/C. (EXC. 4JJ1/4JK1 Engine)..............................................................................
REAR
J4043
ADD:
A - With A/C. (EXC. 4JJ1/4JK1 Engine)..............................................................................
BOTH
J4047
ADD:
A - With A/C. (EXC. 4JJ1/4JK1 Engine)..............................................................................
ENGINE J - 67
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.4
1.4
.3
-
1.4
1.4
.3
-
.7
.7
A - To Replace Rotor, Drive End Frame, Pulley, Fan and/or Front Bearing........................
.4
.4
B - To Replace Stator..........................................................................................................
.1
.1
C - To Replace Diode Trio...................................................................................................
.7
.7
D - To Recondition Complete..............................................................................................
.7
.7
.3
-
.4
-
A - To Replace Rotor, Drive End Frame, Pulley, Fan and/or Front Bearing........................
.4
-
B - To Replace Stator..........................................................................................................
.1
-
C - To Replace Diode Trio...................................................................................................
.7
-
D - To Recondition Complete..............................................................................................
.7
-
DIODE, CHARGING SYSTEM (JUMPER) - REPLACE
J4050
NOTE: EXC. HFV6 engine.
INC: R&R and disassemble generator as necessary.
ADD:
A - 4JA1/4JH1 Engine with A/C...........................................................................................
REGULATOR, VOLTAGE - TEST AND REPLACE
J4060
POLICY: T
NOTE: EXC. HFV6 engine.
INC: R&R and disassemble generator as necessary.
ADD:
A - 4JA1/4JH1 Engine with A/C...........................................................................................
GENERATOR ASSEMBLY - DISASSEMBLE, INSPECT, TEST AND REASSEMBLE
POLICY: T
NOTE: EXC. HFV6 engine.
INC: R&R generator assembly.
DIESEL
J4080
ADD:
INC: All of the above additions.
NOTE: All of the above additions include time to inspect and test the
components on the bench upon installation of a new part.
E - 4JA1/4JH1 Engine with A/C...........................................................................................
GASOLINE
J4081
ADD:
INC: All of the above additions.
NOTE: All of the above additions include time to inspect and test the
components on the bench upon installation of a new part.
(CONTINUED)
J - 68 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
-
.7
.7
.3
-
.4
-
.3
-
J4120
.3
.3
J4160
.9
.9
.3
-
.7
-
A - 6V*1 Engine...................................................................................................................
.3
-
B - HFV6 Engine..................................................................................................................
.1
-
(CONT'D)
E - 6V*1 Engine...................................................................................................................
GENERATOR ASSEMBLY - REPLACE
POLICY: T
INC: Transfer pulley and adjust belt tension.
DIESEL
J4100
ADD:
A - 4JA1/4JH1 Engine with A/C...........................................................................................
GASOLINE
J4101
ADD:
A - HFV6 Engine..................................................................................................................
BRACE, GENERATOR ADJUSTING - REPLACE
POLICY: T
BRACKET, GENERATOR MOUNTING - REPLACE
POLICY: T
DIESEL
ADD:
A - 4JA1/4JH1 Engine with A/C...........................................................................................
GASOLINE
J4161
ADD:
WIRES, SPARK PLUG - REPLACE
POLICY: T
ONE OR TWO
J4206
.2
-
ALL
J4207
.3
-
ONE OR TWO
J4226
.3
-
.2
-
PLUGS, SPARK - REPLACE
POLICY: T
ADD:
A - HFV6 Engine..................................................................................................................
(CONTINUED)
ENGINE J - 69
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.4
-
.2
-
.3
-
.9
-
.6
-
A - To Replace All Coils.......................................................................................................
.1
-
B - Diagnosis Time..............................................................................................................
.3
-
.3
-
.3
-
.3
-
.3
-
.3
-
A - To Replace Both Banks.................................................................................................
.1
-
B - Diagnosis Time..............................................................................................................
.3
-
(CONT'D)
ALL
J4227
ADD:
A - HFV6 Engine..................................................................................................................
COIL, IGNITION - REPLACE
J4340
POLICY: E, T
ADD:
A - C24*E Engine.................................................................................................................
COIL, ELECTRONIC IGNITION CONTROL - REPLACE
J4345
POLICY: E, T
NOTE: For HFV6 engine.
ADD:
SENSOR, CAMSHAFT POSITION - REPLACE
J4350
POLICY: E, T
NOTE: For HFV6 engine.
ADD:
A - Diagnosis Time..............................................................................................................
SENSOR, CRANKSHAFT POSITION - REPLACE
J4355
POLICY: E, T
NOTE: For HFV6 engine.
ADD:
A - Diagnosis Time..............................................................................................................
SENSOR, KNOCK - REPLACE
J4437
POLICY: E, T
NOTE: For HFV6 engine.
ADD:
J - 70 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.5
.7
A - 4JA1/4JH1 Engine.........................................................................................................
.2
-
B - 6VE1 Engine..................................................................................................................
.5
-
C - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.2
-
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.2
.2
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
F - For 4x4 Model (Fitted 2012 Cab Model).........................................................................
.2
-
.7
.9
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.2
-
B - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.2
.2
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
D - For 4x4 Model (Fitted 2012 Cab Model)........................................................................
.2
-
.4
.6
A - To Replace Starter Drive Assy.......................................................................................
.3
.3
B - To Recondition Starter Motor.........................................................................................
.6
.6
C - To Replace Field Coils...................................................................................................
.4
.4
D - To Recondition Armature...............................................................................................
.2
.2
E - 6VE1 Engine..................................................................................................................
.4
-
F - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)...................................................................
.2
-
G - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.2
.2
H - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
J - For 4x4 Model (Fitted 2012 Cab Model).........................................................................
.2
-
SOLENOID, STARTER MOTOR - REPLACE
J4580
POLICY: T
NOTE: EXC. HFV6 engine.
ADD:
DRIVE ASSEMBLY, STARTER MOTOR - REPLACE
J4600
POLICY: T
INC: R&R starter motor.
NOTE: EXC. HFV6 engine.
ADD:
MOTOR ASSEMBLY, STARTER - R&R
J4620
POLICY: T
NOTE: EXC. HFV6 engine.
ADD:
INC: Adds A and D.
ENGINE J - 71
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.4
.6
A - 6VE1 Engine..................................................................................................................
.4
-
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.2
-
C - HFV6 Engine..................................................................................................................
2.2
-
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.2
.2
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
F - For 4x4 Model (Fitted 2012 Cab Model).........................................................................
.2
-
.3
-
.3
-
.2
.5
A - To Replace Glow Plug (One or Two)..............................................................................
.1
.1
B - To Replace Glow Plugs (All)..........................................................................................
.2
.2
C - 4JJ1/4JK1 Engine..........................................................................................................
.3
-
D - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
E - 4JA1 Engine (Fitted 2012 Cab Model)...........................................................................
.4
-
F - 4JA1 Engine with EGR System (Fitted 2012 Cab Model)..............................................
.2
-
MOTOR ASSEMBLY, STARTER - REPLACE
J4640
POLICY: T
ADD:
SOLENOID, OR ACTUATOR FAST IDLE (DIESEL) - REPLACE
J4750
INC: Adjustment of fast idle speed.
ADD:
A - Diagnosis Time..............................................................................................................
GLOW PLUG - REPLACE
ONE
J4790
ADD:
CONTROL MODULE, GLOW PLUG - REPLACE
J4792
.2
-
AFTER GLOW TIMER - REPLACE
J4794
.2
-
SWITCH, QOS THERMO - REPLACE
J4796
.3
-
J - 72 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
AIR CLEANER ASSEMBLY - REPLACE
POLICY: A, E
C24*E
J5000
.2
-
HFV6
J5002
.2
-
4J
J5003
.3
.3
6V
J5007
.3
-
ELEMENT, AIR CLEANER - REPLACE
J5010
.2
.2
DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE
J5020
.7
.7
DUCT AND/OR HOSE, AIR CLEANER TO INLET MANIFOLD - REPLACE
J5021
.2
.2
DUCT AND/OR HOSE, TURBO. TO INLET MANIFOLD - REPLACE
J5023
.3
.3
SOLENOID, SWIRL CONTROL, INTAKE MANIFOLD - REPLACE
J5260
.2
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
C - EXC. 2 Stage Turbocharger...........................................................................................
.3
-
D - For 4x4 Model (EXC. 2 Stage Turbocharger).................................................................
.3
-
.2
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
POLICY: E
ADD:
SOLENOID, BYPASS VALVE, COMPRESSOR - REPLACE
J5269
ADD:
COMPRESSOR, BYPASS VALVE - REPLACE
J5270
.4
-
VALVE ASSEMBLY, INTAKE THROTTLE - R&R OR REPLACE
J5275
.3
.3
A - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
B - Diagnosis Time..............................................................................................................
.3
.3
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
ADD:
ENGINE J - 73
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CABLE, ACCELERATOR CONTROL - REPLACE
POLICY: T
C24*E
J5330
.3
-
4J
J5333
.4
-
6V
J5337
.2
-
DIESEL
J5345
.3
-
PEDAL, ACCELERATOR - REPLACE
J5350
.4
.4
FILTER, FUEL ELEMENT - REPLACE
J5420
.3
.5
.2
-
SOLENOID, ENGINE STOP - REPLACE
POLICY: E
ADD:
A - Fitted 2003 Cab Model...................................................................................................
PUMP AND/OR GASKET, FUEL - REPLACE
POLICY: T
IN TANK ELECTRIC
J5431
.9
-
GASOLINE
J5560
.6
-
.4
-
J5640
.8
-
HFV6 (All Injector)
J5649
1.0
-
6V
J5650
.9
-
C24*E
J5654
.4
-
A - To Replace Each Additional Injector..............................................................................
.1
-
B - To Replace All Injector...................................................................................................
.2
-
C - Diagnosis Time..............................................................................................................
.3
-
REGULATOR, FUEL PRESSURE - REPLACE
ADD:
A - 6V*1 Engine...................................................................................................................
PIPES & HOSES, FUEL FEED AND RETURN (FUEL PIPE ~ FUEL RAIL) - REPLACE
INJECTOR, FUEL (GASOLINE) - REPLACE
ADD:
J - 74 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
RAIL, FUEL INJECTOR - REPLACE
6V
J5660
1.0
-
C24*E
J5663
.5
-
HFV6
J5664
1.0
-
J5665
1.0
1.5
.5
-
.3
-
.3
-
.5
.5
A - 4JA1/4JH1 Engine.........................................................................................................
.5
-
B - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.4
.4
.3
-
.2
-
.3
.3
.1
-
.2
.2
.2
-
.2
.2
A - To Replace Third Piece Rubber Hose............................................................................
.1
.1
B - 4JA1/4JH1 Engine.........................................................................................................
.2
-
RAIL ASSEMBLY, COMMON, FUEL INJECTION (DIESEL) - R&R OR REPLACE
ADD:
A - Fitted 2003 Cab Model...................................................................................................
SENSOR, MASS AIR FLOW - REPLACE
J5670
NOTE: For HFV6 engine.
ADD:
A - Diagnosis Time..............................................................................................................
INTERCOOLER COMPONENTS - REPLACE
INTERCOOLER ASSEMBLY
J5685
ADD:
TURBO TO INTERCOOLER INLET PIPE
J5690
ADD:
A - 4JA1/4JH1 Engine.........................................................................................................
INTER COOLER TO INTAKE MANIFOLD PIPE
J5691
ADD:
A - 4JA1/4JH1 Engine.........................................................................................................
ONE RUBBER HOSE
J5692
ADD:
A - 4JA1/4JH1 Engine.........................................................................................................
TWO RUBBER HOSE
J5693
ADD:
TURBOCHARGER ASSEMBLY, LOW PRESSURE - REPLACE
J5857
3.5
-
TURBOCHARGER ASSEMBLY, HIGH PRESSURE - REPLACE
J5858
1.8
-
ENGINE J - 75
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
1.1
2.1
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
1.0
-
B - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.6
-
C - 4JA1-TC/4JH1-TC Engine ............................................................................................
.3
-
.4
.7
.3
-
.3
.7
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.4
-
B - 4JA1/4JH1 Engine ........................................................................................................
.2
-
TURBOCHARGER ASSEMBLY - REPLACE
POLICY: A (EXC. UC* MODEL)
POLICY: P
4J
J5863
ADD:
PIPE, OIL PRESSURE (TURBO) - REPLACE
J5866
ADD:
A - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
PIPE, OIL RETURN (TURBO) - REPLACE
J5867
ADD:
PIPE, OIL PRESSURE (LOW PRESSURE TURBOCHARGER) - REPLACE
J5871
.9
-
PIPE, OIL PRESSURE (HIGH PRESSURE TURBOCHARGER) - REPLACE
J5872
.9
-
PIPE, OIL RETURN (LOW PRESSURE TURBOCHARGER) - REPLACE
J5873
3.5
-
.5
-
ADD:
A - For 4x4 Model................................................................................................................
PIPE, OIL RETURN (HIGH PRESSURE TURBOCHARGER) - REPLACE
J5874
1.8
-
PIPE, OIL PRESSURE & RETURN (TURBO) - REPLACE
J5875
1.2
1.2
.3
.3
.3
.3
ADD:
A - For 4x4 Models...............................................................................................................
HOSE, WATER RETURN (TURBO) - REPLACE
J5885
J - 76 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.8
A - With A/C. (EXC. 4JJ1/4JK1 Engine)..............................................................................
.5
-
B - 4JJ1/4JK1 Engine .........................................................................................................
.5
-
.2
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
1.0
A - To Replace Additional Injector (One or Two).................................................................
.2
.2
B - To Replace All Injectors.................................................................................................
.3
.3
C - To Adjust Injection Pressure (1 - 2)...............................................................................
.2
-
D - To Adjust Injection Pressure (3 - 4)...............................................................................
.4
-
E - To Lap Nozzle................................................................................................................
ST
-
F - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)...................................................................
.6
-
G - Diagnosis Time..............................................................................................................
.3
.3
H - Program ECM................................................................................................................
.3
.3
J - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)...........................................
.3
.3
K - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.8
-
L - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
M - 4JA1/4JH1 Engine without EGR. Cooler (Fitted 2003 Cab Model)................................
.2
-
N - 4JA1/4JH1 Engine with EGR. Cooler (Fitted 2003 Cab Model).....................................
.6
-
P - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
HOSE, WATER FEED (TURBO) - REPLACE
J5886
ADD:
SOLENOID, TURBOCHARGER CONTROL - REPLACE
J5891
ADD:
SOLENOID, TURBIN BYPASS CONTROL, TURBOCHARGER - REPLACE
J5892
ADD:
INJECTOR, FUEL (DIESEL) - R&R OR REPLACE
POLICY: T
ONE
J5926
ADD:
ENGINE J - 77
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.5
.9
A - To Replace Additional Line (One)..................................................................................
.1
.1
B - To Replace Additional Line (Two)..................................................................................
.2
.2
C - To Replace All Lines......................................................................................................
.3
.3
D - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.4
-
E - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
F - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)...................................................................
.2
-
.3
.3
.3
.3
1.8
4.5
A - 4JA1-TC/4JH1-TC Engine .............................................................................................
.3
-
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
2.7
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
2.1
-
E - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
F - 4JA1 Engine with EGR. System (Fitted 2012 Cab Model).............................................
.2
-
J5960
.3
-
J5962
1.7
1.7
J5965
.5
-
LINE, FUEL INJECTION HIGH PRESSURE DIESEL - R&R OR REPLACE
POLICY: T
ONE
J5935
ADD:
LINE, FUEL RETURN - REPLACE
J5937
ADD:
A - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
PUMP, FUEL INJECTION DIESEL - REPLACE
POLICY: A, P, T
GEAR TYPE; 4J
J5953
ADD:
GASKET, TIMING COVER TO HOUSING, INJECTION PUMP - REPLACE
POLICY: P
NOTE: EXC. 4JJ1/4JK1 engine.
GEAR AND/OR ADVANCE TIMING MECHANISM, FUEL INJECTION PUMP - REPLACE
POLICY: P, T
TIMING, FUEL INJECTION PUMP DIESEL - ADJUST
POLICY: E
J - 78 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
4.1
4.7
.6
-
J5995
1.0
1.0
J6000
.3
.3
J6200
.4
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
-
.3
-
.3
.4
A - 4JJ1/4JK1 Engine..........................................................................................................
.1
-
B - Diagnosis Time..............................................................................................................
.3
.3
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
.2
-
.5
.7
A - 4JJ1/4JK1 Engine..........................................................................................................
.2
-
B - Intercooler of Upside Installation Type (4JJ1/4JK1 Engine)..........................................
.3
.3
C - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
.8
-
1.3
-
FRP(FUEL RAIL PRESSURE) / SCV(SUCTION CONTROL VALVE)
J5990
- REPLACE (INC. SUPPLY PUMP REMOVALAND REINSTALL TIME)
ADD:
A - Fitted 2003 Cab Model...................................................................................................
FRP(FUEL RAIL PRESSURE) / SCV(SUCTION CONTROL VALVE)
- REPLACE (ON VEHICLE)
VALVE, PCV - REPLACE
POLICY: E
SENSOR, AIR CLEANER TEMPERATURE - REPLACE
POLICY: E
ADD:
PIPE, EGR - R&R OR REPLACE
J6269
ADD:
A - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
VALVE AND/OR GASKET, EGR - REPLACE
J6270
POLICY: E, P
ADD:
COOLER, EGR VALVE - REPLACE
J6275
ADD:
BYPASS VALVE AND/OR GASKET, EGR - REPLACE
J6285
ENGINE J - 79
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
J6340
.4
-
VACUUM SWITCHING VALVE, THROTTLE - REPLACE
J6351
.2
-
SENSOR, CRANKSHAFT ANGLE - REPLACE
J6355
.3
.8
A - C24*E Engine.................................................................................................................
.9
-
B - 4JJ1/4JK1 Engine..........................................................................................................
.5
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
.8
A - C24*E Engine.................................................................................................................
.9
-
B - 4JJ1/4JK1 Engine..........................................................................................................
.5
-
.5
.5
A - 2005 ~ 2006 Model (4JJ1/4JK1 Engine)........................................................................
.4
.4
B - 2007 Model ~ (4JJ1/4JK1 Engine).................................................................................
.1
.1
.2
-
A - C24*E Engine.................................................................................................................
.1
-
B - 4JA1/4JH1 Engine.........................................................................................................
.8
-
SOLENOID, BYPASS CONTROL,EGR - REPLACE
J6286
ADD:
SWITCH, EGR/EFE THERMAL VACUUM - REPLACE
POLICY: E
NOTE: EXC. HFV6 engine.
ADD:
OIL SEAL (O-RING), SENSOR, CRANKSHAFT ANGLE - REPLACE
J6356
ADD:
SERVICE PROGRAMMING SYSTEM - REPROGRAM
J6358
ADD:
CONTROLLER, EDU(ENGINE DRIVE UNIT) - REPLACE
J6359
ADD:
J - 80 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.3
A - To Program....................................................................................................................
.3
.3
B - EXC.4JJ1/4JK1 Engine..................................................................................................
.3
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - 4JJ1/4JK1 Engine..........................................................................................................
.8
-
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
.2
A - HFV6 Engine..................................................................................................................
.1
-
B - Diagnosis Time..............................................................................................................
.3
.3
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
.3
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
CONTROLLER, ECM (ENGINE CONTROL MODULE) - R&R OR REPLACE
J6360
POLICY: E
ADD:
SENSOR, BARO (BAROMETRIC PRESSURE) - REPLACE
J6366
ADD:
SENSOR, FUEL TEMPERATURE - REPLACE
J6368
ADD:
SENSOR, COOLANT TEMPERATURE - REPLACE
J6369
ADD:
SENSOR, MAP (MANIFOLD ABSOLUTE PRESSURE) - REPLACE
J6370
POLICY: E
ADD:
SENSOR, IAT/MAT (INTAKE AIR TEMPERATURE/MANIFOLD AIR TEMPERATURE)
J6371
- REPLACE
ADD:
ENGINE J - 81
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
-
A - 6V*1 Engine...................................................................................................................
.1
-
B - HFV6 Engine..................................................................................................................
.2
-
C - To Replace Each Additional Sensor..............................................................................
.1
-
D - Diagnosis Time..............................................................................................................
.3
-
.4
.4
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
.4
.3
.3
.2
.3
A - 6V*1 Engine...................................................................................................................
.2
-
B - 4JJ1/4JK1 Engine..........................................................................................................
.1
-
C - Diagnosis Time..............................................................................................................
.3
.3
D - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
-
.3
-
SENSOR, O-2 (EXHAUST OXYGEN) - REPLACE
J6372
POLICY: E
ADD:
SENSOR, ACCEL POSITION - REPLACE
J6373
NOTE: Include clean all connector pins.
ADD:
SENSOR, THROTTLE POSITION - REPLACE
J6374
ADD:
A - Diagnosis Time..............................................................................................................
SENSOR, CAMSHAFT ANGLE - REPLACE
J6376
NOTE: EXC. HFV6 engine.
ADD:
SENSOR, AIR FLOW - REPLACE
J6378
NOTE: EXC. HFV6 Engine.
ADD:
SENSOR, KNOCK - REPLACE
J6379
NOTE: EXC. HFV6 engine.
ADD:
A - Diagnosis Time..............................................................................................................
J - 82 ENGINE
ENGINE
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
-
.3
-
.7
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.8
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
CONTROLLER, EGR - REPLACE
J6396
ADD:
SENSOR, ENGINE SPEED - REPLACE
J6540
ADD:
A - Diagnosis Time..............................................................................................................
SENSOR, EGR TEMPERATURE (IN) - REPLACE
J6543
ADD:
SENSOR, EGR TEMPERATURE (OUT) - REPLACE
J6544
ADD:
K TRANSAXLE AND TRANSMISSION
K
K - 8 TRANSAXLE AND TRANSMISSION
CLUTCH & CONTROLS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CLUTCH SYSTEM, HYDRAULIC - BLEED
K0040
.2
.2
PEDAL, SHAFT AND/OR BUSHING, CLUTCH - REPLACE
K0060
.4
.6
A - Fitted 2003 Cab Model...................................................................................................
.2
-
B - Fitted 2012 Cab LHD. Model..........................................................................................
.1
-
K0080
.4
.4
K0100
.4
.6
.2
-
K0580
.2
-
K0600
.4
.4
A - To Recondition Clutch Master Cylinder..........................................................................
.2
.2
B - HFV6 Engine..................................................................................................................
.3
-
C - Fitted 2012 Cab LHD. Model..........................................................................................
.3
-
D - Fitted 2012 Cab RHD. Model.........................................................................................
.2
-
.5
.5
INC: Adjust linkage.
ADD:
PUSH ROD AND/OR SEAL, CLUTCH PEDAL - REPLACE
POLICY: T
INC: Adjust linkage.
SPRING, CLUTCH PEDAL RETURN - REPLACE
ADD:
A - Fitted 2003 Cab Model...................................................................................................
RESERVOIR,CLUTCH FLUID - REPLACE
NOTE: For HVF6 engine.
CYLINDER, CLUTCH MASTER - R&R OR REPLACE
POLICY: T
INC: Bleed system.
ADD:
CYLINDER, CLUTCH DAMPER - R&R OR REPLACE
POLICY: T
INC: Bleed system.
K0610
TRANSAXLE AND TRANSMISSION K - 9
CLUTCH & CONTROLS
OPERATION DESCRIPTION
OPERATION
NUMBER
CYLINDER, SLAVE - R&R OR REPLACE
K0620
CAB STYLE
VIN CODE
TF*
UC*
.3
.3
.1
.1
POLICY: T
INC: Bleed system.
ADD:
A - To Recondition Slave Cylinder.......................................................................................
LINE, CLUTCH HYDRAULIC (MASTER CYLINDER TO SLAVE CYLINDER) - REPLACE
POLICY: T
PIPE
K0646
.5
.5
(4 x 2)
K0700
2.8
2.8
A - 6V*1 Engine...................................................................................................................
.5
-
B - To Replace Clutch Disc and/or Pressure Plate..............................................................
.3
.3
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.5
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
1.7
-
3.8
3.8
A - 6V*1 Engine...................................................................................................................
.5
-
B - To Replace Clutch Disc and/or Pressure Plate..............................................................
.3
.3
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.5
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.2
-
3.5
-
.8
-
2.8
2.8
.1
.1
BEARING, CLUTCH RELEASE - REPLACE
INC: R&R trans, adjust clutch free travel and/or linkage for all series.
ADD:
(4 x 4)
K0701
ADD:
CYLINDER,CLUTCH ACTUATOR - R&R OR REPLACE
K0720
NOTE:For HFV6 engine
ADD:
A - For 4x4 Model................................................................................................................
DISC AND/OR PRESSURE PLATE, CLUTCH - REPLACE
POLICY: A, T
INC: R&R trans, adjust clutch free travel and/or linkage for all series.
(4 x 2)
K0800
ADD:
A - To Replace Clutch Fork Shaft and/or Bushings.............................................................
(CONTINUED)
K - 10 TRANSAXLE AND TRANSMISSION
CLUTCH & CONTROLS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
B - To Replace Clutch Pilot Bearing for Pick Up Model.......................................................
.2
-
C - To Replace Clutch Pilot Bearing for Wagon Model........................................................
.4
-
D - To Replace Flywheel......................................................................................................
.2
.2
E - To Replace Clutch Release Bearing..............................................................................
.2
.2
F - 6V*1 Engine...................................................................................................................
.5
-
G - To Replace Clutch Pilot Bearing....................................................................................
-
.4
H - HFV6 Engine..................................................................................................................
.8
-
J - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)...................................................................
.7
-
K - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
1.8
-
3.8
3.8
A - To Replace Clutch Fork Shaft and/or Bushings.............................................................
.1
.1
B - To Replace Clutch Pilot Bearing for Pick Up Model.......................................................
.2
-
C - To Replace Clutch Pilot Bearing for Wagon Model........................................................
.4
-
D - To Replace Flywheel......................................................................................................
.2
.2
E - To Replace Clutch Release Bearing..............................................................................
.2
.2
F - 6V*1 Engine...................................................................................................................
.5
-
G - To Replace Clutch Pilot Bearing....................................................................................
-
.4
H - HFV6 Engine..................................................................................................................
.8
-
J - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)...................................................................
.7
-
K - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.3
-
(CONT'D)
(4 x 4)
K0801
ADD:
TRANSAXLE AND TRANSMISSION K - 11
MANUAL TRANSMISSION CONTROLS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
KNOB, TRANSMISSION SHIFT CONTROL LEVER - REPLACE
K1000
.2
.2
LEVER, GEARSHIFT CONTROL - REPLACE
K1060
.4
.4
K1080
.3
.3
.1
-
.2
.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
.3
POLICY: T
SEAL AND/OR BOOT, FLOOR MOUNTED GEARSHIFT - REPLACE
TRANSMISSION GEARSHIFT
ADD:
A - Fitted 2012 Cab Model...................................................................................................
SENSOR, VEHICLE SPEED - REPLACE
K2050
ADD:
GEAR AND/OR SEAL SPEEDOMETER DRIVEN - REPLACE
K2060
K - 12 TRANSAXLE AND TRANSMISSION
MANUAL TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
SEAL, TRANSMISSION EXTENSION REAR OIL - REPLACE
CAB STYLE
VIN CODE
TF*
UC*
K2160
.6
.6
K2240
.6
.6
K2283
.6
.6
.2
-
POLICY: P
INC: D&C front universal joint and hanger bearing support to frame.
Drain and refill transmission. R&R hand brake and yoke flange.
DOES NOT INC: R&R transmission assembly or recondition universal joint.
COVER AND/OR GASKET, TRANSMISSION SHIFT - R&R OR REPLACE
POLICY: P
INC: R&R floor mat, floor access cover, shift linkage and shift cover
and gasket. Clean, inspect and retorque.
DOES NOT INC: Recondition remote control assembly.
MOUNT, TRANSMISSION - REPLACE
POLICY: P, T
REAR
ADD:
A - Fitted 2012 Cab Model...................................................................................................
6V REAR
K2284
.6
-
REMOVE AND REINSTALL TRANS AY-6
K2698
4.4
-
A - For 4x4 Model................................................................................................................
1.6
-
B - Recondition Transmission Assembly.............................................................................
3.0
-
2.6
2.6
A - To Recondition Shifter Cover.........................................................................................
.4
.4
B - To Replace Main Drive Gear Bearing Retainer and/or Gasket or Seal..........................
.3
.3
C - To Replace Main Drive Gear Bearing............................................................................
1.9
1.9
D - To Recondition Main Shaft.............................................................................................
2.5
2.5
E - To Replace Case Extension And Seal...........................................................................
.5
.5
F - To Replace Speedometer Drive Gear............................................................................
.5
.5
TRANSMISSION ASSEMBLY - RECONDITION
POLICY: P, T
INC: R&R trans, adjust clutch free travel and/or linkage for all series.
DOES NOT INC: Recondition transmission.
ADD:
(4 x 2)
K2700
ADD:
INC: The above add condition.
(CONTINUED)
TRANSAXLE AND TRANSMISSION K - 13
MANUAL TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
G - To Replace Case...........................................................................................................
1.2
1.2
H - 6V*1 Engine...................................................................................................................
.5
-
J - HFV6 Engine..................................................................................................................
.8
-
K - Fitted 2012 Cab Model...................................................................................................
.8
-
3.6
3.6
A - To Recondition Shifter Cover.........................................................................................
.4
.4
B - To Replace Main Drive Gear Bearing Retainer and/or Gasket or Seal..........................
.3
.3
C - To Replace Main Drive Gear Bearing............................................................................
1.9
1.9
D - To Recondition Main Shaft.............................................................................................
2.5
2.5
E - To Replace Case Extension And Seal...........................................................................
.5
.5
F - To Replace Speedometer Drive Gear............................................................................
.5
.5
G - To Replace Case...........................................................................................................
1.2
1.2
H - 6V*1 Engine...................................................................................................................
.5
-
J - HFV6 Engine..................................................................................................................
.8
-
K - Fitted 2012 Cab Model...................................................................................................
.8
-
3.6
3.6
A - To Replace Front Oil Seal..............................................................................................
.6
.6
B - To Replace Main & Counter Gear and/or Bearing.........................................................
2.5
2.5
C - To Replace Output Shaft & Bearing and/or Seal...........................................................
.9
.9
D - To Replace Front Case..................................................................................................
.6
.6
E - To Replace Rear Case...................................................................................................
.9
.9
F - Fitted 2012 Cab Model...................................................................................................
.8
-
2.6
2.6
A - To Replace Front Oil Seal..............................................................................................
.6
.6
B - To Replace Main & Counter Gear and/or Bearing.........................................................
2.5
2.5
C - To Replace Output Shaft & Bearing and/or Seal...........................................................
.9
.9
D - To Replace Front Case..................................................................................................
.6
.6
E - To Replace Rear Case...................................................................................................
.9
.9
F - Fitted 2012 Cab Model...................................................................................................
.8
-
(CONT'D)
(4 x 4)
K2701
ADD:
INC: The above add condition.
(MUX 4x4)
K2709
ADD:
(MUX 4x2)
K2712
ADD:
K - 14 TRANSAXLE AND TRANSMISSION
MANUAL TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
4.7
-
1.5
-
2.7
2.7
A - 6V*1 Engine...................................................................................................................
.4
-
B - HFV6 Engine..................................................................................................................
.7
-
C - Fitted 2012 Cab Model...................................................................................................
.8
-
3.7
3.7
A - 6V*1 Engine...................................................................................................................
.4
-
B - HFV6 Engine..................................................................................................................
.7
-
C - Fitted 2012 Cab Model...................................................................................................
.8
-
TRANSMISSION ASSEMBLY - REPLACE
POLICY: A, P, T
INC: Separate transfer case assembly.
AY-6
K2719
ADD:
A - For 4x4 Model................................................................................................................
(4 x 2)
K2720
ADD:
(4 x 4)
K2721
ADD:
TRANSAXLE AND TRANSMISSION K - 15
AUXILIARY TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
ACTUATOR, TRANSFER 2W/4W SHIFT - REPLACE
K4140
.4
.4
SEAL, OIL, ACTUATOR SHAFT - REPLACE
K4145
.5
.5
FRONT
K4162
.7
.7
REAR
K4163
.6
.6
FRONT INPUT
K4164
2.5
2.5
K4300
.3
.3
A - Diagnosis Time..............................................................................................................
.3
.3
B - Fitted 2012 Cab Model...................................................................................................
.1
-
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
.4
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
2.1
4.0
A - For Wagon Model..........................................................................................................
1.9
-
B - For AR5 Trans................................................................................................................
2.9
-
C - MUX Transmission.........................................................................................................
.9
.9
SEAL, TRANSFER CASE OIL - REPLACE
POLICY: P
CONTROL UNIT, TRANSFER (2W-4W) - REPLACE
ADD:
CONTROL UNIT, TRANSFER (2W-4W) - CLEAR MEMORY
K4305
ADD:
TRANSFER CASE ASSEMBLY - RECONDITION
POLICY: P, T
MAN TRANS
K4400
ADD:
AUTO TRANS
K4401
4.0
4.0
M/T MUX
K4408
1.5
1.5
M/T MUA
K4409
1.5
1.5
M/T AR5
K4411
1.7
-
A/T JR405
K4414
1.5
1.5
A/T AW30-40E
K4415
1.5
-
TRANSFER CASE ASSEMBLY - REPLACE
(CONTINUED)
K - 16 TRANSAXLE AND TRANSMISSION
AUXILIARY TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
A/T 4L60E
K4416
1.4
-
A/T TB-50LS
K4417
1.5
-
TRANSAXLE AND TRANSMISSION K - 17
AUTOMATIC TRANSMISSION CONTROLS
OPERATION DESCRIPTION
INDICATOR PLATE AND/OR ASSEMBLY SHIFT RANGE INDICATOR - REPLACE
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.3
.1
-
K5110
.2
.2
K5170
.3
.3
K5250
.9
.9
K5100
ADD:
A - Fitted 2012 Cab Model...................................................................................................
SHIFT KNOB - R&R OR REPLACE
POLICY: T
SHIFT LEVER, CONTROL LINKAGE - REPLACE
POLICY: T
SHIFT CABLE, CONTROL - REPLACE
INC: Adjust.
K - 18 TRANSAXLE AND TRANSMISSION
AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.7
.7
.3
.3
.7
.7
.3
.3
.9
.9
.3
.3
K5287
.3
.3
LEVEL GAUGE (DIPSTICK), TRANSMISSION ATF - REPLACE
K6130
.2
.2
FILLER TUBE AND/OR GASKET, TRANSMISSION - REPLACE
K6140
.3
.3
K6275
.3
.3
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
1.0
1.0
2.0
-
.3
.3
OIL COOLER PIPES, TRANSMISSION - REPAIR OR REPLACE
POLICY: T
INLET
K5262
ADD:
A - For 4x4 Model................................................................................................................
OUTLET
K5263
ADD:
A - For 4x4 Model................................................................................................................
BOTH
K5267
ADD:
A - For 4x4 Model................................................................................................................
OIL COOLER HOSES, TRANSMISSION - REPAIR OR REPLACE
POLICY: T
RADIATOR SIDE : BOTH
POLICY: P
INHIBITOR SWITCH, TRANSMISSION - REPLACE
POLICY: P, T
INC: D&C shift arm, cable-transmission side
ADD:
BOLTS, CONVERTER TO FLYWHEEL - REPLACE
K6300
POLICY: P
ADD:
A - HFV6 Engine .................................................................................................................
DRIVEN GEAR AND/OR GASKET, SPEEDOMETER - REPLACE
POLICY: P
K6320
TRANSAXLE AND TRANSMISSION K - 19
AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.3
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
.3
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
K6360
.6
.6
OIL PRESSURE TEST
K6400
.5
.5
DRAIN PLUG AND/OR GASKET - R&R OR REPLACE
K6490
.2
.2
K6500
.6
.6
.1
.1
.5
.5
SENSOR, VEHICLE SPEED - REPLACE
K6330
ADD:
SENSOR, SPEED, REVOLUTION - REPLACE
K6331
ADD:
OIL SEAL, EXTENSION HOUSING FLANGE YOKE - REPLACE
POLICY: P
INC: Drain and refill ATF.
OIL PAN AND/OR GASKET, TRANSMISSION - R&R OR REPLACE
POLICY: P
TRANSMISSION
ADD:
A - To Replace Oil filter........................................................................................................
B - To Replace Solenoids (One or All)
(EXC. Pressure Control Solenoid) (INC. Diagnosis).......................................................
SOLENOID, SHIFT LOCK - REPLACE
K6508
.5
.5
CONTROLLER, SHIFT LOCK SOLENOID - REPLACE
K6509
.6
.6
K6510
.8
.8
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
HARNESS AND/OR CONNECTOR, VALVE BODY - REPLACE
MAIN CASE
ADD:
K - 20 TRANSAXLE AND TRANSMISSION
AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
A - Diagnosis Time..............................................................................................................
.3
.3
B - Program TCM.................................................................................................................
.3
.3
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
.3
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.8
.8
A - To Replace Separator Plate or Gaskets........................................................................
.6
.6
B - To Replace Solenoids (One or All) (INC. Diagnosis).....................................................
.6
.6
C - To Clean and Recondition Valve Body (Main Case)......................................................
1.6
1.6
1.1
1.1
.9
.9
.7
.7
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
TRANSMISSION CONTROL MODULE - R&R OR REPLACE
K6517
POLICY: P
ADD:
SENSOR, TURBIN SPEED - REPLACE
K6520
ADD:
VALVE BODY, TRANSMISSION - R&R OR REPLACE
POLICY: P
INC: K6500 R&R transmission oil pan.
MAIN CASE
K6560
ADD:
PARKING PAWL SHAFT, ROD OR SPRING - REPLACE
K6640
POLICY: P
INC: Drain and refill, R&R prop shaft, center bearing,
speedometer drive gear and cable.
ADD:
A - For 4x4 Model................................................................................................................
ATF THERMO SENSOR - REPLACE
K6645
ADD:
TRANSAXLE AND TRANSMISSION K - 21
AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
2.9
2.9
A - To Replace Torque Converter........................................................................................
.1
.1
B - To Flush Cooling Line....................................................................................................
.6
.6
C - For 4 x 4 Model..............................................................................................................
.9
.9
D - 6VE1 Engine..................................................................................................................
1.3
-
E - HFV6 Engine..................................................................................................................
2.5
-
F - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)...................................................................
1.5
-
G - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.8
-
H - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
3.0
3.0
A - For 4 x 4 Model..............................................................................................................
.9
.9
B - 6VE1 Engine..................................................................................................................
1.3
-
C - HFV6 Engine..................................................................................................................
2.5
-
D - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.3
-
E - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.6
-
F - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)................
1.5
-
3.1
3.1
A - For 4x4 Model................................................................................................................
.9
.9
B - 6VE1 Engine..................................................................................................................
1.3
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.3
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.6
-
E - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
AUTOMATIC TRANSMISSION ASSEMBLY - REPLACE
K7000
POLICY: A, P, T
ADD:
TORQUE CONVERTER ASSEMBLY - REPLACE
K7020
POLICY: A, P, T
INC: K7000 R/R automatic transmission assembly.
ADD:
CONVERTER HOUSING, TRANSMISSION - REPLACE
K7040
POLICY: P, T
INC: R&R torque converter.
ADD:
K - 22 TRANSAXLE AND TRANSMISSION
AUTOMATIC TRANSMISSION
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
3.3
3.3
A - For 4x4 Model................................................................................................................
.9
.9
B - 6VE1 Engine..................................................................................................................
1.3
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.3
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.6
-
E - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
3.2
3.2
A - To Replace Front Oil Pump Seal...................................................................................
.1
.1
B - To Recondition Oil Pump...............................................................................................
.4
.4
C - For 4x4 Models..............................................................................................................
.9
.9
D - 6VE1 Engine..................................................................................................................
1.3
-
E - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.3
-
F - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.6
-
G - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
7.6
7.6
A - For 4x4 Model................................................................................................................
.9
.9
B - 6VE1 Engine..................................................................................................................
1.3
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
1.3
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
2.6
-
E - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.5
-
SEAL, TRANSMISSION OIL PUMP - REPLACE
K7100
POLICY: P
ADD:
OIL PUMP AND/OR GASKET, TRANSMISSION - REPLACE
K7120
POLICY: P, T
INC: K7000 R&R automatic transmission assembly.
K7020 R&R torque converter.
ADD:
AUTOMATIC TRANSMISSION ASSEMBLY - RECODITION
K7900
POLICY: A, P, T
INC: K7000 R&R automatic transmission assembly.
K7020 R&R torque converter.
ADD:
L FUEL AND EXHAUST
L
FUEL AND EXHAUST L - 3
FUEL AND EXHAUST
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
PIPES, FUEL - REPLACE
POLICY: T
NOTE: This is a ST (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
RETURN OR FEED LINES, TANK TO ENGINE COMPARTMENT
L0120
.5
.5
FUEL TANK AREA PIPES
L0160
.5
.5
L0220
.3
.3
L0240
.2
.2
.7
-
L0260
.7
-
L0621
.3
-
BRACKET, FUEL SEDIMENTER - REPLACE
L0700
.4
.4
SEDIMENTER ASSEMBLY, FUEL - REPLACE
L0740
.3
.3
SENSOR ASSEMBLY, SEDIMENTOR - REPLACE
L0748
.4
.4
CAP, FUEL TANK - REPLACE
L1020
.2
.2
NECK, PIPE, FUEL TANK FILLER - REPLACE
L1065
.5
.5
HOSES, FUEL AND EVAPORATIVE EMISSION CONTROL
(ENGINE COMPARTMENT) - REPLACE
POLICY: T
HOSES, FUEL TANK AREA - REPLACE
POLICY: T
ADD:
A - Fitted 2012 Cab Model...................................................................................................
HOSES, FUEL AND EVAPORATIVE EMISSION CONTROL
(FUEL TANK AREA) - REPLACE
POLICY: T
CANISTER, FUEL VAPOR - REPLACE
GASOLINE
L - 4 FUEL AND EXHAUST
FUEL AND EXHAUST
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.4
.5
A - For Wagon Model..........................................................................................................
.1
-
B - Fitted 2012 Cab Model...................................................................................................
.4
-
.8
.9
A - EXC. 4JJ1/4JK1 Engine.................................................................................................
.3
-
B - For Wagon Model..........................................................................................................
.1
-
C - Fitted 2012 Cab Model...................................................................................................
.1
-
NECK, HOSE AND/OR VENT HOSE, FUEL TANK FILLER - REPLACE
REAR TANK
L1068
ADD:
GAUGE UNIT ASSEMBLY, FUEL TANK - REPLACE
L1228
ADD:
FUEL WAXING KIT - INSTALL
L1250
1.0
-
TANK, FUEL - REPLACE
L1280
.8
.9
A - EXC. 4JJ1/4JK1 Engine.................................................................................................
.3
-
B - For Wagon Model..........................................................................................................
.1
-
C - Fitted 2012 Cab Model...................................................................................................
.2
-
.3
.3
A - To Replace Additional Hanger and/or Clamp.................................................................
.1
.1
B - To Replace Two Additional Hanger and/or Clamp.........................................................
.2
.2
.4
.4
A - With Skid Plate...............................................................................................................
.2
.2
B - 6V*1 Engine...................................................................................................................
.3
-
1.1
-
INC: Drain and refill tank. Transfer gage and filler neck as necessary.
ADD:
HANGER AND/OR CLAMP, EXHAUST SYSTEM - REPLACE
L2020
ADD:
SEAL, EXHAUST PIPE - REPLACE
L2040
POLICY: E
ADD:
PIPE, RIGHT - FRONT EXHAUST - REPLACE
POLICY: E
NOTE: For HFV6 engine.
L2100
FUEL AND EXHAUST L - 5
FUEL AND EXHAUST
OPERATION DESCRIPTION
OPERATION
NUMBER
PIPE, LEFT - FRONT EXHAUST - REPLACE
CAB STYLE
VIN CODE
TF*
UC*
L2101
1.0
-
L2160
.4
.4
.3
-
.7
-
.2
-
L2163
1.0
-
L2200
.5
-
.1
-
POLICY: E
NOTE: For HFV6 engine.
PIPE, FRONT EXHAUST - REPLACE
POLICY: E
NOTE: EXC. HFV6 engine.
ADD:
A - C24*E Engine.................................................................................................................
DUAL RIGHT
L2162
ADD:
A - For 4x4 Model................................................................................................................
DUAL LEFT
PIPE, CENTER EXHAUST - REPLACE
ADD:
A - For HFV6 engine............................................................................................................
HEAT SHIELD, EXHAUST CATALYTIC CONVERTER - REPLACE
L2280
.3
-
CONVERTER, EXHAUST CATALYTIC - REPLACE
L2300
.3
1.1
A - EXC. 4JJ1/4JK1/6V*1 Engine........................................................................................
.3
-
B - 4JJ1/4JK1 Engine (Fitted 2003 Cab Model)..................................................................
.8
-
C - 4JJ1/4JK1 Engine (Fitted 2012 Cab Model)..................................................................
.2
-
D - 4JK1 Engine (Fitted 2012 Cab Model 2 Stage Turbocharger).......................................
1.4
-
E - For 4x4 Model (4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger)...............
1.3
-
1.5
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
POLICY: E, T
INC: Check system for leaks.
ADD:
SENSOR, TEMPERATURE, CATALYTIC CONVERTER (IN) - REPLACE
L2310
ADD:
L - 6 FUEL AND EXHAUST
FUEL AND EXHAUST
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.5
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
SENSOR, TEMPERATURE, CATALYTIC CONVERTER (OUT) - REPLACE
L2311
ADD:
PIPE, INTERMEDIATE EXHAUST - REPLACE
L2420
.4
.4
MUFFLER - REPLACE
L2584
.4
.4
L2600
1.0
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
L2611
.5
-
L2630
.5
-
L2680
.4
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
INC: Check system for leaks.
DIESEL PARTICULATE DEFUSER ASSY - R&R OR REPLACE
POLICY: A
ADD:
DIESEL PARTICULATE DEFUSER - SLOW REGENERATION
POLICY: A
INC: Replace engine oil.
NOTE: This operation code is to be used with other operation code. Do not use by itself.
PIPE, DIFFERENTIAL PRESSURE,DIESEL PARTICULATE DEFUSER
- REPLACE (ONE OR ALL)
SENSOR, TEMPERATURE,DIESEL PARTICULATE DEFUSER
- REPLACE (ONE OR ALL)
ADD:
SENSOR, DIFFERENTIAL PRESSURE,DIESEL PARTICULATE DEFUSER
L2685
- REPLACE
ADD:
FUEL AND EXHAUST L - 7
FUEL AND EXHAUST
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.6
.6
A - 6V*1 Engine...................................................................................................................
.4
-
B - HFV6 Engine..................................................................................................................
.7
-
EXHAUST SYSTEM (COMPLETE) - REPLACE
L2904
POLICY: A
INC: Replace hangers, brackets or clamps as necessary.
ADD:
N ELECTRICAL
N
ELECTRICAL N - 13
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
A - Diagnosis Time..............................................................................................................
.2
.2
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
.3
A - HFV6 Engine..................................................................................................................
.6
-
B - Fitted 2012 Cab Model...................................................................................................
.6
-
.3
.3
.6
-
BATTERY - REPLACE
POLICY: A, T
ONE
N0110
ADD:
CABLES, BATTERY - REPLACE
POLICY: T
POSITIVE
N0120
ADD:
NEGATIVE
N0126
ADD:
A - Fitted 2012 Cab Model...................................................................................................
RETAINER AND/OR BOLTS, BATTERY - REPLACE
N0150
.2
.3
TRAY OR SUPPORT, BATTERY - REPLACE
N0160
.2
.2
HIGH NOTE
N0200
.2
.2
LOW NOTE
N0201
.2
.2
ONE
N0250
.6
.6
BOTH
N0252
.8
.8
ONE
N0260
.6
.6
BOTH
N0261
1.0
1.0
HORN ASSEMBLY - REPLACE
HEADLAMP ASSEMBLY - REPLACE
INC: Aim headlamps.
HEADLAMP HOUSING - REPLACE
INC: Aim headlamps.
N - 14 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
HEADLAMP - AIM
ONE
N0265
.3
.3
BOTH
N0266
.3
.3
RIGHT
N0270
.6
-
LEFT
N0271
.6
-
RIGHT
N0281
.6
-
LEFT
N0282
.6
-
RIGHT
N0320
.2
.2
LEFT
N0321
.2
.2
BACK UP; RH; ONE
N0415
.2
.2
BACK UP; LH; ONE
N0416
.2
.2
BACK UP; BOTH; TWO
N0417
.3
.3
HEAD; RH; ONE OR ALL
N0442
.3
.6
.3
-
.3
.6
.3
-
.4
.9
.5
-
STARTER, DISCHARGE, HEAD LAMP - REPLACE
INC: Aim headlamps.
ACTUATOR, HEADLIGHT LEVELING - REPLACE
TURN SIGNAL LAMP, OUT SIDE MIRROR - REPLACE
BULBS, LAMP - REPLACE
NOTE: Per ONE LAMP HOUSING
: NAMES of LAMP; HOUSINGS; BULBS
ADD:
A - For Wagon Model (N0442 Only)....................................................................................
HEAD; LH; ONE OR ALL
N0443
ADD:
A - For Wagon Model (N0443 Only)....................................................................................
HEAD; BOTH; TWO OR ALL
N0444
ADD:
A - For Wagon Model (N0444 Only)....................................................................................
(CONTINUED)
DOME; ONE; ONE
N0507
.2
.2
INSTRUMENT PANEL WARNING; ONE; ONE OR ALL
N0647
.2
.2
LICENSE; ONE; ONE
N0657
.2
.2
LICENSE; TWO; TWO
N0658
.2
.2
ELECTRICAL N - 15
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.5
.2
-
.3
.5
.2
-
.4
.7
.3
-
(CONT'D)
PARK AND TURN SIGNAL; RH; ONE OR ALL
N0685
ADD:
A - For Wagon Model (N0685 Only)....................................................................................
PARK AND TURN SIGNAL; LH; ONE OR ALL
N0686
ADD:
A - For Wagon Model (N0686 Only)....................................................................................
PARK AND TURN SIGNAL; BOTH; TWO OR ALL
N0687
ADD:
A - For Wagon Model (N0687 Only)....................................................................................
POSITION INDICATOR; ONE; ONE
N0725
.3
.3
SIDE MARKER, FRONT; RH; ONE
N0736
.2
.2
SIDE MARKER, FRONT; LH; ONE
N0737
.2
.2
STOP, TAIL AND TURN SIGNAL; RH; ONE OR ALL
N0765
.2
.2
.1
-
.2
.2
.1
-
.3
.3
.1
-
.2
.3
.1
-
ADD:
A - For Pick Up Model (N0765 Only)...................................................................................
STOP, TAIL AND TURN SIGNAL; LH; ONE OR ALL
N0766
ADD:
A - For Pick Up Model (N0766 Only)...................................................................................
STOP, TAIL AND TURN SIGNAL; BOTH; TWO OR ALL
N0767
ADD:
A - For Pick Up Model (N0767 Only)...................................................................................
HIGH MOUNTED STOP; ONE; ONE
N0769
ADD:
A - For Wagon Model (N0769 Only)....................................................................................
MAP; RH; ONE
N0824
.2
.2
MAP; LH; ONE
N0825
.2
.2
FOG; RH; ONE
N0852
.3
.4
.1
-
.3
.4
.1
-
.4
.5
.1
-
ADD:
A - For Wagon Model (N0852 Only)....................................................................................
FOG; LH; ONE
N0853
ADD:
A - For Wagon Model (N0853 Only)....................................................................................
FOG; BOTH; TWO
N0854
ADD:
A - For Wagon Model (N0854 Only)....................................................................................
(CONTINUED)
N - 16 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
LUGGAGE COMPARTMENT; ONE; ONE
N0855
.2
.2
REAR FOG LIGHT; LEFT
N0884
.2
.2
LUGGAGE COMPARTMENT; ONE; ONE
N1145
.2
.2
DOME; ONE; ONE
N1156
.2
.2
LICENSE; ONE; ONE
N1176
.2
.2
LICENSE; TWO; TWO
N1177
.2
.2
STOP, TAIL AND TURN SIGNAL; RH; ONE
N1224
.2
.2
.1
.1
.2
.2
.1
.1
.3
.3
.1
.1
LENS AND/OR GASKET, LAMP - REPLACE
NOTE: Per ONE LAMP HOUSING
: NAMES of LAMP; HOUSINGS; LENSES
ADD:
A - For Pick Up Model (N1224 Only)...................................................................................
STOP, TAIL AND TURN SIGNAL; LH; ONE
N1225
ADD:
A - For Pick Up Model (N1225 Only)...................................................................................
STOP, TAIL AND TURN SIGNAL; BOTH; TWO
N1226
ADD:
A - For Pick Up Model (N1226 Only)...................................................................................
REAR FOG LIGHT; LEFT
N1237
.2
.2
HIGH MOUNTED STOP; ONE; ONE
N1289
.2
.2
.1
.1
ADD:
A - For Wagon Model (N1289 Only)....................................................................................
MAP; RH; ONE
N1314
.2
.2
MAP; LH; ONE
N1315
.2
.2
MAP; BOTH; TWO
N1316
.2
.2
LUGGAGE COMPARTMENT
N1445
.2
.2
DOME; ONE OR ALL
N1456
.2
.2
FOG; RIGHT
N1466
.3
.4
.1
-
LAMP ASSEMBLY - REPLACE
ADD:
A - For Wagon Model (N1466 Only)....................................................................................
(CONTINUED)
ELECTRICAL N - 17
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
.4
.1
-
(CONT'D)
FOG; LEFT
N1467
ADD:
A - For Wagon Model (N1467 Only)....................................................................................
REAR FOG LIGHT; RIGHT
N1473
.2
.2
REAR FOG LIGHT; LEFT
N1474
.2
.2
LICENSE; ONE OR BOTH
N1477
.2
.2
PARK AND TURN SIGNAL; RIGHT
N1520
.5
.5
PARK AND TURN SIGNAL; LEFT
N1521
.5
.5
REAR COMBINATION; RIGHT
N1524
.2
.2
.1
-
.2
.2
.1
-
ADD:
A - For Pick Up Model (N1524 Only)...................................................................................
REAR COMBINATION; LEFT
N1525
ADD:
A - For Pick Up Model (N1525 Only)...................................................................................
MAP; ONE OR ALL
N1597
.2
.2
HIGH MOUNTED STOP
N1599
.2
.3
.1
-
N1720
.2
.2
N1750
.2
.2
BACK-UP LIGHT
N2030
.3
.3
TRANSFER INDICATOR
N2032
.3
.3
HI-LOW NEUTRAL
N2033
.3
.3
DOOR LOCK
N2114
.2
.2
POWER WINDOW; FRONT RIGHT
N2144
.2
.2
POWER WINDOW; FRONT LEFT
N2145
.2
.2
POWER WINDOW; REAR RIGHT
N2154
.2
.2
POWER WINDOW; REAR LEFT
N2155
.2
.2
ADD:
A - For Wagon Model (N1599 Only)....................................................................................
FUSE, FUSIBLE LINK - REPLACE
INC: One or more.
FLASHER UNIT - REPLACE
SWITCH - REPLACE
INC: Replace fuse where necessary.
NOTE: Switch or sending unit.
(CONTINUED)
N - 18 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
DOOR JAMB; RIGHT FRONT
N2174
.2
.2
DOOR JAMB; LEFT FRONT
N2175
.2
.2
DOOR JAMB; RIGHT REAR
N2184
.2
.2
DOOR JAMB; LEFT REAR
N2185
.2
.2
ENGINE OIL PRESSURE
N2220
.3
.3
.2
-
.2
.2
.1
-
.2
.2
.1
-
ADD:
A - HFV6 Engine (N2220 Only)............................................................................................
ENGINE COOLANT TEMPERATURE
N2230
ADD:
A - For Pick Up Model (N2230 Only)...................................................................................
4WD (FOUR WHEEL DRIVE)
N2240
ADD:
A - For Pick Up Model (N2240 Only)...................................................................................
REAR WIPER/WASHER
N2242
.2
.2
REAR DEFOGGER
N2243
.3
.5
.2
-
ADD:
A - For Wagon Model (N2243 Only)....................................................................................
FOG LAMP
N2244
.7
.7
POWER MIRROR
N2245
.2
.2
HAZARD WARNING
N2247
.3
.3
REAR FOG LAMP
N2248
.2
.2
REAR A/C MAIN
N2249
.2
.2
LIGHTING
N2290
.5
.7
.2
-
.5
.7
.2
-
.2
.2
.1
-
ADD:
A - With SRS. (N2290 Only)................................................................................................
HEADLIGHT DIMMER (COMBINATION)
N2310
ADD:
A - With SRS.......................................................................................................................
HEADLIGHT LEVELING
N2315
ADD:
A - For Pick Up Model (N2315 Only)...................................................................................
(CONTINUED)
IGNITION
N2320
.4
.4
NEUTRAL; A/T
N2323
.3
.3
POWER/3RD START
N2325
.3
.3
VACUUM
N2345
.3
.3
ELECTRICAL N - 19
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
CLUTCH
N2350
.3
-
NEUTRAL; M/T
N2360
.3
.3
NEUTRAL; T/F
N2365
.3
.3
PARKING BRAKE LIGHT
N2380
.3
.3
PARKING BRAKE LIGHT (STICK TYPE)
N2381
2.1
-
STOP LIGHT
N2440
.2
.2
.2
-
ADD:
A - Fitted 2012 Cab Model (N2440 Only).............................................................................
TURN SIGNAL (COMBINATION)
N2530
.5
.7
WINDSHIELD WIPER/WASHER (COMBINATION)
N2610
.5
.7
.2
-
ADD:
A - With SRS.......................................................................................................................
4x4 INDICATOR LIGHT
N2778
.3
.3
TCS/ESC OFF
N2779
.2
-
ENGINE MAIN (ECM)
N2800
.2
.2
STARTER
N2810
.2
.2
HEAD LIGHT
N2820
.2
.2
TAIL LIGHT
N2830
.2
.2
DIMMER
N2850
.2
.2
FOG LAMP
N2856
.2
.2
REAR FOG
N2857
.2
.2
HORN
N2880
.2
.2
WIPER
N2900
.2
-
A/C COMPRESSOR
N2910
.2
.2
A/C CONDENSOR
N2912
.2
.2
HAZARD/TURN SIGNAL
N2920
.3
.3
GLOW PLUG
N2922
.2
.2
ACCESSORY SOCKET
N2930
.2
.2
HEATER
N2932
.2
.2
HAZARD RIGHT
N2933
.2
.2
HAZARD LEFT
N2934
.2
.2
THERMO (A/C)
N2937
.2
.2
RELAY - REPLACE
INC: Replace fuse where necessary.
(CONTINUED)
N - 20 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
FUEL PUMP
N2960
.2
.2
POWER WINDOW
N2980
.2
.2
REAR DEFOGGER
N2990
.2
.2
POWER WINDOW; FRONT RIGHT
N3310
.5
.6
.1
-
.5
.6
.1
-
.4
.4
.3
-
.4
.4
.3
-
.5
.5
.1
-
.5
.5
.1
-
.4
.4
.1
-
.4
.4
.1
-
.3
.3
MOTOR - REPLACE
POLICY: A
ADD:
A - For Wagon Model..........................................................................................................
POWER WINDOW; FRONT LEFT
N3311
ADD:
A - For Wagon Model..........................................................................................................
POWER WINDOW; REAR RIGHT
N3312
ADD:
A - Fitted 2003 Cab Pick Up Model.....................................................................................
POWER WINDOW; REAR LEFT
N3313
ADD:
A - Fitted 2003 Cab Pick Up Model.....................................................................................
ACTUATOR ASSY, DOOR LOCK - R&R OR REPLACE
FRONT RIGHT
N3314
ADD:
A - For Pick Up Model..........................................................................................................
FRONT LEFT
N3315
ADD:
A - For Pick Up Model..........................................................................................................
REAR RIGHT
N3324
ADD:
A - For Pick Up Model..........................................................................................................
REAR LEFT
N3325
ADD:
A - For Pick Up Model..........................................................................................................
BACK DOOR
N3327
ELECTRICAL N - 21
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
.2
-
MOTOR, WIPER - R&R
INC: Replace fuse where necessary.
WINDSHIELD
N3510
ADD:
A - Fitted 2012 Cab Model...................................................................................................
BACK GLASS
N3511
.3
.3
WINDSHIELD
N3520
.2
.2
.2
-
MOTOR, WIPER - REPLACE
ADD:
A - Fitted 2012 Cab Model...................................................................................................
BACK GLASS
N3521
.3
.3
WINDSHIELD
N3615
.2
.2
BACK GLASS
N3616
.2
.2
WINDSHIELD
N3620
.2
.2
BACK GLASS
N3621
.2
.2
RIGHT
N3630
.4
.5
LEFT
N3631
.4
.5
.1
-
.4
.6
BLADE, WIPER - REPLACE
ARM, WIPER - REPLACE
INC: One or both.
LINK, WINDSHIELD WIPER OPERATING - REPLACE
ADD:
A - Fitted 2003 Cab Model...................................................................................................
BOTH
N3637
ADD:
A - Fitted 2003 Cab Model...................................................................................................
.2
HOSES, NOZZLES, WASHER AND/OR WIPER STOPS - REPLACE
INC: One or all.
WINDSHIELD
N3700
.2
.2
.1
-
ADD:
A - Fitted 2012 Cab Model...................................................................................................
(CONTINUED)
N - 22 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
BACK GLASS
N3701
.3
.3
WINDSHIELD
N3750
.7
1.0
.3
-
CONTAINER AND COVER, WASHER - REPLACE
ADD:
A - For Wagon Model..........................................................................................................
BACK GLASS
N3751
1.0
1.0
WINDSHIELD
N3860
.7
.9
.2
-
N3861
.9
.9
N4010
.2
.4
.2
-
PUMP ASSEMBLY, WASHER - R&R OR REPLACE
INC: One or both
ADD:
A - For Wagon Model..........................................................................................................
BACK GLASS
LIGHTER ASSEMBLY, CIGARETTE - REPLACE
ADD:
A - Fitted 2003 Cab Model...................................................................................................
SOCKET, ACCESSORY - REPLACE
FRONT CONSOLE
N4015
.3
.3
LUGGAGE ROOM
N4018
.2
.2
LENS AND/OR BEZEL, INSTRUMENT CLUSTER - REPLACE
N4120
.4
.4
CLOCK ASSEMBLY - R&R
N4200
.2
.2
CLOCK ASSEMBLY - REPLACE
N4210
.2
.2
METER BOARD ASSEMBLY - REPLACE
N4410
.2
.2
POLICY: A
ELECTRICAL N - 23
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.7
.7
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
COIL ASSEMBLY, SRS (AIR BAG) - REPLACE
N5810
ADD:
SRS - AIR BAG - REPLACE
POLICY: A
DRIVER
N5820
.2
.2
PASSENGER
N5821
.3
.6
A - Fitted 2003 Cab Pick Up Model (N5821 Only)...............................................................
.4
-
B - Diagnosis Time..............................................................................................................
.3
.3
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.4
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
C - To Replace Each Additional...........................................................................................
.3
-
.8
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
C - To Replace Each Additional...........................................................................................
.2
-
.3
.5
A - For Wagon Model..........................................................................................................
.2
-
B - Diagnosis Time..............................................................................................................
.3
.3
C - Fitted 2012 Cab Model...................................................................................................
.1
-
D - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.2
.3
.1
-
ADD:
SRS - AIR BAG, SIDE - REPLACE
N5825
ADD:
SRS - AIR BAG, ROOF - REPLACE
N5826
ADD:
SENDING AND DIAGNOSTIC MODULE (SRS) - REPLACE
N5830
ADD:
CONTROL UNIT, ALARMER - REPLACE
N5840
ADD:
A - For Wagon Model..........................................................................................................
N - 24 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
CONTROL UNIT, REAR FOG LAMP - REPLACE
N5850
.2
.2
G-SENSOR - REPLACE
N5900
.4
.6
A - Diagnosis Time..............................................................................................................
.3
.3
B - For Wagon Model..........................................................................................................
.2
-
C - Fitted 2003 Cab Pick Up Model.....................................................................................
.2
-
D - Front Bumper Side (One)...............................................................................................
.1
-
E - Front Bumper Side (Both)..............................................................................................
.2
-
F - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
.3
-
A - Diagnosis Time..............................................................................................................
.3
-
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
N5950
.3
-
N5951
.3
-
N5953
.5
-
N5954
.6
-
AIR CONDITIONING
N6030
.5
.5
BACK GLASS WIPER MOTOR
N6065
.5
.5
ADD:
CONTROL MODULE,PIM (POWER TRAIN INTERFACE MODULE) - REPLACE
N5920
ADD:
DATA RECORDING MODULE (DRM) - DOWNLOAD
POLICY: A
BODY CONTROL MODULE (BCM) - DOWNLOAD
POLICY: A
DATA RECORDING MODULE (DRM) - REPLACE
POLICY: A
BODY CONTROL MODULE (BCM) - REPLACE
POLICY: A
WIRING AND/OR CONNECTOR - REPAIR
NOTE: This is a ST (straight time) operation which requires time
documentation as detailed in the claims processing manual.
Authorization request is required beyond .5 hours.
INC: Connect and use diagnostic equipment to locate problem,
R&R any necessary components and replace fuse if necessary.
(CONTINUED)
ELECTRICAL N - 25
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
CAB MAIN
N6070
.5
.5
CHASSIS; FRONT
N6112
.5
.5
CHASSIS; REAR
N6113
.5
.5
DOME; LIGHT
N6180
.5
.5
DOOR LOCK; RIGHT FRONT
N6224
.5
.5
DOOR LOCK; LEFT FRONT
N6225
.5
.5
DOOR LOCK; RIGHT REAR
N6234
.5
.5
DOOR LOCK; LEFT REAR
N6235
.5
.5
DOOR LOCK; BACK DOOR
N6238
.5
.5
DOOR WINDOW; RIGHT FRONT
N6254
.5
.5
DOOR WINDOW; LEFT FRONT
N6255
.5
.5
DOOR WINDOW; RIGHT REAR
N6264
.5
.5
DOOR WINDOW; LEFT REAR
N6265
.5
.5
ENGINE
N6270
.5
.5
HEADLIGHT
N6290
.5
.5
HEATER
N6310
.5
.5
INSTRUMENT PANEL
N6360
.5
.5
REAR BODY
N6398
.5
.5
REAR WINDOW DEFOGGER
N6440
.5
.5
HARNESS, FUEL INJECTOR (HFV6 Engine only)
N6985
.3
-
INSTRUMENT PANEL
N7060
1.6
1.9
A - For Wagon Model (N7060 Only)....................................................................................
.3
-
B - Diagnosis Time..............................................................................................................
.5
.5
C - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
1.0
3.0
A - With A/C. (N7063 Only)..................................................................................................
.1
.1
B - 4JH1-T Engine (N7063 Only).........................................................................................
1.4
-
C - For 4x4 Model (N7063 Only)..........................................................................................
.2
.2
D - 4JJ1/4JK1 Engine (N7063 Only)....................................................................................
2.0
-
E - HFV6 Engine (N7063 Only)............................................................................................
.6
-
F - Intercooler of Upside Installation Type (4JJ* Engine)....................................................
.3
.3
HARNESS, WIRING - REPLACE
ADD:
ENGINE
N7063
ADD:
(CONTINUED)
N - 26 ELECTRICAL
ELECTRICAL
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.9
1.0
.1
-
.9
1.0
.1
-
.6
.6
.4
-
.6
.6
.4
-
(CONT'D)
DOOR; RIGHT FRONT
N7066
ADD:
A - For Wagon Model (N7066 Only)....................................................................................
DOOR; LEFT FRONT
N7067
ADD:
A - For Wagon Model (N7067 Only)....................................................................................
DOOR; RIGHT REAR
N7068
ADD:
A - For Pick Up Model (N7068 Only)...................................................................................
DOOR; LEFT REAR
N7069
ADD:
A - For Pick Up Model (N7069 Only)...................................................................................
SIDE ACCESS PANEL; RIGHT
N7071
.5
-
SIDE ACCESS PANEL; LEFT
N7072
.5
-
BATTERY TO STARTER
N7073
.9
.9
ENGINE ROOM
N7080
4.0
7.2
A - For Parking Brake T-Handle and Bench Seat Type (N7080 Only).................................
.3
-
B - 4JJ1/4JK1 Engine (N7080 Only)....................................................................................
3.2
-
ADD:
REAR BODY
N7081
1.7
1.7
REAR WINDOW GLASS WIPER MOTOR
N7082
.3
.3
DOOR LOCK, BACK DOOR
N7083
.3
.3
ROOF
N7084
2.0
2.0
TRANSFER
N7093
1.0
-
REAR DEFOGGER
N7096
.3
.3
HIGH MOUNT STOP LAMP
N7097
.9
.9
IMOBILIZER EXTENSION
N7098
.9
.9
R ACCESSORIES
R
R - 4 ACCESSORIES
ACCESSORIES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
STANDING WAVE RATIO SWR - ADJUST
R0120
.4
-
ANTENNA COMPONENTS - REPLACE
R0220
.4
.4
A - For Extend Cab Model (Roof Center Mount Type).........................................................
.5
-
B - For Crew Cab Model (Roof Center Mount Type)............................................................
.8
-
C - Fitted 2003 Cab Model (Roof Center Mount Type)........................................................
.3
-
.3
-
.1
-
.3
-
.1
-
.3
-
.1
-
.3
-
.1
-
ADD:
RADIO RECEIVER - R&R
R0750
ADD:
A - For Wagon Model..........................................................................................................
CASSETTE DECK - R&R
R0751
ADD:
A - For Wagon Model..........................................................................................................
RADIO RECEIVER - REPLACE
R0760
ADD:
A - For Wagon Model..........................................................................................................
CASSETTE DECK - REPLACE
R0761
ADD:
A - For Wagon Model..........................................................................................................
DISPLAY ASSEMBLY - R&R OR REPLACE
R0770
.2
-
CAMERA, REAR - REPLACE
R0771
.3
-
REAR RIGHT
R0920
.2
.2
REAR LEFT
R0921
.2
.2
FRONT RIGHT
R0940
.2
.2
.1
-
GRILLE, RADIO SPEAKER - R&R OR REPLACE
SPEAKER, RADIO - REPLACE
ADD:
A - For Pick Up Model..........................................................................................................
(CONTINUED)
ACCESSORIES R - 5
ACCESSORIES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.2
.2
.1
-
(CONT'D)
FRONT LEFT
R0941
ADD:
A - For Pick Up Model..........................................................................................................
REAR RIGHT
R0950
.2
.2
REAR LEFT
R0951
.2
.2
FRONT DOOR RIGHT
R0980
.3
.3
FRONT DOOR LEFT
R0981
.3
.3
INSTRUMENT PANEL RIGHT
R0982
.2
-
INSTRUMENT PANEL LEFT
R0983
.2
-
ROOF
R0984
.9
-
.3
-
.2
-
.2
-
TWEETER, SPEAKER - R&R OR REPLACE
ADD:
A - For Crew Cab Model (Only R0984)................................................................................
CHAIN, CABLE OR ROD, CRUISE CONTROL POWER TO CARBURETOR - REPLACE
R1180
ADD:
A - To Adjust Cable..............................................................................................................
SERVO OR ACTUATOR ASSEMBLY, CRUISE CONTROL - REPLACE
R1190
.4
-
RECEIVER UNIT, PASSIVE ENTRY AND START SYSTEM - REPLACE
R1200
.2
-
.3
-
.3
-
.3
-
ADD:
A - Diagnosis Time..............................................................................................................
CONTROL UNIT, PASSIVE ENTRY AND START SYSTEM - REPLACE
R1201
ADD:
A - Diagnosis Time..............................................................................................................
BUZZER, PASSIVE ENTRY AND START SYSTEM - REPLACE
R1202
.5
-
ELECTRONIC KEY, PASSIVE ENTRY AND START SYSTEM - REPLACE
R1203
.2
-
BATTERY, ELECTRONIC KEY, PASSIVE ENTRY AND START SYSTEM - REPLACE
R1204
.1
-
R - 6 ACCESSORIES
ACCESSORIES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
.3
-
.3
-
.3
-
.3
-
.3
-
.3
-
ANTENNA, PASSIVE ENTRY AND START SYSTEM - REPLACE
DOOR HANDLE
R1206
ADD:
A - Diagnosis Time..............................................................................................................
CENTER CONSOLE
R1207
ADD:
A - Diagnosis Time..............................................................................................................
REAR PANEL
R1208
ADD:
A - Diagnosis Time..............................................................................................................
MODULE, CRUISE CONTROL - REPLACE
R1220
.4
-
CONTROL UNIT, IMMOBILIZER - REPLACE
R1230
.4
.6
.2
-
.4
.4
A - Diagnosis Time..............................................................................................................
.3
.3
B - Diagnosis Time & Data Recording Module (DRM.) - Download.....................................
.5
-
ADD:
A - For Wagon Model..........................................................................................................
CONTROL UNIT (WITH ANTENNA), IMOBILIZER - REPLACE
R1231
ADD:
ANTENNA, IMMOBILIZER (IGNITION LOCK) - REPLACE
R1235
.3
.3
ANTENNA, KEYLESSENTRY - REPLACE
R1236
.3
.3
R1240
.3
-
SWITCH, CRUISE CONTROL ENGAGEMENT - REPLACE
R1260
.7
-
DEFLECTOR, TAILGATE WIND - REPLACE
R2400
.3
.3
MANUAL; RIGHT
R3260
.2
-
MANUAL; LEFT
R3261
.2
-
SWITCH, CRUISE CONTROL RELEASE - R&R OR REPLACE
BRAKE
GLASS; MIRROR, OUTSIDE REAR VIEW - REPLACE
(CONTINUED)
ACCESSORIES R - 7
ACCESSORIES
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
(CONT'D)
ELECTRIC REMOTE CONTROL; RIGHT
R3290
.2
.2
ELECTRIC REMOTE CONTROL; LEFT
R3291
.2
.2
R3318
.2
.2
MANUAL; RIGHT
R3390
.2
-
MANUAL; LEFT
R3391
.2
-
ELECTRIC REMOTE CONTROL; RIGHT
R3395
.2
.2
ELECTRIC REMOTE CONTROL; LEFT
R3396
.2
.2
CONTROL UNIT, ANTI-THEFT - REPLACE
R9000
.4
.4
HORN ASSEMBLY, ANTI-THEFT - REPLACE
R9010
.2
.2
SWITCH, ANTI-THEFT ENGINE HOOD - REPLACE
R9040
.2
.2
CONTROL UNIT
R9050
.4
.4
KEY; REMOTE CONTROLLER
R9054
.1
.1
BATTERY; KEY, REMOTE CONTROLLER
R9056
.2
.2
SWITCH, REMOTE CONTROL MIRROR - REPLACE
MIRROR COMPONENTS, OUTSIDE REAR VIEW - REPLACE
KEYLESS ENTRY SYSTEM
S NON WARRANTY (PANEL REPLACEMENT)
S
S - 4 NON WARRANTY (PANEL REPLACEMENTS)
PANEL REPLACEMENTS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
S0150
.4
.4
RIGHT
S0280
.5
.5
LEFT
S0281
.5
.5
.1
.1
S0350
.2
.2
RIGHT
S0850
1.9
1.9
LEFT
S0851
1.9
1.9
RIGHT
S0950
1.4
1.4
LEFT
S0951
1.4
1.4
S1856
1.6
1.6
PANEL HOOD - REPLACE
FENDER, FRONT - REPLACE
ADD:
A - With Molding (Each).......................................................................................................
COWL COVER - REPLACE
DOOR ASSEMBLY, FRONT - REPLACE
INC: R&R trim, glass and hardware.
DOOR ASSEMBLY, REAR - REPLACE
INC: R&R trim, glass and hardware.
DOOR ASSEMBLY, BACK (SINGLE DOOR TYPE) - REPLACE
INC: R&R trim and hardware.
NON WARRANTY (PANEL REPLACEMENTS) S - 5
CORROSION PERFORATION REPAIRS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
THE FOLLOWING OPERATIONS SHOULD BE USED TO IDENTIFY
REPAIRS ON RUST THROUGH PERFORATION DAMAGE
THE TIME ALLOWANCES SHOWN INCLUDE ALL METAL
AND PAINT WORK NECESSARY TO COMPLETE THE REPAIR.
RADIATOR SUPPORT AND/OR TIE BAR - CORROSION PERFORATION REPAIR
S5050
1.5
1.5
PANEL HOOD - CORROSION PERFORATION REPAIR
S5070
1.5
1.5
FENDER - CORROSION PERFORATION REPAIR
S5090
1.5
1.5
PANEL MOTOR COMPARTMENT SIDE AND WHEELHOUSE INCLUDING
S5110
1.5
1.5
COWL AND/OR VENT GRILLE - CORROSION PERFORATION REPAIR
S5130
1.5
1.5
PILLAR, WINDSHIELD - CORROSION PERFORATION REPAIR
S5150
1.5
1.5
PANEL ROOF - CORROSION PERFORATION REPAIR
S5170
1.5
1.5
PILLAR, CENTER - CORROSION PERFORATION REPAIR
S5190
1.5
1.5
PANEL ROCKER - CORROSION PERFORATION REPAIR
S5210
1.5
1.5
PANEL FLOOR - CORROSION PERFORATION REPAIR
S5230
1.5
1.5
DOOR - CORROSION PERFORATION REPAIR
S5250
1.5
1.5
PANEL CAB REAR - CORROSION PERFORATION REPAIR
S5310
1.5
-
PANEL QUARTER - CORROSION PERFORATION REPAIR
S5350
1.5
1.5
PANEL PICKUP BOX - CORROSION PERFORATION REPAIR
S5410
1.5
-
STRUT TOWER - CORROSION PERFORATION REPAIR
S - 6 NON WARRANTY (PANEL REPLACEMENTS)
CORROSION PERFORATION REPAIRS
OPERATION DESCRIPTION
OPERATION
NUMBER
CAB STYLE
VIN CODE
TF*
UC*
PANEL REAR END - CORROSION PERFORATION REPAIR
S5430
1.5
-
LID. GATE OR MATCH REAR COMPARTMENT - CORROSION PERFORATION REPAIR
S5450
1.5
1.5
WINDSHIELD
S5500
1.5
1.5
DOORS
S5520
1.5
1.5
QUARTER GLASS
S5550
1.5
1.5
BACK GLASS
S5570
1.5
1.5
BODY OPENING - CORROSION PERFORATION REPAIR
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