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1. LTGL1NOS N 7 ELECTRICAL N 9 ELECTRICAL LTGLIND 7 N2980 je IN p 29 LTGL1NOS ILLUSTRATION INDEX ELECTRICAL N 10 11 ELECTRICAL view A N5830 0647 N3510 N3520 2 EP CoS NE FRONT 4210 VIEW N5950 N5951 595 LTGL1N10 LTGL1N11 ELECTRICAL N 12 R 1 ACCESSORIES LTGL1N12 LTGL1RO1 ILLUSTRATION INDEX ACCESSORIES R 2 R 3 ACCESSORIES R1230 en eas ss 6 R3260R3290 R3261R3291 R3390R3395 R3391R3396 LTGLIRO2 LTGLIRO3 NON WARRANTY PANEL REPLACEMENT 5 1 80950 50951 50850 50851 51856 11611501 11611802 ILLUSTRATION INDEX NON WARRANTY PANEL REPLACEMENT S 3 LTGL1503 PAINT A0347 A0260 PAINT A 1 REAR A2500 A2501 A0680 A0681 LTGL1A01 2 PAINT
2. LTGL1S01 S 2 NON WARRANTY PANEL REPLACEMENT 5570 LTGL1S02 NON WARRANTY PANEL REPLACEMENT S 3 5250 LTGL1S03 4 NON WARRANTY PANEL REPLACEMENTS PANEL REPLACEMENTS NUMBER PANEL HOOD REPLACE FENDER FRONT REPLACE ADD With Molding Each COWL COVER REPLACE DOOR ASSEMBLY FRONT REPLACE INC R amp R trim glass and hardware DOOR ASSEMBLY REAR REPLACE INC R amp R trim glass and hardware DOOR ASSEMBLY BACK SINGLE DOOR TYPE REPLACE INC R amp R trim and hardware NON WARRANTY PANEL REPLACEMENTS S 5 CORROSION PERFORATION REPAIRS NUMBER T 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 PANEL HOOD CORROSION PERFORATION REPAIR 5070 FENDER CORROSION PERFORATION REPAIR PANEL MOTOR COMPARTMENT SIDE AND WHEELHOUSE INCLUDING STRUT TOWER CORROSION PERFORATION REPAIR NNNM ar ek knr UC 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 PANEL QUARTER CORROSION PERFORATION REPAIR
3. LTGL1A02 PAINT PAINT EXTERIOR CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 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 GRILLE ING R amp R grille emblem and headlight bezels COLOR COAT A0260 COLOR COAT COMPLETE A0347 PANEL SHROUD UPPER AND OR VENT GRILLE COLOR COAT A0420 FENDER FRONT COMPLETE DOES NOT ING Fender extension ALLIGATOR TYPE HOOD COLOR COAT RIGHT A0680 ALLIGATOR TYPE HOOD COLOR COAT LEFT A0681 PILLAR WINDSHIELD COLOR COAT RIGHT A0800 COLOR COAT LEFT A0801 ROOF POLICY A Except SPOT REPAIR COLOR COAT A0880 WHEEL OPENING EXTENSION FRONT COLOR COAT RIGHT A0650 ST ST COLOR COAT LEFT A0651 ST ST ST ST ST ST ST ST ST ST 4 PAINT PAINT EXTERIOR CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER T PILLAR CENTER COLOR COAT RIGHT A1020 COLOR COAT LEFT A1021 ROCKER COLOR COAT RIGHT A1040 COLOR COAT LEFT A1041 FRAME FRONT DOOR WINDOW COLOR COAT RIGHT A1100 COLOR COAT LEFT A1101 DOOR FRONT INC Door window frame R amp R mirror DOES NOT INC Drivers vent On aluminum tilt series use spot repair for vent COLOR COAT RIGHT COLOR COAT LEFT PANEL CAB BACK POLICY A Except SPOT
4. 4JA 4JH LTGL1J08 ENGINE J 9 6V HFV6 C24 EXC 6V LTGL1J09 J 10 ENGINE 6V C24 4JA 4JH 4JJ 4JK HFV6 LTGL1J10 ENGINE 11 C24 4J J1800 J1600 J1803 LTGL1J11 J 12 ENGINE 1 9 J1822 LTGL1J12 J3340 8 ENGINE J 13 J3249 13247 93250 J3248 J3250 J3340 ENG J3363 J3367 LTGL1J13 9 14 ENGINE C24 4JA 4JH 4JJ 4JK J3487 LTGL1J14 ENGINE J 15 HFV6 4JA 4JH LTGL1J15 16 ENGINE 4160 J4161 LTGL1J16 ENGINE J 17 RIP PR Na ass IN gt SW TSS 55 ER E 4 S 75891 4 5 5260 m J 18 ENGINE FRONT TURBO CHARGER J5023 _ INL PIPE LTGL1J18 ENGINE J 19 GASOLINE LTGL1J19 J 20 ENGINE HFV6 C24 J5640 LTGL1J20 WATER OUTLET PIPE 95886 X x 4 ho FRONT J5885 SUCTION PIPE CHARGE AIR COOLER ENGINE J 21
5. J5691 5 J5692 J5690 J5693 J 22 ENGINE 4JA 4JH 4JJ 4JK H 2 amp 2 74 CoS OI 4JA 4JH 6V 16009 6 J6000 LTGL1J22 ENGINE J 23 4JJ 4JK J6275 4JA1 TC 4JH1 TC LTGL1J23 J 24 ENGINE 4JA 4JH LTGL1J24 ENGINE J 25 4JA 4JH LTGL1J25 J 26 ENGINE 05 PS m k 4JA 4JH LTGL1J26 ENGINE J 27 4JA 4JH LTGL1J27 J 28 ENGINE 4JA 4JH N gt LTGL1J28 ENGINE J 29 4JJ 4JK LTGL1J29 J 30 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER MANIFOLD AND OR GASKET EXHAUST REPLACE POLICY P E NOTE For HFV6 engine RIGHT BANK LEFT BANK MANIFOLD AND OR GASKET EXHAUST REPLACE POLICY P E NOTE EXC HFV6 engine E ADD 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model C Intercooler of Upside Installation Type 4JJ1 4JK1 Engine D 4JJ1 4JK1 Engine Fitted 2012 Cab Model E 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F For 4x4
6. CONT D V For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger W For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger ONE CYL 6V To Recondition or Replace All Valves B To Replace Piston Rod and or Rings One C To Replace Piston Rod and or Rings Two D To Replace Cylinder Head E For 4x4 Model F For 4x4 Pick Up Model G For 4x4 Wagon Model H For A T Pick Up Model J For A T Wagon Model K For Pick Up Model with A C L For Wagon Model with M To Replace Piston Rod and or Rings All 6V 1 Engine To Recondition or Replace All Valves To Replace Piston Rod and or Rings One C To Replace Piston Rod and or Rings Two D To Replace Piston Rod and or Rings All E To Replace Cylinder Head F For 4x4 Pick Up Model G For 4x4 Wagon Model H For A T Pick Up Model 9 For A T Wagon Model K For Pick Up Model with A C L For Wagon Model with A C FLYWHEEL AUTOMATIC TRANSMISSION REPLACE POLICY P ADD A For 4x4 Pick Up Model Fitted 2003 Cab Model B For 4x4 Wagon Model CONTINUED J 56 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D C For Pick Up Model Fitted 2003 Cab Model D HFV6 Engine E 4JJ1 4JK1 Engine Fitted 2012 Cab Model F For 4x4 Model 4JJ1 4JK1 Engine Fitted 2012 Cab Model G 4JK1 Engine Fitted 2012 Cab Model 2
7. L 6 FUEL AND EXHAUST FUEL AND EXHAUST OPERATION DESCRIPTION SENSOR TEMPERATURE CATALYTIC CONVERTER OUT REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download PIPE INTERMEDIATE EXHAUST REPLACE MUFFLER REPLACE INC Check system for leaks DIESEL PARTICULATE DEFUSER ASSY R amp R OR REPLACE POLICY A ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download 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 A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SENSOR DIFFERENTIAL PRESSURE DIESEL PARTICULATE DEFUSER REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download CAB STYLE OPERATION VIN CODE NUMBER L2311 L2420 4 4 L2584 4 12600 1 0 2630 L2680 L2685 FUEL AND EXHAUST L 7 FUEL AND EXHAUST CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER EXHAUST SYSTEM COMPLETE REPLACE POLICY A INC Replace hangers brackets or clamps as necessary ADD A 6V 1 Engine B HFV6 Engine I
8. OPERATION NUMBER CAB STYLE VIN CODE OPERATION DESCRIPTION PULLEY COOLANT PUMP REPLACE POLIGY P T NOTE Applicable for both w fan clutch and w o fan clutch models ING Adjust belt tension ADD 6V 1 Engine 8 C24 E Engine C 4JJ1 4JK1 Engine Fitted 2003 Cab Model D 4JJ1 4JK1 Engine Fitted 2012 Cab Model E 4JA1 Engine Fitted 2012 Cab Model PUMP AND OR GASKET COOLANT REPLACE POLIGY P T ING Drain and refill radiator as necessary ADD With A C For Pick Up Model With A C B Fitted 2003 Cab Pick Up Model C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JA1 Engine Fitted 2012 Cab Model With A C For Pick Up Model 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 OPERATION NUMBER ENGINE J 65 CAB STYLE VIN CODE J 66 ENGINE CAB STYLE VIN CODE OPERATION DESCRIPTION THERMOSTAT INLET AND OR GASKET REPLACE POLIGY P NOTE For 6V 1 and HFV6 engines ING Drain and refill radiator as necessary and test thermostat ADD HFV6 Engine HOUSING AND OR GASKET THERMOSTAT REPLACE POLICY P ADD 4JA1 4JH1 Engine COOLING SYSTEM FLUSH INC Drain cooling system R amp R thermostat flush with clear water and test coolant PULLEY AND OR FAN GENERATOR REPLACE POLIGY T ADD 6V 1 Engine B 4JA1 4J
9. 1 55 1 55 1 55 1 55 1 55 1 55 1 55 1 55 1 55 1 5 1 5 1 5 1 5 1 5 PANEL PICKUP BOX CORROSION PERFORATION REPAIR 6 NON WARRANTY PANEL REPLACEMENTS CORROSION PERFORATION REPAIRS CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER PANEL REAR END CORROSION PERFORATION REPAIR LID GATE OR MATCH REAR COMPARTMENT CORROSION PERFORATION REPAIR BODY OPENING CORROSION PERFORATION REPAIR F 1 5 1 5 WINDSHIELD DOORS QUARTER GLASS BACK GLASS
10. 4180 E4181 E4187 LTGL1E05 HEE STEERING SUSPENSION WHEELS AND TIRES E 7 F 1 AXLE AND DIFFERENTIAL F1010 F0040 e D F1003 1288 1002 1010 LTGL1F01 LTGL1E07 AXLE AND DIFFERENTIAL F 2 22 gs LTGL1F02 BRAKES H 2 LTGL1H02 ILLUSTRATION INDEX H 1BRAKES 3 BRAKES LTGL1HO1 SIMBR RH LTGL1HO3 ILLUSTRATION INDEX BRAKES 4 J 1 ENGINE STICK LEVER TYPE H2860 H2800 LTGL1H04 ENGINE J 2 J 3 ENGINE 40260 9250 LTGL1J02 LTGL1J03 ILLUSTRATION INDEX ENGINE J 4 40861 3 gt 90858 40361 40361 ML 40548 D 20528 LTGL1J04 ENGINE J 6 6 40818 4JJI4JK view 40685 17611206 J 5 ENGINE HFV6 LTGL1J05 J0703 STR HFV6 LTGL
11. 9 To Replace Springs Caps and or Seals One Additional To Replace Springs Caps and or Seals Two Additional Cyl 1 To Replace All Springs Caps and or Seals M 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model N 4JA1 Engine with EGR System Fitted 2012 Cab Model To Replace Springs Caps and or Seals One Additional To Replace Springs Caps and or Seals Two Additional Cyl C To Replace All Springs Caps and or Seals D 6V 1 Engine Right CONTINUED CAB STYLE VIN CODE OPERATION DESCRIPTION OPERATION NUMBER CONT D ONE CYL C24 E ADD To Replace Springs Caps and or Seals One Additional B To Replace Springs Caps and or Seals Two Additional Cyl C To Replace All Springs Caps and or Seals ADJUSTER VALVE LASH REPLACE POLIGY P T ADD To Replace Left Bank Adjuster To Replace Both Bank Adjuster PUSH ROD REPLACE POLICY P T ONE CYL 4J ADD To Replace All Push Rods B 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model C 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model D 4JA1 Engine with EGR System Fitted 2012 Cab Model LIFTER VALVE REPLACE POLICY P T ONE CYL 4J ADD A With A C 4x4 Model C To Replace All Lifters D For A T E 4JA1 Engine Fitted 2012 Cab Model ENGINE J 37 CAB STYLE VIN CODE J 38 ENGINE
12. B1490 81500 B1630 81710 5t 81711 81717 Ed B1600 B1650 5 PR11891 LTGL1B02 ILLUSTRATION INDEX BUMPERS DOORS AND EXTERIOR TRIM 8 3 B 4 BUMPERS DOORS AND EXTERIOR TRIM B4000B4005 B4001B4006 LTGL1B03 LTGL1B04 BUMPERS DOORS AND EXTERIOR TRIM B 5 8 6 BUMPERS DOORS AND EXTERIOR TRIM EZET 07772 2722 122223 77722 LTGL1B05 17911806 ILLUSTRATION INDEX GLASS INTERIOR TRIM AND SEATS 1 LTGL1C01 GLASS INTERIOR TRIM AND SEATS C 3 LTGL1C03 C 2 GLASS INTERIOR TRIM AND SEATS C0100 C0101 C0110 C0180 C01 C0111 C018 01 00114 00115 x 0170 0171 0380 C0381 C0370 C0371 C1120 01121 4 GLASS INTERIOR TRIM AND SEATS 82 C1130 LTGL1C02 R SCR BS N i C2200 2410 p LTGL1CO4 ILLUSTRATION INDEX GLASS INTERIOR TRIM AND SEATS C 5 C 6 GLASS INTERIOR TRIM AND SEATS C7050 C6691 LTGL1CO6 LTGL1C05 GLASS INTERIOR TRIM AND SEATS C
13. GLASS INTERIOR TRIM AND SEATS C 17 INTERIOR TRIM OPERATION DESCRIPTION OPERATION VIN CODE 2 2 NUMBER PAD INSTRUMENT PANEL COVER REPLACE C2475 ING R amp 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 C2480 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 F 4 4 5 INSTRUMENT PANEL ASSEMBLY R amp R C2500 9 2 2 2 5 T 2 1 DOOR AND OR PAD CONSOLE COMPARTMENT R amp R OR REPLACE C2740 ONSOLE ASSEMBLY R amp R REPLACE C2860 C2861 HEADLINING ASSEMBLY REPAIR ONE PIECE C3098 HEADLINING ASSEMBLY R amp R ONE PIECE C3108 ADD To Replace Headlining for Crew Cab To Replace Headlining for Extend Cab C For Wagon Model D Fitted 2003 Cab Model TRIM ASSEMBLY A PILLAR R amp R OR REPLACE C3220 C3221 C 18 GLASS INTERIOR TRIM AND SEATS INTERIOR TRIM CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TRIM ASSEMBLY FRONT DOOR R amp R OR REPLACE RIGHT ONE PIECE LEFT ONE PIECE ADD For Window Manual Type PLATE AND OR INSERT FRONT DOOR SILL REPLACE REST FOOT R amp R OR REPLACE C3370 TRIM COVER KICKING PLATE REPLACE C3380 2 2 C3381 2 2 GARNISH DOOR M
14. NUMBER CHANNEL FRONT DOOR WINDOW RUN R amp R OR REPLACE INC R amp R door glass as necessary C0140 5 C0141 5 EXTENSION FRONT DOOR WINDOW CHANNEL AT REAR R amp R OR REPLACE C0160 5 C0161 5 HANDLE FRONT DOOR WINDOW REGULATOR REPLACE C0170 2 0171 2 REGULATOR FRONT DOOR WINDOW MANUAL R amp R OR ING D amp C glass prop in up position and transfer motor where necessary C0180 5 C0181 5 REGULATOR FRONT DOOR WINDOW POWER R amp R OR REPLACE INC D amp C glass prop in up position and transfer motor where necessary C0182 5 C0183 5 GLASS REAR DOOR ALIGN C0300 3 C0301 3 GLASS REAR DOOR R amp R C0310 ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model C0311 ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model 5 5 5 5 5 5 3 3 12 GLASS INTERIOR TRIM AND SEATS GLASS AND ATTACHING PARTS CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TF UC GLASS REAR DOOR REPLACE ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model WAIST SEAL REAR DOOR WINDOW INNER R amp R OR REPLACE WAIST SEAL REAR DOOR WINDOW OUTER R amp R OR REPLACE CHANNEL REAR DOOR WINDOW RUN R amp R OR REPLACE ADD A For Pick Up Model Fitted 2003 Cab Model ADD A For Pick Up Model Fitted 2003 Cab Model HANDLE REAR DOOR WINDOW REGULATOR R
15. V HILIM H3ENNN NOILVH43dO dO V 01804 M3IA3H 803 LSANOAY LABOR OP OPERATION DESCRIPTION STEP NO DESCRIPTION OF BASIC STEPS TIME IN MIN Leet Corpse Bert _ lt Prost Pawa 2 23 2 2 The actual time required 10 perform this labor operation in Our Shop i Venicie information vin AMP TEP IG 7 engme ram y APR Trans Rear Aree _ Body Type Sme Special Eque le ___ Common Holk Tits 10 ATI _ DESCRIPTION OF BASIC STEPS TIME IN MIN STEP NO The actual time required to perform this labor operation in our shop is Vehicle Information VIN Rear Axle Additional Comments hr Trans Engine Family Special Equip Body Type N TROUBLE CODES 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 FORE
16. 32 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER COVER AND OR GASKET ROCKER R amp R OR REPLACE POLICY P ADD A Right Bank B Clean Rocker Cover Assembly A 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model B 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model C Clean Rocker Cover Assembly D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine 4JJ1 4JK1 Engine Fitted 2012 Cab Model 4JJ1 4JK1 Engine Fitted 2003 Cab Model 4JA1 Engine with EGR System Fitted 2012 Cab Model A 6V 1 Engine Right B Clean Rocker Cover Assembly A Clean Rocker Cover Assembly ROCKER ARM REPLACE POLICY P T INC R amp R rocker cover and install new gasket ADD A Left Bank ADD 4JJ1 4JK1 Engine B 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model C Intercooler of Upside Installation Type 4JJ1 4JK1 Engine D 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model E 4JA1 Engine with EGR System Fitted 2012 Cab Model CONTINUED ENGINE J 33 CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D 7 VALVE LASH ADJUST ADD 4JJ1 4JK1 Engine Fitted 2003 Cab Model B 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model C Intercooler of Upside Installation Type 4JJ1 4JK1 Engine D 4JJ1 4JK1 Engine Fitted 2012 Cab Model E 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab M
17. 6V 1 Engine PUMP ASSEMBLY POWER STEERING R amp R POLICY T INC Bleed hydraulic system ADD A To Replace Reservoir and or Hose B To Recondition EXC 4JJ1 4JK1 Engine C To Recondition 4JJ1 4JK1 Engine D To Replace Mounting Bracket E 6V 1 Engine 4JJ1 4JK1 Engine Fitted 2003 Cab Model G Diagnosis Time H 4JJ1 4JK1 Engine Fitted 2012 Cab Model 3 6 3 2 2 6 3 3 PUMP ASSEMBLY POWER STEERING REPLACE POLICY T INC Bleed hydraulic system ADD 6V 1 Engine B 4JJ1 4JK1 Engine Fitted 2003 Cab Model C Diagnosis Time D 4JJ1 4JK1 Engine Fitted 2012 Cab Model RESERVOIR ASSEMBLY POWER STEERING FLUID REMOTE REPLACE POLICY T INC Bleed hydraulic system STEERING SUSPENSION WHEELS AND TIRES E 23 STEERING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER GEAR ASSEMBLY POWER STEERING R amp R POLIGY T ING R amp R steering gear assembly drain and refill bleed hydraulic system ADD A Diagnosis Time B For 4x4 Model GEAR ASSEMBLY POWER STEERING REPLACE POLICY T ADD A Diagnosis Time B For 4x4 Model BELT POWER STEERING PUMP DRIVE REPLACE E9750 ks DUST COVER RACK AND PINION REPLACE Inc Adjust Set Toe in E9880 E9882 AXLE AND DIFFERENTIAL AXLE AND DIFFERENTIAL 1 diti F1280 F1004 F1281 F1010 F0040 F1002 F
18. A For Regular Cab B For Wagon Model ADD A For Regular Cab B For Wagon Model CENTER SEAT BELT 3RD BUCKLE SIDE REPLACE C9230 2 2 C9231 2 2 SEAT BELT 3RD TONGUE SIDE REPLACE C9235 BOLTS FASTENERS AND FITTINGS TIGHTEN C9990 2 2 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 HEATING AND AIR CONDITIONING D 1 D142 D1420 6 a D2800 D2802 074 02820 p2220 02822 LTGL1D01 D 2 HEATING AND AIR CONDITIONING LTGL1D02 HEATING AND AIR CONDITIONING D 3 D5010 D5010 LTGL1D03 D 4 HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 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 WITH A C ADD A Fitted 2003 Cab Pick Up Model D0362 Only B For Wagon Model AUTO A C CABLES AIR DISTRIBUTION R amp R OR REPLACE INC Fabricate new cable and adjust HEATER NON A C AIR INLET HEATER NON A C TEMPERATURE HEATER DEFROSTER AIR CONDITIONING TEMPERATURE AIR SOURCE SELECT ACTUATOR AIR DISTRIBUTION REPLACE D0500 RESISTOR BLOW
19. A With SRS EMBLEM AND OR PAD HORN BUTTON REPLACE INC Transfer parts WHEEL STEERING REPLACE ADD A With SRS HORN CONTACT REPLACE CYLINDER IGNITION LOCK R amp R OR REPLACE POLICY T ADD A With SRS COVER LOCK HOUSING REPLACE ADD A With SRS COLUMN ASSEMBLY STEERING R amp R E7660 UNIVERSAL JOINT STEERING SHAFT R amp R OR REPLACE ADD A Fitted 2003 Cab Model ADD A Fitted 2003 Cab Model STEERING SUSPENSION WHEELS AND TIRES E 21 STEERING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TIE ROD INNER REPLACE POLICY T INC Check and adjust toe in R amp R rack and pinion gear assembly as necessary 1 3 1 3 1 5 TIE ROD END AND OR ADJUST SLEEVE REPLACE POLICY T INC Check and adjust toe in PULLEY POWER STEERING PUMP REPLACE E8360 POLICY T SEAL POWER STEERING PUMP SHAFT OIL REPLACE E8380 POLICY T VALVE POWER STEERING PUMP FLOW CONTROL REPLACE E8440 POLICY T ADD A Diagnosis Time HOSES POWER STEERING HYDRAULIC REPLACE POLICY T INC Check and add fluid PRESSURE E8622 i RETURN E8623 1 3 1 3 1 5 6 6 1 1 CAP POWER STEERING PUMP RESERVOIR REPLACE E8300 8 6 6 1 1 8 E 22 STEERING SUSPENSION WHEELS AND TIRES STEERING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER UC SWITCH PRESSURE POWER STEERING R amp R OR REPLACE NOTE Include flush power steering system ADD
20. C Diagnosis Time amp Data Recording Module DRM Download PEDAL AND OR BUSHING BRAKE R amp R OR REPLACE ADD A Fitted 2003 Cab Model PAD BRAKE PEDAL REPLACE SPRING BRAKE PEDAL RETURN REPLACE ADD A Fitted 2003 Cab Model PARKING BRAKE ADJUST LEVER AND OR SUPPORT PARKING BRAKE ASSEMBLY R amp R OR REPLACE ADD A For Stick T Handle Type BRAKES 11 BRAKES OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CABLE PARKING BRAKE REPLACE FRONT SECTION REAR SECTION 1 PIECE REAR SECTION 2 PIECE ENGINE ENGINE 1 30240 LTGL1J01 40302 4JA 4JH HFV6 4 2 ENGINE LOR REN JO290 4JJ 4JK LTGL1J02 ENGINE 3 4JA 4JH 4JJ 4JK LTGL1J03 J 4 ENGINE 6V C24 amp 90427 J0547 J0547 J0527 LTGL1J04 ENGINE 5 HFV6 AK C 29 ER 4JA 4JH J0753 C24 LTGL1J05 9 6 ENGINE HFV6 J0867 LTGL1J06 4J C24 J1309 41180 5 gt WO e ENGINE 7 J1157 HFV6 LTGL1J07 9 8 ENGINE
21. CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D B To Replace Clutch Pilot Bearing for Pick Up Model C To Replace Clutch Pilot Bearing for Wagon Model D To Replace Flywheel E To Replace Clutch Release Bearing F 6V 1 Engine G To Replace Clutch Pilot Bearing H HFV6 Engine J 4JJ1 4JK1 Engine Fitted 2012 Cab Model K 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger A To Replace Clutch Fork Shaft and or Bushings To Replace Clutch Pilot Bearing for Pick Up Model C To Replace Clutch Pilot Bearing for Wagon Model D To Replace Flywheel E To Replace Clutch Release Bearing F 6V 1 Engine G To Replace Clutch Pilot Bearing H HFV6 Engine J 4JJ1 4JK1 Engine Fitted 2012 Cab Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger TRANSAXLE AND TRANSMISSION K 11 MANUAL TRANSMISSION CONTROLS CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER KNOB TRANSMISSION SHIFT CONTROL LEVER REPLACE w SSES LEVER GEARSHIFT CONTROL REPLACE 4 4 POLICY T SEAL AND OR BOOT FLOOR MOUNTED GEARSHIFT REPLACE TRANSMISSION GEARSHIFT ADD A Fitted 2012 Cab Model SENSOR VEHICLE SPEED REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download GEAR AND OR SEAL SPEEDOMETER DRIVEN REPLACE K 12 TRANSAXLE AND TRANSMISSION MANUAL TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN
22. Except Includes Instrument Panel Manual Necessary Overhead Camshaft Power Steering Remove and Reinstall Transmission Throttle Position Sensor Turbocharger Throttle Valve Vehicle Identification Number With Without JYNLIVNDIS 5 JYNIVYNDIS solAJes UBIDIUYD9 1senbai 14 Med 1 SIU 10 peuinbai 1001 jenuesse OU JO uonipuoo Aypiqejrene oU Ju A PIG nzns ueioiuugoo au S enue N 8911199 nzns eui SPIS 49 94 eu uo eui s odq ASN YOLNAIYLSIG 39IAH3S GALLINGNS 3000 723 ASIHONVYS NOILVINHOHNI SUBIDIUYDSL uonoes 9 0 SUBIDIUYDS u equose 10U10 J98 pJ029H 129103 1 SI epis esjo oJ uo uonduosep Joqe deis Aq days jo JUSIDYINSUI SI SWL SJUSUIUIOD SUBIDIUYD9 ino si uonduosep 10987 V 31591099 SI JO 5
23. 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 Power train Requires Authorization T Towing Allowed E 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 sup plement 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 Num ber if the ADD is performed These letters are not to appear on the Warranty Claim ACTION WORDS Each labor operation d
24. 7 C 8 GLASS INTERIOR TRIM AND SEATS C9051 C9040 C9047 C9200 C7950 C7951 LTGL1C07 LTGL1C08 ILLUSTRATION INDEX GLASS INTERIOR TRIM AND SEATS C 9 D 1 HEATING AND AIR CONDITIONING NM LTGL1COS LTGL1D01 HEATING AND AIR CONDITIONING D 2 D 3 HEATING AND AIR CONDITIONING D5010 D5010 D5020 4 7 05000 05100 5 051 10 05080 v D3140 LTGL1D02 UTGI DOG ILLUSTRATION INDEX STEERING SUSPENSION WHEELS AND TIRES E 1 E0022 E0023 50200 50413 20027 E0201 50414 E0202 0420 50203 E0421 E0411 50422 E0412 0423 LTGL1E01 4X2 HIGH RIDE SUSPENSION 4X4 LTGL1EOS 2 STEERING SUSPENSION WHEELS AND TIRES E2220 E2248 E2221 E2260 E2227 E2261 E2240 E2262 E2241 E2263 E2242 E2267 E2243 E2268 E2247 4X2 HIGH RIDE 4X4 EXC MANUAL 4X4 MANUAL SUSPENSION LOCKING HUB LOCKING HUB E2220 E2258 E2221 E2260 E2227 E2261 E2250 E2262 E2251 E2263 E2252 E2267 E2253 E2268 E2257 LTGL1EO2 E 4STEERING SUSPENSION WHEELS AND TIRES 4X2 EXC HIGH RIDE SUSPENSION E2920 E2921 E2927 LTGL1EO4 ILLUSTRATION INDEX STEERING SUSPENSION WHEELS AND TIRES E 5 E 6 STEERING SUSPENSION WHEELS AND TIRES
25. B HFV6 Engine J 44 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER FILTER OIL REPLACE ADAPTER OIL FILTER REPLACE ADD 6V 1 Engine B 4JA1 4JH1 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger PAN AND OR GASKET OIL REPLACE ADD 4JA1 4JH1 Engine ADD A With Auto Trans 5 For 4x4 Model CRANKCASE OR MAIN PAN AND OR GASKET OIL REPLACE POLICY P INC R amp R engine assembly or front axle case assembly clean oil pump screen ADD With A C B For A T Pick Up Model C For A T Wagon Model D For 4x4 Pick Up Model 4JJ1 4JK1 Engine E For 4x4 Wagon Model 4JJ1 4JK1 Engine CONTINUED ENGINE J 45 CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D For 4x4 Model 4JA1 4JH1 Engine G 4JJ1 4JK1 Engine H Intercooler of Upside Installation Type 4JJ1 4JK1 Engine J Engine Fitted 2012 Cab Model 2 Stage Turbocharger K For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger L For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger M For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger A With A C B For A T Wagon Model C For 4x4 Model PUMP ENGINE OIL REPLACE POLICY P T NOTE 4J EXC 4JJ1 4JK1
26. GASOLINE c LTGL1J18 LTGL1J19 ILLUSTRATION INDEX ENGINE J 20 11 21 ENGINE 5886 __ WATER OUTLET PIPE HFV amp lt J5650 z FRONT 95640 C24 45663 P 15654 2 95560 95640 J5640 LTGL1J20 LTGL1J21 ENGINE J 22 J 23 ENGINE 4JA1 TC14JH1 TC 4JJMJK e gt 35937 t sA J5926 BR om 15936 5937 4 lt 5 pna amp sr E gt GE LTGL1J22 LTGL1J23 ILLUSTRATION INDEX ENGINE J 24 J6355 LTGL1J24 ENGINE J 26 4 4 LTGL1J26 25 ENGINE AJJIAJK LTGL1J25 AJJIAJK LTGL1J27 ILLUSTRATION INDEX ENGINE J 28 LTGL1J28 TRANSAXLE AND TRANSMISSION K 1 K0600 K0060 10060 LTGL1KO1 J 29 ENGINE J6376 K 2 TRANSAXLE AND TRANSMISSION LTGL1J29 K1080 jejep 4X2 2 K2283 K2283 i K2284 1060 LTGL1K02 ILLUSTRATION INDEX TRANSAXLE
27. P ADD A 4JJ1 4JK1 Engine Fitted 2003 Cab Model B 4JJ1 4JK1 Engine Fitted 2012 Cab Model C 4JA1 TC 4JH1 TC Engine PIPE OIL PRESSURE TURBO REPLACE ADD A 4JJ1 4JK1 Engine Fitted 2003 Cab Model PIPE OIL RETURN TURBO REPLACE ADD A 4JJ1 4JK1 Engine Fitted 2003 Cab Model B 4JA1 4JH1 Engine PIPE OIL PRESSURE LOW PRESSURE TURBOCHARGER REPLACE J5871 PIPE OIL PRESSURE HIGH PRESSURE TURBOCHARGER REPLACE J5872 EIER PIPE OIL RETURN LOW PRESSURE TURBOCHARGER REPLACE J5873 3 5 ADD A For 4x4 Model 5 PIPE OIL RETURN HIGH PRESSURE TURBOCHARGER REPLACE J5874 PIPE OIL PRESSURE amp RETURN TURBO REPLACE J5875 1 2 1 2 ADD A For 4x4 Models 3 3 HOSE WATER RETURN TURBO REPLACE J5885 76 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER UC HOSE WATER FEED TURBO REPLACE ADD With A C EXC 4JJ1 4JK1 Engine B 4JJ1 4JK1 Engine SOLENOID TURBOCHARGER CONTROL REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SOLENOID TURBIN BYPASS CONTROL TURBOCHARGER REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download INJECTOR FUEL DIESEL R amp R OR REPLACE POLICY T ADD A To Replace Additional Injector One or Two B To Replace All Injectors C To Adjust Injection Pressure 1 2 D To Adjust Injection Pressure
28. RH ONE ADD A For Pick Up Model N1224 Only ADD A For Pick Up Model N1225 Only ADD A For Pick Up Model N1226 Only REAR FOG LIGHT LEFT HIGH MOUNTED STOP ONE ONE ADD A For Wagon Model N1289 Only MAP RH ONE MAP LH ONE MAP BOTH TWO LAMP ASSEMBLY REPLACE LUGGAGE COMPARTMENT DOME ONE OR ALL FOG RIGHT ADD A For Wagon Model N1466 Only CONTINUED ELECTRICAL N 17 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D FOG LEFT ADD A For Wagon Model N1467 Only REAR FOG LIGHT RIGHT REAR FOG LIGHT LEFT LICENSE ONE OR BOTH PARK AND TURN SIGNAL RIGHT PARK AND TURN SIGNAL LEFT REAR COMBINATION RIGHT ADD A For Pick Up Model N1524 Only ADD A For Pick Up Model N1525 Only MAP ONE OR ALL HIGH MOUNTED STOP ADD A For Wagon Model N1599 Only FUSE FUSIBLE LINK REPLACE N1720 2 2 ING One or more FLASHER UNIT REPLACE N1750 SWITCH REPLACE ING Replace fuse where necessary NOTE Switch or sending unit BACK UP LIGHT TRANSFER INDICATOR HI LOW NEUTRAL DOOR LOCK POWER WINDOW FRONT RIGHT POWER WINDOW FRONT LEFT POWER WINDOW REAR RIGHT POWER WINDOW REAR LEFT N m N N N N m N N N CONTINUED N 18 ELECTRICAL ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D DOOR JAMB RIGHT FRONT DOOR JAMB LEFT FRONT DOOR JAMB RIGHT REAR DOOR JAMB LEFT
29. SEAT ASSEMBLY REAR BENCH R amp R OR REPLACE C7700 SEAT ASSEMBLY REAR BENCH R amp R OR REPLACE CUSHION 1 PIECE BACK 1 OR 2 PIECE TYPE C7809 SLIDE ADJUSTER ASSEMBLY REAR SEAT REPLACE C7910 C7911 CONTROL CABLE REAR SEAT DEVICE REPLACE C7920 ADD A Additional Each Control Cable RECLINING ADJUSTER ASSEMBLY REAR SEAT REPLACE C7950 C7951 COVER AND OR PAD 3RD SEAT CUSHION REPLACE BENCH TYPE C8350 GLASS INTERIOR TRIM AND SEATS C 23 SEATS AND SEAT TRIM CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER COVER AND OR PAD 3RD SEAT BACK REPLACE BENCH TYPE C8351 EIES HINGE 3RD SEAT REPLACE BENCH TYPE C8355 LIES SEAT BELT FRONT BUCKLE SIDE REPLACE ADD For Wagon Model ADD For Wagon Model ADD A For Bucket Seat Type SEAT BELT FRONT RETRACTOR SIDE R amp R OR REPLACE ADD A For Regular Cab or Extend Cab Fitted 2003 Cab Model ADD A For Regular Cab or Extend Cab Fitted 2003 Cab Model ADD A For Regular Cab or Extend Cab Fitted 2003 Cab Model GUIDE AND OR COVER SEAT BELT R amp R OR REPLACE ADD For Wagon Model ADD For Wagon Model SEAT BELT FRONT CENTER REPLACE C 24 GLASS INTERIOR TRIM AND SEATS SEATS AND SEAT TRIM CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SEAT BELT REAR BUCKLE SIDE REPLACE RIGHT LEFT CENTER ADD SEAT BELT REAR RETRACTOR SIDE REPLACE ADD
30. SOLENOID STARTER MOTOR REPLACE POLICY T NOTE EXC HFV6 engine ADD A 4JA1 4JH1 Engine 6VE1 Engine C 4JJ1 4JK1 Engine Fitted 2003 Cab Model D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine E 4JJ1 4JK1 Engine Fitted 2012 Cab Model F For 4x4 Model Fitted 2012 Cab Model DRIVE ASSEMBLY STARTER MOTOR REPLACE POLICY T INC R amp R starter motor NOTE EXC HFV6 engine ADD A 4JJ1 4JK1 Engine Fitted 2003 Cab Model B Intercooler of Upside Installation Type 4JJ1 4JK1 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D For 4x4 Model Fitted 2012 Cab Model MOTOR ASSEMBLY STARTER R amp R POLICY T NOTE EXC HFV6 engine ADD To Replace Starter Drive Assy 8 To Recondition Starter Motor INC Adds A and D C To Replace Field Coils D To Recondition Armature 6VE1 Engine 4JJ1 4JK1 Engine Fitted 2003 Cab Model G Intercooler of Upside Installation Type 4JJ1 4JK1 Engine H 4JJ1 4JK1 Engine Fitted 2012 Cab Model J For 4x4 Model Fitted 2012 Cab Model ENGINE 71 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER MOTOR ASSEMBLY STARTER REPLACE POLICY T ADD A 6VE1 Engine B 4JJ1 4JK1 Engine Fitted 2003 Cab Model C HFV6 Engine D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine 4JJ1 4JK1 Engine Fitted 2012 Cab Model F For 4x4 Model Fitted 2012 Cab Model SOLENOID OR ACTUATOR FAST IDLE DIESEL
31. 2003 Cab Model Roof Center Mount RADIO RECEIVER R amp R R0750 ADD For Wagon Model CASSETTE DECK R amp R R0751 ADD For Wagon Model RADIO RECEIVER REPLACE R0760 ADD For Wagon Model CASSETTE DECK REPLACE 0761 ADD For Wagon Model DISPLAY ASSEMBLY R amp R OR REPLACE R0770 CAMERA REAR REPLACE R0771 GRILLE RADIO SPEAKER R amp R OR REPLACE REAR RIGHT R0920 REAR LEFT R0921 SPEAKER RADIO REPLACE FRONT RIGHT R0940 ADD A For Pick Up Model CONTINUED ACCESSORIES R 5 ACCESSORIES CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D FRONT LEFT ADD A For Pick Up Model REAR RIGHT REAR LEFT TWEETER SPEAKER R amp R OR REPLACE FRONT DOOR RIGHT FRONT DOOR LEFT INSTRUMENT PANEL RIGHT INSTRUMENT PANEL LEFT ADD A For Crew Cab Model Only R0984 CHAIN CABLE OR ROD CRUISE CONTROL POWER TO CARBURETOR REPLACE ADD To Adjust Cable SERVO OR ACTUATOR ASSEMBLY CRUISE CONTROL REPLACE RECEIVER UNIT PASSIVE ENTRY AND START SYSTEM REPLACE ADD A Diagnosis Time CONTROL UNIT PASSIVE ENTRY AND START SYSTEM REPLACE ADD A Diagnosis Time BUZZER PASSIVE ENTRY AND START SYSTEM REPLACE ELECTRONIC KEY PASSIVE ENTRY AND START SYSTEM REPLACE He BATTERY ELECTRONIC KEY PASSIVE ENTRY AND START SYSTEM REPLACE 6 ACCESSORIES ACCESSORIES CAB STYLE OPERATION DES
32. 2W 4W REPLACE ADD A Diagnosis Time Fitted 2012 Cab Model C Diagnosis Time amp Data Recording Module DRM Download CONTROL UNIT TRANSFER 2W 4W CLEAR MEMORY ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download TRANSFER CASE ASSEMBLY RECONDITION POLICY P T MAN TRANS ADD A For Wagon Model B For AR5 Trans C MUX Transmission AUTO TRANS TRANSFER CASE ASSEMBLY REPLACE M T MUX M T MUA M T AR5 A T JR405 A T AW30 40E CONTINUED K 16 TRANSAXLE AND TRANSMISSION AUXILIARY TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER A T 41 60 5015 TRANSAXLE AND TRANSMISSION K 17 AUTOMATIC TRANSMISSION CONTROLS CAB STYLE OPERATION DESCRIPTION VIN CODE OPERATION NUMBER 2 2 TF UC INDICATOR PLATE AND OR ASSEMBLY SHIFT RANGE INDICATOR REPLACE ADD A Fitted 2012 Cab Model SHIFT KNOB R amp R OR REPLACE POLIGY T SHIFT LEVER CONTROL LINKAGE REPLACE POLIGY T SHIFT CABLE CONTROL REPLACE ING Adjust K 18 TRANSAXLE AND TRANSMISSION AUTOMATIC TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER OIL COOLER PIPES TRANSMISSION REPAIR OR REPLACE POLICY T ADD A For 4x4 Model ADD A For 4x4 Model ADD A For 4x4 Model OIL COOLER HOSES TRANSMISSION REPAIR OR REPLACE POLICY T RADIATOR SIDE BOTH FILLER TUBE AND OR GASKE
33. 4 x 2 BOTH 4 x 4 E 14 STEERING SUSPENSION WHEELS AND TIRES FRONT SUSPENSION OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 1 7 1 7 1 7 1 7 2 8 2 8 BEARING KNUCKLE REPLACE SEAL KNUCKLE OIL REPLACE 1 5 1 5 1 5 1 5 2 3 2 3 DUMPER CONTROL ARM REPLACE NOTE Maximum time not to exceed operation number E2837 LOWER RIGHT 2 2 LOWER LEFT 2 2 LOWER BOTH 3 3 BALL JOINT CONTROL ARM REPLACE POLICY T UPPER RIGHT UPPER LEFT ADD A Fitted 2003 Cab Model ADD Fitted 2003 Cab Model LOWER RIGHT LOWER LEFT ADD A Fitted 2003 Cab Model B Fitted 2012 Cab 4x4 Model ADD A Fitted 2003 Cab Model B Fitted 2012 Cab 4x4 Model STEERING SUSPENSION WHEELS AND TIRES E 15 STYLE VIN CODE FRONT SUSPENSION SUSPENSION OPERATION DESCRIPTION SPRING FRONT COIL REPLACE POLIGY A T ADD A Fitted 2012 Cab Model 8 Fitted 2012 Cab 4x4 Model ADD A Fitted 2012 Cab Model B Fitted 2012 Cab 4x4 Model BAR FRONT TORSION ADJUST NOTE Use operation E2020 instead of this one if front end alignment is necessary BAR FRONT TORSION REPLACE ING Adjust trim height ADD With Skid Plate ARM TORSION BAR PIVOT REPLACE ING Adjust trim height ADD With Skid Plate ARM ASSEMBLY FRONT CONTROL REPLACE UPPER RIGHT UPPER LEFT ADD A Fitted 2003 Cab Model CONTINUED OPERATION NUMBER E 16 STEERING SUSPENSION
34. 5 6 6 CLUTCH PLATE AND HUB ASSEMBLY COMPRESSOR REPLACE ING R amp R compressor assembly ADD A Discharge Charge A C System 6V 1 Engine C C24 E Engine COMPRESSOR ASSEMBLY REPLACE ADD A Discharge Charge A C System 6V 1 Engine C C24 E Engine ne kne ss i Ks BLOWER MOTOR ASSEMBLY REAR COOLER REPLACE D5070 HEATING AND AIR CONDITIONING D 9 HEATING AND AIR CONDITIONING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER PIPE 1 HIGH OR LOW PRESSURE LINE REAR COOLER REPLACE D5080 1 2 1 2 ADD A Each Additional 2 2 RESISTER REAR COOLER REPLACE D5090 SWITCH BLOWER REAR COOLER REPLACE WHEELS SUSPENSION STEERING STEERING SUSPENSION WHEELS AND TIRES E 1 E0200 E0413 2 ES E0201 E0414 ED E0202 E0420 E0203 E0421 E0411 E0422 E0412 E0423 LTGL1EO1 E 2 STEERING SUSPENSION WHEELS AND TIRES E2220 E2248 E2221 E2260 E2227 E2261 E2180 SQ E2140 E2141 E2147 E2240 E2262 lt E2241 E2263 gt E2242 52267 E2243 2268 E2247 4X2 HIGH RIDE 4X4 EXC MANUAL 4X4 MANUAL SUSPENSION LOCKING HUB LOCKING HUB OG E2360 gt E2361 NS FR 8 AL 63 o 0 o E2230 E2231 E2230 Qa E2237 E2231 E2237 E2220 E2258 E2221 E2260 E2227 E2261 E2250 E2
35. 6V Inc R amp R engine assembly and R amp R oil pan ADD A For 4x4 Model B For A T C For Wagon Model A For Wagon Model A For 4x4 Model 4JA1 4JH1 Engine B With A C C For A T 4JA1 4JH1 Engine D 4JA1 4JH1 Engine E For Wagon Model A For 4x4 Model For A T CONTINUED 9 46 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D C For Wagon Model STRAINER OIL REPLACE ADD A For 4x4 Model With A C 4JJ1 4JK1 Engine B 4JJ1 4JK1 Engine C For 4x4 Model 4JJ1 4JK1 Engine D For A T 4JJ1 4JK1 Engine E Intercooler of Upside Installation Type 4JJ1 4JK1 Engine F 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger A For 4x4 Model B With A C Engine Remove Work only A With A G Engine Remove Work only B For 4x4 Model C With Auto Trans OIL GALLERY REPLACE KIT OIL CATCH TANK INSTALL POLICY A ENGINE J 47 CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER SEALS CRANKSHAFT REAR MAIN REPLACE POLIGY P ING R amp R transmission ADD A For 4x4 Model For A T Pick Up Model C For A T Wagon Model A For 4x4 Model B With Auto Trans A For 4x4 Model For A T Pick Up Model Fitted 2003 Cab Model C For A T Wagon Model D For Pick Up Model Fitted 2003 Cab Model 4JJ1 4JK1 Engine Fitted 2012 Cab Model F For 4x4 Model 4JJ1 4
36. ADD A For 4 x 4 Model B 6VE1 Engine C HFV6 Engine D 4JJ1 4JK1 Engine Fitted 2012 Cab Model E 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger CONVERTER HOUSING TRANSMISSION REPLACE POLICY P T INC R amp R torque converter ADD A For 4x4 Model B 6VE1 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger K 22 TRANSAXLE AND TRANSMISSION AUTOMATIC TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SEAL TRANSMISSION OIL PUMP REPLACE POLIGY P ADD A For 4x4 Model 6VE1 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger OIL PUMP AND OR GASKET TRANSMISSION REPLACE POLIGY P T ING K7000 R amp R automatic transmission assembly K7020 R amp R torque converter ADD A To Replace Front Oil Pump Seal To Recondition Oil Pump C For 4x4 Models 6VE1 Engine 4JJ1 4JK1 Engine Fitted 2012 Cab Model F 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger G For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger AUTOMATIC TRANSMISSION ASSEMBLY RECODITION POLICY A P T INC K7000 R a
37. AND TRANSMISSION K 3 K 4 TRANSAXLE AND TRANSMISSION LTGL1K04 LTGL1K03 TRANSAXLE AND TRANSMISSION K 5 K 6 TRANSAXLE AND TRANSMISSION AISIN AISIN JATCO K7020 R 2 2 PE lt KAAS LTGL1K06 LTGL1K05 ILLUSTRATION INDEX TRANSAXLE AND TRANSMISSION K 7 L 1 FUEL AND EXHAUST FRONT T MISSION P lt 5 AISIN JATCO FUEL TANK LTGL1K07 LTGL1LO1 FUEL AND EXHAUST L 2 1 ELECTRICAL L2020 e L2160 L2020 N0260 NO281 0251 0282 0265 1520 0266 1521 LTGL1LO2 LTGL1NO1 ILLUSTRATION INDEX ELECTRICALN 2 N 3 ELECTRICAL N0769 N N1156 REAR STEP BUMPER 1289 N1599 EXC REAR STEP BUMPER N1176 N1177 N0824 N0825 LTGLINO2 LTGLINOS ELECTRICAL N 4 5 ELECTRICAL LTGL1NOS LTGL1NO4 ILLUSTRATION INDEX ELECTRICAL 6 4JA1 4JH1 E N P N Pr E CY 7 N2230 N2230 ey 4JJ 4JK Z4 2980 P w LTGL1NO6 ELECTRICAL N 8
38. CODE NUMBER SEAL TRANSMISSION EXTENSION REAR REPLACE POLIGY P ING D amp C front universal joint and hanger bearing support to frame Drain and refill transmission R amp R hand brake and yoke flange DOES NOT INC R amp R transmission assembly or recondition universal joint COVER AND OR GASKET TRANSMISSION SHIFT R amp R OR REPLACE POLIGY P ING R amp R floor mat floor access cover shift linkage and shift cover and gasket Clean inspect and retorque DOES NOT ING Recondition remote control assembly MOUNT TRANSMISSION REPLACE POLIGY P T ADD A Fitted 2012 Cab Model 6V REAR TRANSMISSION ASSEMBLY RECONDITION POLIGY P T ING R amp R trans adjust clutch free travel and or linkage for all series DOES NOT ING Recondition transmission REMOVE AND REINSTALL TRANS AY 6 ADD A For 4x4 Model Recondition Transmission Assembly To Recondition Shifter Cover To Replace Main Drive Gear Bearing Retainer and or Gasket or Seal C To Replace Main Drive Gear Bearing INC The above add condition D To Recondition Main Shaft E To Replace Case Extension And Seal F To Replace Speedometer Drive Gear CONTINUED TRANSAXLE AND TRANSMISSION K 13 MANUAL TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER CONT D G To Replace Case H 6V 1 Engine J HFV6 Engine K Fitted 2012 Cab Model A To Recondition Shifter Cover To Repl
39. DEFOGGER LTGL1NO9 N 10 ELECTRICAL N3630 VIEW N3521 LTGL1N10 ELECTRICAL 11 VIEW FRONT N5830 NA LTGL1N11 N 12 ELECTRICAL N6440 N6224 N7084 LTGL1N12 ELECTRICAL N 13 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER BATTERY REPLACE POLIGY A T ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download CABLES BATTERY REPLACE POLIGY T ADD HFV6 Engine Fitted 2012 Cab Model ADD A Fitted 2012 Cab Model RETAINER AND OR BOLTS BATTERY REPLACE TRAY OR SUPPORT BATTERY REPLACE HORN ASSEMBLY REPLACE HIGH NOTE LOW NOTE HEADLAMP ASSEMBLY REPLACE ING Aim headlamps HEADLAMP HOUSING REPLACE ING Aim headlamps 14 ELECTRICAL ELECTRICAL OPERATION DESCRIPTION HEADLAMP AIM STARTER DISCHARGE HEAD LAMP REPLACE ING 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 BACK UP RH ONE BACK UP LH ONE BACK UP BOTH TWO HEAD RH ONE OR ALL ADD A For Wagon Model N0442 Only ADD A
40. DOOR R amp R OR REPLACE B6197 LID FUEL FILLER REPLACE B6701 CABLE RELEASE FUEL FILLER LID REPLACE B6702 ADD For Wagon Model KNOB RELEASE CABLE FUEL FILLER LID REPLACE ADD A Fitted 2003 Cab Model 5 16 BUMPERS DOORS AND EXTERIOR TRIM DOORS AND REAR COMPARTMENT CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER WHEEL OPENING EXTENSION REAR REPLACE BUMPERS DOORS AND EXTERIOR TRIM B 17 EXTERIOR TRIM OPERATION DESCRIPTION OPERATION VIN CODE NUMBER EMBLEM GRILLE REPLACE B7100 2 2 ING R amp R grille if necessary PLATE MODEL DESIGNATION REPLACE B7390 2 2 2 3 MOULDING ROOF REPLACE B7790 ADD A Additional Each Moulding B For Wagon Model MOULDING DOOR REPLACE B7795 ADD A Additional Each Moulding BODY INTERIOR GLASS INTERIOR TRIM AND SEATS C 1 LTGL1CO1 C 2 GLASS INTERIOR TRIM AND SEATS C0100 C0101 C0110 C0111 C0114 C0115 ve C3544 C1130 C1131 C0320 C0321 2250 te 2251 LTGL1C02 GLASS INTERIOR TRIM AND SEATS 3 LTGL1C03 C 4 GLASS INTERIOR TRIM AND SEATS LTGL1C04 GLASS INTERIOR TRIM AND SEATS 5 C3098 C3108 LTGL1C05 C 6 GLASS INTERIOR TRIM AND S
41. Fitted 2003 Cab Model L 4JA1 Engine with EGR System Fitted 2012 Cab Model M To Recondition All Valves 4JA1 4JH1 Engine ONE CYL 6V A To Recondition Valves One Additional Cyl 6V 1 Engine The Same Cyl Head INC Replace valves as necessary B To Recondition All Valves 6V 1 Engine The Same Cyl Head C 6V 1 Engine Right D 6V 1 Engine Both E With A C for Wagon Model CONTINUED ENGINE J 35 CAB STYLE VIN CODE J 36 ENGINE OPERATION DESCRIPTION CONT D ADD A To Recondition All Valves B With A C for Wagon Model SPRING CAP AND OR SEAL VALVE REPLACE POLICY T P INC R amp R Cylinder head assy 6V 1 C24 E ADD To Replace Springs Caps and or Seals One Additional Cyl B To Replace Springs Caps and or Seals Two Additional Cyl C To Recondition All Springs Caps and or Seals D Left Bank OPERATION NUMBER ONE CYL C24 E ONE CYL HFV6 ONE CYL 4J To Replace Springs Caps and or Seals One Additional Cyl 4JJ1 4JK1 Engine B To Replace Springs Caps and or Seals Two Additional Cyl 4JJ1 4JK1 Engine C To Replace All Springs Caps and or Seals 4JJ1 4JK1 Engine D To Recondition All Springs Caps and or Seals 4JJ1 4JK1 Engine E 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model 4JJ1 4JK1 Engine Fitted 2003 Cab Model G Intercooler of Upside Installation Type 4JJ1 4JK1 Engine H 4JJ1 4JK1 Engine Fitted 2012 Cab Model
42. G B To Recondition or Replace All Valves C To Replace Cyl Head D For 4x4 Pick Up Model E For 4x4 Wagon Model F For A T Pick Up Model A To Recondition or Replace All Valves B To Replace Cylinder Head One Bank C To Replace Cylinder Head Both Bank D For 4x4 Pick Up Model E For 4x4 Wagon Model F With Auto Trans A With A C 8 To Recondition or Replace All Valves C To Replace Cylinder Head D To Replace Cylinder Head 4JJ1 4JK1 Engine E For 4x4 Pick Up Model F For 4x4 Wagon Model G For A T Pick Up Model For A T Wagon Model J 4JJ1 4JK1 Engine K With EGR Cooler 4JA1 4JH1 Engine L Intercooler of Upside Installation Type 4JJ1 4JK1 Engine 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger N For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger P For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger Q For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger CONTINUED ENGINE J 61 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D 4JA1 Engine Fitted 2012 Cab Model With A C 8 To Recondition or Replace All Valves C To Replace Cylinder Head D For 4x4 Pick Up Model E For 4x4 Wagon Model F For A T Pick Up Model G For A T Wagon Model ENGINE ASSEMBLY REPLACE POLICY A P T ADD With A C B For 4x4 Pick
43. Model BRAKES 9 BRAKES CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER BOOSTER ASSEMBLY VACUUM POWER BRAKE REPLACE POLIGY T ADD A Fitted 2012 Cab Model VALVE FILTER HOSE AND OR PIPE VACUUM POWER BRAKE REPLACE SPEED SENSOR ABS R amp R FRONT RIGHT FRONT LEFT FRONT BOTH REAR BOTH ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download RING EXCITOR ABS R amp R FRONT RIGHT ADD A For 4x4 Model For Pick Up Model C Diagnosis Time D Diagnosis Time amp Data Recording Module DRM Download A For 4x4 Model For Pick Up Model C Diagnosis Time D Diagnosis Time amp Data Recording Module DRM Download A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download ADD A Diagnosis Time CONTINUED 10 BRAKES BRAKES OPERATION DESCRIPTION OPERATION VIN CODE NUMBER F CONT D B Diagnosis Time amp Data Recording Module DRM Download 5 4 HYDRAULIC UNIT ABS R amp R INC R amp R battery time to bleed brakes ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download G SENSOR ABS R amp R INC R amp R center console assembly ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download CONTROL MODULE ABS ELECTRONIC BRAKE R amp R ADD A For Pick Up Model B Diagnosis Time
44. Other labor hours not allowed with this labor operation This operation may only be claimed in conjunction with a failed part operation CAB STYLE OPERATION VIN CODE NUMBER HEATER ONLY WITH A C HEATER ONLY WITH A C HEATER ONLY WITH A C HEATING AND AIR CONDITIONING D 7 HEATING AND AIR CONDITIONING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SEALS REFRIGERANT O RING REPLACE COMPRESSOR MANIFOLD CONDENSER CONDENSER OUTLET PIPE EXPANSION VALVE EVAPORATOR FILTER DRYER ADD A Discharge Charge A C System HOSES AND OR LINES REFRIGERANT REPLACE INC Assemble service hose as necessary COMPRESSOR DISCHARGE COMPRESSOR SUCTION FILTER DRYER OUTLET CONDENSOR OUTLET ADD A Discharge Charge A C System CONDENSER REPLACE ADD A Discharge Charge A C System B With Intercooler Fitted 2003 Cab Model C With Condenser Fan Moter D For Wagon Model E 4JJ1 4JK1 Engine Fitted 2012 Cab Model F 4JA1 Engine Fitted 2012 Cab Model VALVE EXPANSION REPLACE ADD A Discharge Charge A C System DRYER IN LINE FILTER REPLACE ADD A Discharge Charge A C System 8 HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 4 4 CORE EVAPORATOR REPLACE ADD A Discharge Charge A C System PULLEY IDLER A C R amp R D4020 BRACKET S COMPRESSOR MOUNTING R amp R OR REPLACE D4237 5
45. REPAIR COLOR COAT FRAME REAR DOOR WINDOW COLOR COAT RIGHT A1400 COLOR COAT LEFT A1401 FRAME SIDE ACCESS PANEL WINDOW COLOR COAT RIGHT A1403 COLOR COAT LEFT A1404 DOOR REAR COLOR COAT RIGHT COLOR COAT LEFT F ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST OPERATION DESCRIPTION DOOR SIDE ACCESS PANEL QUARTER COMPLETE LOAD FLOOR WHEEL OPENING EXTENSION REAR TAILGATE COMPLETE REAR BUMPER WHEELS COLOR COAT RIGHT COLOR COAT LEFT COLOR COAT RIGHT COLOR COAT LEFT COLOR COAT COLOR COAT RIGHT COLOR COAT LEFT COLOR COAT COLOR COAT COLOR COAT RIGHT FRONT COLOR COAT LEFT FRONT COLOR COAT RIGHT REAR COLOR COAT LEFT REAR OPERATION NUMBER A2180 A2181 A2500 A2501 PAINT 5 PAINT EXTERIOR T F ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST BODY EXTERIOR BUMPERS DOORS AND EXTERIOR TRIM 1 2 B1710 B1711 B1717 LTGL1B01 B 2 BUMPERS DOORS AND EXTERIOR TRIM LTGL1B02 BUMPERS DOORS AND EXTERIOR TRIM B 3 B4824 B4825 2 55 84817 4818 4520 AR B4521 B4700 B4701 B4720 B4721 LTGL1B03 B 4 BUMPERS DOORS AND EXTERIOR TRIM LTGL1 B04 BUMPERS DOORS AND
46. REPLACE INC Adjustment of fast idle speed ADD A Diagnosis Time GLOW PLUG REPLACE ADD A To Replace Glow Plug One or Two B To Replace Glow Plugs All C 4JJ1 4JK1 Engine D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine E 4JA1 Engine Fitted 2012 Cab Model F 4JA1 Engine with EGR System Fitted 2012 Cab Model AFTER GLOW TIMER REPLACE SWITCH QOS THERMO REPLACE J 72 ENGINE OPERATION DESCRIPTION OPERATION NUMBER AIR CLEANER ASSENBLY REPLACE POLICY A E ELEMENT AIR CLEANER REPLACE J5010 DUCT AND OR HOSE OUTSIDE AIR REPLACE J5020 7 7 POLIGY E DUCT AND OR HOSE AIR CLEANER TO INLET MANIFOLD REPLACE J5021 DUCT AND OR HOSE TURBO TO INLET MANIFOLD REPLACE J5023 Dt SOLENOID SWIRL CONTROL INTAKE MANIFOLD REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM C EXC 2 Stage Turbocharger D For 4x4 Model EXC 2 Stage Turbocharger SOLENOID BYPASS VALVE COMPRESSOR REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM VALVE ASSEMBLY INTAKE THROTTLE R amp R OR REPLACE ADD A Intercooler of Upside Installation Type 4JJ1 4JK1 Engine B Diagnosis Time C Diagnosis Time amp Data Recording Module DRM ENGINE J 73 CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER T U CABLE ACCELERATOR CONTROL REPLACE POLIGY T F 3 4 2 SOLENOID ENGINE ST
47. SEATS C 21 SEATS AND SEAT TRIM OPERATION DESCRIPTION SLIDE ADJUSTER ASSEMBLY FRONT SEAT MANUAL R amp R OR REPLACE BUCKET SEAT ONE SIDE PASSENGER BUCKET SEAT ONE SIDE DRIVER ADD To Replace Both Sides Same Seat RECLINING ADJUSTER ASSEMBLY FRONT SEAT MANUAL R amp R OR REPLACE BUCKET SEAT PASSENGER BUCKET SEAT DRIVER HEADREST FRONT SEAT R amp R OR REPLACE PASSENGER DRIVER SEAT ASSEMBLY FRONT REPLACE BUCKET SEAT PASSENGER BUCKET SEAT DRIVER COVER AND OR PAD FRONT SEAT CUSHION R amp R OR REPLACE BUCKET SEAT PASSENGER BUCKET SEAT DRIVER COVER AND OR PAD FRONT SEAT BACK R amp R OR REPLACE BUCKET SEAT PASSENGER BUCKET SEAT DRIVER HEADREST REAR SEAT R amp R OR REPLACE CAB STYLE OPERATION VIN CODE NUMBER C6110 3 3 C6111 3 3 C6690 2 2 C6691 2 2 C6820 2 2 C6821 2 2 BENCH SEAT ASSEMBLY FRONT REPLACE C6830 EAEN C6870 1 0 C6871 1 1 C 22 GLASS INTERIOR TRIM AND SEATS SEATS AND SEAT TRIM CAB STYLE OPERATION DESCRIPTION DE VIN CODE NUMBER COVER AND OR PAD REAR SEAT CUSHION R amp R OR REPLACE C7250 ADD A For Pick Up Model CUSHION 1 PIECE TYPE C7253 COVER AND OR PAD REAR SEAT BACK R amp R OR REPLACE C7260 ING Replace frame as necessary ADD A For Crew Cab For Wagon Model COVER AND OR PAD REAR SEAT BACK R amp R OR REPLACE ING Replace frame as necessary BACK 1 PIECE TYPE C7278 3 ADD A For Crew Cab
48. SWITCH EGR EFE THERMAL VACUUM REPLACE 4 POLICY E i 8 VACUUM SWITCHING VALVE THROTTLE REPLACE J6351 EE SENSOR CRANKSHAFT ANGLE REPLACE J6355 NOTE EXC HFV6 engine ADD A C24 E Engine 4JJ1 4JK1 Engine C Diagnosis Time D Diagnosis Time amp Data Recording Module DRM Download OIL SEAL O RING SENSOR CRANKSHAFT ANGLE REPLACE J6356 ADD A C24 E Engine 4JJ1 4JK1 Engine SERVICE PROGRAMMING SYSTEM REPROGRAM J6358 ADD A 2005 2006 Model 4JJ1 4JK1 Engine B 2007 Model 4JJ1 4JK1 Engine CONTROLLER EDU ENGINE DRIVE UNIT REPLACE ADD A C24 E Engine B 4JA1 4JH1 Engine J 80 ENGINE OPERATION DESCRIPTION OPERATION NUMBER CONTROLLER ECM ENGINE CONTROL MODULE R amp R OR REPLACE POLICY E ADD A To Program B EXC 4JJ1 4JK1 Engine C Diagnosis Time D Diagnosis Time amp Data Recording Module DRM Download SENSOR BARO BAROMETRIC PRESSURE REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SENSOR FUEL TEMPERATURE REPLACE ADD A Diagnosis Time 4JJ1 4JK1 Engine C Diagnosis Time amp Data Recording Module DRM Download SENSOR COOLANT TEMPERATURE REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SENSOR MAP MANIFOLD ABSOLUTE PRESSURE REPLACE POLICY E ADD A HFV6 Engine B Diagnosis Time C Diagnosis Time
49. Time 8 Diagnosis Time amp Data Recording Module DRM Download SENSOR EGR TEMPERATURE OUT REPLACE ADD A Diagnosis Time 8 Diagnosis Time amp Data Recording Module DRM Download IK TRANSAXLE AND TRANSMISSION TRANSAXLE AND TRANSMISSION 1 LTGL1K01 K 2 TRANSAXLE AND TRANSMISSION K1000 4X2 AT 4X4 K2283 K2284 060 LTGL1K02 TRANSAXLE AND TRANSMISSION K 3 LTGL1K03 K 4 TRANSAXLE AND TRANSMISSION K5100 D LTGL1K04 TRANSAXLE AND TRANSMISSION K 5 AISIN K6645 JATCO LTGL1KOS K 6 TRANSAXLE AND TRANSMISSION AISIN LTGL1K06 TRANSAXLE AND TRANSMISSION K 7 FRONT T MISSION VIEW JATCO AISIN K6560 4 Nyx 90 8 IR WM 8 YARN 4 N AN 2 6 A SR LTGL1K07 K 8 TRANSAXLE AND TRANSMISSION CLUTCH amp CONTROLS OPERATION DESCRIPTION OPERATION VIN CODE PEDAL SHAFT AND OR BUSHING CLUTCH REPLACE K0060 ING Adjust linkage ADD A Fitted 2003 Cab Model 5 8 Fitted 2012 Cab LHD Model PUSH ROD AND OR SEAL CLUTCH PEDAL REPLACE K0080 POLICY T INC Adjust linkage SPRING CLUTCH PEDAL RETURN REPLACE ADD A Fitted 2003 Cab Model 2 RESERVOIR CLUTCH FLUID REPLACE K0580 NOTE
50. Up Model C For 4x4 Wagon Model D For A T Pick Up Model E For A T Wagon Model A For 4x4 Pick Up Model B For 4x4 Wagon Model C With Auto Trans CONTINUED ENGINE UNIVERSAL REPLACE POLICY P T INC R amp R engine assembly ADD A With A C B For 4x4 Model With Auto Trans J 62 ENGINE OPERATION DESCRIPTION OPERATION NUMBER CONT D ADD With A C 4JJ1 4JK1 Engine C For 4x4 Pick Up Model D For 4x4 Wagon Model E For A T Pick Up Model F For A T Wagon Model G Intercooler of Upside Installation Type 4JJ1 4JK1 Engine H 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger J For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger K For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger L For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger M 4JA1 Engine Fitted 2012 Cab Model With A C B For 4x4 Pick Up Model C For 4x4 Wagon Model D For A T Pick Up Model E For A T Wagon Model CAP RADIATOR FILLER REPLACE INC Diagnosis to pressure test cap COCK OF PLUG RADIATOR DRAIN REPLACE INC Drain and refill RADIATOR ASSEMBLY R amp R ADD 6V 1 Engine B 4JA1 4JH1 Engine C 4JJ1 4JK1 Engine D HFV6 Engine OPERATION DESCRIPTION RADIATOR ASSEMBLY REPLACE POLICY T INC Drain and refill ADD A 6V 1 Engine B 4JA1 4JH1 Engine C 4JJ1 4J
51. door assembly to door opening LOCK FRONT DOOR R amp R OR REPLACE HANDLE FRONT DOOR INSIDE OPENING R amp R OR REPLACE CHECK ASSEMBLY REAR DOOR REPLACE KNOB FRONT DOOR INSIDE LOCKING REPLACE ROD FRONT DOOR INSIDE LOCKING R amp R OR REPLACE DOOR OPENING EXTENSION REAR REPLACE DOOR ASSEMBLY REAR ALIGN BUMPERS DOORS AND EXTERIOR TRIM B 11 DOORS AND REAR COMPARTMENT OPERATION NUMBER CAB STYLE VIN CODE 2 2 2 2 2 2 2 2 3 3 3 3 2 2 2 2 2 2 2 2 3 3 3 B 12 BUMPERS DOORS AND EXTERIOR TRIM DOORS AND REAR COMPARTMENT CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 1 2 1 2 1 2 1 2 DOOR ASSEMBLY REAR R amp R HINGE REAR DOOR BOLT ON REPLACE RIGHT UPPER LEFT UPPER RIGHT LOWER LEFT LOWER HANDLE REAR DOOR OUTSIDE REPLACE ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model STRIKER REAR DOOR LOCK REPLACE LOCK REAR DOOR R amp R OR REPLACE ADD A For Pick Up Model ADD A For Pick Up Model HANDLE REAR DOOR INSIDE OPENING R amp R OR REPLACE OPERATION DESCRIPTION KNOB REAR DOOR INSIDE LOCKING REPLACE ROD REAR DOOR INSIDE LOCKING R amp R OR REPLACE ADD A For Pick Up Model ADD A For Pick Up Model PANEL ASSEMBLY SIDE ACCESS ALIGN PANEL ASSEMBLY SIDE ACCESS R amp R HINGE SIDE ACCESS PANEL REPL
52. 012 Cab Model E 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F 4JA1 Engine Fitted 2012 Cab Model 6V FRONT RIGHT 6V FRONT LEFT FRONT BOTH A 4JJ1 4JK1 Engine Fitted 2003 Cab Model B HFV6 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D For 4x4 Model Fitted 2012 Cab Model E 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger 4JA1 Engine Fitted 2012 Cab Model 6V FRONT BOTH J 58 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 4 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 amp R flywheel ADD A Fitted 2012 Cab Model B For 4x4 Model Fitted 2012 Cab Model C For A T Model Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger G For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger BLOCK ENGINE FITTED R amp R OR REPLACE POLICY P T INC R amp R engine assembly ADD A With A C B For 4x4 Pick Up Model C For 4x4 Wagon Model D To Boring E To Replace Cylinder H
53. 1010 3080 j F1445 F1440 2 e FR ben F1300 0 F1301 1550 F1420 gt 2 1427 F1401 F1404 1504 Se A LTGL1F01 F 2 AXLE AND DIFFERENTIAL m AK 6 S 62 O LTGL1F02 AXLE AND DIFFERENTIAL F 3 AXLE AND DIFFERENTIAL NUMBER BEARING CENTER SUPPORT REPLACE POLICY T P INC D amp C front and intermediate U joints R amp R center bearing support to frame R amp R propeller shaft and hanger bearing to shaft UNIVERSAL JOINT PROPELLER SHAFT REPLACE FRONT 1 0 1 0 REAR 1 0 1 0 INTERMEDIATE 1 0 1 0 YOKE PROPELLER SHAFT REPLACE ADD A For Wagon Model INNER SHAFT FRONT OUTPUT REPLACE PROPELLER SHAFT ASSEMBLY R amp R OR REPLACE POLICY P T ONE PIECE TYPE 4 TWO PIECE TYPE 4 4 FRONT DRIVE 4x4 4 4 DUST COVER FRONT DRIVE SHAFT REPLACE ING Adjust set toe in RIGHT OUTER RIGHT INNER RIGHT BOTH LEFT OUTER LEFT INNER LEFT BOTH F 4 AXLE AND DIFFERENTIAL AXLE AND DIFFERENTIAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SHAFT FRONT OUTPUT REPLACE POLICY P ADD A Fitted 2003 Cab Model ADD A Fitted 2003 Cab Model ADD A Fitted 2003 Cab Model SEALS FRONT OUTPUT SHAFT REPLACE POLICY P ADD A For Wagon Model B Fitted 2003 Cab Model A For Wagon Model B Fitted 2003 Cab Model A For Wagon Model B Fitted
54. 1J07 ILLUSTRATION INDEX ENGINE 8 J 9 ENGINE 8r v gt 1009 20996 4 HFV6 ev 624 7 SK x 40957 LTGL1J08 LTGL1J09 4l 41600 41 11 024 ca J1800 Ds 41023 z 19 7 1023 31034 J1034 HFVS LTGL1J10 LTGL1J11 ILLUSTRATION INDEX ENGINE J 12 J 13 ENGINE J1822 HFV6 9 N gt 0 2 Lo LTGL1J12 J 15 ENGINE M J3249 93247 53250 43248 33340 8250 23362 13367 23340 43340 ENG J3363 J3367 LTGL1J13 HFV6 93487 LTGL1J14 23500 3505 LTGL1J15 ILLUSTRATION INDEX ENGINE J 16 9 17 ENGINE 4080 J4120 SN 4081 4101 J4042 74047 34043 24047 ee 14050 4060 J5010 75007 45021 LTGL1J17 LTGL1J16 ENGINE J 18 19 ENGINE TURBO CHARGER GEE J5023 INL PIPE J5023 N J5431 42
55. 2 Model B Fitted 2012 Cab 4x4 Model E 18 STEERING SUSPENSION WHEELS AND TIRES REAR SUSPENSION NUMBER BAR REAR STABILIZER REPLACE INSULATOR AND OR SUPPORT REAR STABILIZER BAR REPLACE DUMPER AXLE REPLACE SPRING ASSEMBLY REAR LEAF REPLACE POLICY A T INC D amp 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 2 2 3 3 3 3 3 4 E BOLT REAR LEAF SPRING CENTER REPLACE POLICY T INC D amp C spring to axle and align spring leaves DOES NOT INC Rebushing 8 8 8 8 1 5 1 5 7 7 7 7 1 3 1 3 9 9 9 9 1 7 1 7 STEERING SUSPENSION WHEELS AND TIRES E 19 REAR SUSPENSION NUMBER BUSHING REAR LEAF SPRING EYE REPLACE SHACKLE AND OR BUSHING REAR LEAF SPRING REPLACE POLIGY T 8 8 8 8 1 5 1 5 4 4 4 4 6 6 U BOLT OR RETAINING BOLT REAR LEAF SPRING REPLACE POLICY T INC Both U bolts or retaining bolts 4 4 4 4 5 5 3 3 3 3 4 4 5 5 5 5 7 7 2 2 2 2 3 3 BOLT REAR LEAF SPRING EYE OR LINK REPLACE POLIGY T BRACKET REAR SHOCK ABSORBER AND LEAF SPRING MOUNTING REPLACE RIGHT LEFT BOTH SHOCK ABSORBER REAR REPLACE POLICY A E 20 STEERING SUSPENSION WHEELS AND TIRES STEERING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER WHEEL STEERING ALIGN ADD
56. 2003 Cab Model A Fitted 2003 Cab Model ACTUATOR ASSEMBLY ELECTRIC TYPE SHIFT ON THE FLY REPLACE AXLE AND DIFFERENTIAL F 5 AXLE AND DIFFERENTIAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE u SHAFT REAR AXLE REPLACE POLICY P T AXLE ASSEMBLY FRONT DRIVE COMPLETE R amp R ADD A Fitted 2003 Cab Model SEAL AXLE SHAFT OIL REAR AXLE REPLACE POLICY P SEAL AXLE SHAFT OIL INNER REAR AXLE REPLACE BEARING AXLE SHAFT REAR AXLE REPLACE POLICY P T SEAL PINION SHAFT OIL REPLACE POLICY P FRONT DIFFERENTIAL REAR DIFFERENTIAL F 6 AXLE AND DIFFERENTIAL AXLE AND DIFFERENTIAL NUMBER FLANGE PINION SHAFT REPLACE POLIGY P ING Reset bearing preload Pinion seal and add lubricant FRONT DIFFERENTIAL REAR DIFFERENTIAL CARRIER ASSEMBLY FRONT AXLE R amp R OR REPLACE POLICY A P T ADD A To Replace Pinion Shaft and or Side and Pinion Gears B To Replace Side Bearings To Replace Pinion Bearings D To Replace Ring Gear and Pinion E To Replace Case F To Replace Carrier G To Recondition Carrier Complete H Fitted 2003 Cab Model CARRIER ASSEMBLY REAR AXLE R amp R OR REPLACE POLICY A P T ADD A To Replace Pinion Shaft and or Side and Pinion Gears B To Replace Side Bearings To Replace Pinion Bearings D To Replace Ring Gear and Pinion E To Replace Case F To Replace Carrier G To Recondition Carrier Complete To Replace Disc
57. 262 E2251 E2263 E2252 E2267 E2253 E2268 E2257 LTGL1E02 STEERING SUSPENSION WHEELS AND TIRES E 3 4X2 HIGH RIDE SUSPENSION 4X4 E3330 E3331 E3337 E3550 E2337 E3551 E3557 E3531 E3537 LTGL1E03 E 4 STEERING SUSPENSION WHEELS AND TIRES 4X2 EXC HIGH RIDE SUSPENSION E3020 E3021 E3027 E3530 E3520 E3830 E3531 E3521 E3831 E3537 d E3527 E3837 9 LTGL1E04 STEERING SUSPENSION WHEELS AND TIRES E 5 E4181 E4187 E5240 4 5241 5247 E5140 E5141 E5147 LTGL1E05 E 6 STEERING SUSPENSION WHEELS AND TIRES E7200 E8041 E8047 LTGL1E06 STEERING SUSPENSION WHEELS AND TIRES E 7 E9750 de SJ LEST g E8440 E amp We Se LTGL1E07 E 8 STEERING SUSPENSION WHEELS AND TIRES WHEELS AND TIRES NUMBER COVER WHEEL REPLACE 2 2 2 2 3 3 WHEEL BALANCE INC R amp R wheel and tire WHEEL OR TIRE REPLACE NOTE Include separate tire from wheel and wheel balance static WHEEL W TIRE R amp R OR REPLACE ING R amp R wheel to hub NOTE Does not include wheel balance static BOLT WHEEL MOUNTING REPLACE ING R amp R wheel and hub as an assembly RIG
58. 3 4 To Lap Nozzle 4JJ1 4JK1 Engine Fitted 2003 Cab Model G Diagnosis Time H Program ECM J Intercooler of Upside Installation Type 4JJ1 4JK1 Engine K 4JJ1 4JK1 Engine Fitted 2012 Cab Model L Diagnosis Time amp Data Recording Module DRM Download M 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model N 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model P 4JA1 Engine with EGR System Fitted 2012 Cab Model N OPERATION DESCRIPTION OPERATION NUMBER LINE FUEL INJECTION HIGH PRESSURE DIESEL R amp R OR REPLACE POLIGY T ADD To Replace Additional Line One 8 To Replace Additional Line Two C To Replace All Lines D 4JJ1 4JK1 Engine Fitted 2003 Cab Model E Intercooler of Upside Installation Type 4JJ1 4JK1 Engine F 4JJ1 4JK1 Engine Fitted 2012 Cab Model LINE FUEL RETURN REPLACE ADD A Intercooler of Upside Installation Type 4JJ1 4JK1 Engine PUMP FUEL INJECTION DIESEL REPLACE POLICY A P T GEAR TYPE 4J ADD 4JA1 TC 4JH1 TC Engine B 4JJ1 4JK1 Engine Fitted 2003 Cab Model C Diagnosis Time D 4JJ1 4JK1 Engine Fitted 2012 Cab Model E Diagnosis Time amp Data Recording Module DRM Download F 4JA1 Engine with EGR System Fitted 2012 Cab Model GASKET TIMING COVER TO HOUSING INJECTION PUMP REPLACE POLIGY P NOTE EXC 4JJ1 4JK1 engine GEAR AND OR ADVANCE TIMING MECHANISM FUEL INJ
59. 63 Only C For 4x4 Model N7063 Only D 4JJ1 4JK1 Engine N7063 Only E HFV6 Engine N7063 Only F Intercooler of Upside Installation Type 4JJ Engine CONTINUED N 26 ELECTRICAL ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D DOOR RIGHT FRONT ADD A For Wagon Model N7066 Only A For Wagon Model N7067 Only A For Pick Up Model N7068 Only A For Pick Up Model N7069 Only SIDE ACCESS PANEL RIGHT SIDE ACCESS PANEL LEFT BATTERY TO STARTER ENGINE ROOM A For Parking Brake T Handle and Bench Seat Type N7080 Only B 4JJ1 4JK1 Engine N7080 Only REAR BODY REAR WINDOW GLASS WIPER MOTOR DOOR LOCK BACK DOOR ROOF TRANSFER REAR DEFOGGER HIGH MOUNT STOP LAMP IMOBILIZER EXTENSION ACCESSORIES ACCESSORIES R 1 R0950 R0940 ke 2 RO94 1 222 0950 S LTGL1R01 R 2 ACCESSORIES LTGL1RO2 ACCESSORIES R 3 R3260R3290 R3261R3291 R3390R3395 R3391R3396 R9000 R9050 LTGL1RO3 4 ACCESSORIES ACCESSORIES OPERATION DESCRIPTION OPERATION VIN CODE NUMBER KN 4 ANTENNA COMPONENTS REPLACE ADD A For Extend Cab Model Roof Center Mount Type B For Crew Cab Model Roof Center Mount Type Fitted
60. ACE STRIKER SIDE ACCESS PANEL LOCK REPLACE LOCK SIDE ACCESS PANEL R amp R OR REPLACE BUMPERS DOORS AND EXTERIOR TRIM B 13 DOORS AND REAR COMPARTMENT CAB STYLE OPERATION VIN CODE NUMBER RIGHT UPPER LEFT UPPER RIGHT LOWER LEFT LOWER RIGHT UPPER LEFT UPPER RIGHT LOWER LEFT LOWER B 14 BUMPERS DOORS AND EXTERIOR TRIM DOORS AND REAR COMPARTMENT CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER HANDLE SIDE ACCESS PANEL INSIDE OPENING R amp R OR REPLACE ROD SIDE ACCESS PANEL INSIDE LOCKING R amp R OR REPLACE SUPPORT REAR COMPARTMENT LID AND OR TAILGATE COUNTERBALANCE GAS TUBE REPLACE HINGE TAILGATE REAR BODY REPLACE LINK ASSY TAILGATE REAR BODY R amp R OR REPLACE STRIKER TAILGATE LOCK REAR BODY R amp R OR REPLACE LOCK TAILGATE REAR BODY R amp R OR REPLACE BUMPERS DOORS AND EXTERIOR TRIM B 15 DOORS AND REAR COMPARTMENT CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER HANDLE ASSEMBLY TAIL GATE OUTSIDE REPLACE B5835 BEEN RUBBER BUMPER SIDEGATE AND OR TAILGATE REPLACE ONE OR ALL B5850 2 DOOR ASSEMBLY BACK DOOR ALIGN B6000 DOOR ASSEMBLY BACK DOOR R amp R ONE PIECE B6108 HINGE BACK DOOR REPLACE B6112 5 5 B6113 5 5 HANDLE BACK DOOR REPLACE OUTSIDE B6160 3 3 CYLINDER BACK DOOR LOCK R amp R OR REPLACE B6180 STRIKER BACK DOOR LOCK REPLACE CENTER B6191 2 2 LOCK BACK
61. CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER BELT DRIVE ADJUST NOTE EXC serpentine type ADD To Adjust All belts 8 4JJ1 4JK1 Engine Fitted 2012 Cab Model ADD To Adjust All belts BELT DRIVE REPLACE POLIGY T ADD C24 E Engine ADD A C24 E Engine B 4JJ1 4JK1 Engine Fitted 2012 Cab Model SERPENTINE TENSIONER SERPENTINE BELT REPLACE ADD HFV6 engine PULLEY CRANKSHAFT REPLACE POLIGY P T ADD A 4JJ1 4JK1 Engine Fitted 2012 Cab Model B 4JA1 4JH1 Engine ENGINE J 39 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER SPROCKET CAMSHFT TIMING REPLACE POLICY P T NOTE For HFV6 engine RIGHT BANK INLET RIGHT BANK EXHAUST LEFT BANK INLET LEFT BANK EXHAUST SEAL CRANKCASE FRONT COVER REPLACE BELT TYPE POLICY P SEAL TIMING COVER OIL REPLACE GEAR TYPE POLICY P INC R amp R harmonic balancer J0752 J0753 ADD A 4JJ1 4JK1 Engine Fitted 2012 Cab Model B 4JA1 4JH1 Engine TENSIONER AND OR SHOE AND OR GUIDE TIMING CHAIN REPLACE POLICY P T NOTE For HFV6 engine RIGHT BANK SECONDLY LEFT BANK SECONDLY PRIMARILY CHAIN TIMING REPLACE POLICY P T NOTE For HFV6 engine RIGHT BANK SECONDLY LEFT BANK SECONDLY PRIMARILY J 40 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER COVER AND OR GASKET TIMING REPLACE POLICY P ADD A 4JJ1 4JK1 Engine Fitt
62. CRIPTION OPERATION VIN CODE NUMBER TF UC ANTENNA PASSIVE ENTRY AND START SYSTEM REPLACE DOOR HANDLE ADD A Diagnosis Time ADD A Diagnosis Time ADD A Diagnosis Time MODULE CRUISE CONTROL REPLACE CONTROL UNIT IMMOBILIZER REPLACE ADD A For Wagon Model CONTROL UNIT WITH ANTENNA IMOBILIZER REPLACE ADD A Diagnosis Time 8 Diagnosis Time amp Data Recording Module DRM Download ANTENNA IMMOBILIZER IGNITION LOCK REPLACE ANTENNA KEYLESSENTRY REPLACE SWITCH CRUISE CONTROL RELEASE R amp R OR REPLACE SWITCH CRUISE CONTROL ENGAGEMENT REPLACE DEFLECTOR TAILGATE WIND REPLACE GLASS MIRROR OUTSIDE REAR VIEW REPLACE MANUAL RIGHT MANUAL LEFT CONTINUED ACCESSORIES R 7 ACCESSORIES CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D ELECTRIC REMOTE CONTROL RIGHT R3290 2 2 ELECTRIC REMOTE CONTROL LEFT R3291 2 2 SWITCH REMOTE CONTROL MIRROR REPLACE MIRROR COMPONENTS OUTSIDE REAR VIEW REPLACE MANUAL RIGHT MANUAL LEFT ELECTRIC REMOTE CONTROL RIGHT ELECTRIC REMOTE CONTROL LEFT CONTROL UNIT ANTI THEFT REPLACE R9000 HORN ASSEMBLY ANTI THEFT REPLACE R9010 SWITCH ANTI THEFT ENGINE HOOD REPLACE R9040 KEYLESS ENTRY SYSTEM CONTROL UNIT KEY REMOTE CONTROLLER BATTERY KEY REMOTE CONTROLLER 5 NON WARRANTY PANEL REPLACEMENT NON WARRANTY PANEL REPLACEMENT 5 1
63. Cab Model FENDER FRONT R amp R OR REPLACE ADD A Fitted 2012 Cab Model BUMPERS DOORS AND EXTERIOR TRIM 8 9 BUMPER AND FRONT END 3 3 3 3 OPERATION DESCRIPTION FENDER FRONT ALIGN WHEEL OPENING EXTENSION FRONT REPLACE ADD To Replace Front Bumper Extension One Replace Front Bumper Extension Two SKIRT REAR FENDER INNER REPLACE ADD For Wagon Model 8 Fitted 2012 Cab Model ADD For Wagon Model B Fitted 2012 Cab Model PLATE SKID REPLACE CROSSMEMBER TRANSMISSION MOUNTING R amp R OR REPLACE ADD A Fitted 2012 Cab Model STEP ASSEMBLY BODY SIDE REPLACE OPERATION NUMBER B 10 BUMPERS DOORS AND EXTERIOR TRIM DOORS AND REAR COMPARTMENT CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER DOOR ASSEMBLY FRONT ALIGN B4000 B4001 DOOR ASSEMBLY FRONT R amp R B4005 B4006 HINGE FRONT DOOR BOLT ON REPLACE ING Adjust door lock striker plate and door assembly to door opening RIGHT UPPER LEFT UPPER RIGHT LOWER LEFT LOWER CHECK ASSEMBLY FRONT DOOR REPLACE HANDLE FRONT DOOR OUTSIDE REPLACE ADD A Fitted 2003 Cab Model With Passive Entry and Start System C Diagnosis Time ADD A Fitted 2003 Cab Model CYLINDER SET LOCK REPLACE ADD For Wagon Model CYLINDER FRONT DOOR LOCK R amp R OR REPLACE OPERATION DESCRIPTION STRIKER FRONT DOOR LOCK REPLACE DOES NOT ING Aligning
64. DULE REPLACE ADD A Diagnosis Time Diagnosis Time amp Data Recording Module DRM 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 amp R any necessary components and replace fuse if necessary AIR CONDITIONING BACK GLASS WIPER MOTOR CONTINUED ELECTRICAL N 25 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D CAB MAIN CHASSIS FRONT CHASSIS REAR DOME LIGHT DOOR LOCK RIGHT FRONT DOOR LOCK LEFT FRONT DOOR LOCK RIGHT REAR DOOR LOCK LEFT REAR DOOR LOCK BACK DOOR DOOR WINDOW RIGHT FRONT DOOR WINDOW LEFT FRONT DOOR WINDOW RIGHT REAR DOOR WINDOW LEFT REAR ENGINE HEADLIGHT HEATER INSTRUMENT PANEL REAR BODY REAR WINDOW DEFOGGER 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 HARNESS WIRING REPLACE HARNESS FUEL INJECTOR HFV6 Engine only INSTRUMENT PANEL For Wagon Model N7060 Only 5 Diagnosis Time C Diagnosis Time amp Data Recording Module DRM Download A With A C N7063 Only B 4JH1 T Engine N70
65. E CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER PISTON ROD AND OR RINGS REPLACE POLICY P T POLICY A EXC UC MODEL INC R amp R oil pan and cylinder head R amp R piston and rod assembly 6V R amp R front axle housing complete ONE CYL HFV6 A To Recondition or Replace All Valves B To Replace Piston Rod and or Rings One C To Replace Piston Rod and or Rings D To Replace Piston Rod and or Rings All E To Replace Cylinder Head One Bank F To Replace Cylinder Head Both Bank G With Auto Trans H For 4x4 Model Two To Recondition or Replace All Valves B To Replace Piston Rod and or Rings One C To Replace Piston Rod and or Rings Two D To Replace Piston Rod and or Rings All E To Replace Cylinder Liner One F To Replace Cylinder Liner Two G To Replace Cylinder Liner All H To Replace Cylinder Head J 4JJ1 4JK1 Engine K For 4x4 Model 4JA1 4JH1 Engine L For 4x4 Pick Up Model M For 4x4 Wagon Model 4JJ1 4JK1 Engine N For A T Pick Up Model P For A T Wagon Model Q For Pick Up Model with A C R For Wagon Model with A C S Intercooler of Upside Installation Type 4JJ1 4JK1 Engine T 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger U For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger CONTINUED ENGINE J 55 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER
66. EATS C6821 LTGL1C06 GLASS INTERIOR TRIM AND SEATS 7 C7700 fe C7253 C7230 C7231 7260 7920 47 C7950 57951 _ LTGL1C07 C 8 GLASS INTERIOR TRIM AND SEATS C9040 C9047 SN 0 69051 09040 C9041 C9047 LTGL1C08 GLASS INTERIOR TRIM AND SEATS C 9 C9990 LTGL1CO9 C 10 GLASS INTERIOR TRIM AND SEATS GLASS AND ATTACHING PARTS CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER T U 1 1 GLASS WINDSHIELD RESEAL C0020 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 C0034 MIRROR INSIDE REAR VIEW REPLACE C0040 GLASS FRONT DOOR ALIGN C0100 C0101 GLASS FRONT DOOR R amp R INC Necessary lubrication and adjustments C0110 0111 GLASS FRONT DOOR REPLACE ING Necessary lubrication and adjustments C0114 C0115 WAIST SEAL AND OR RETAINER FRONT DOOR WINDOW INNER R amp R OR REPLACE C0120 C0121 WAIST SEAL FRONT DOOR WINDOW OUTER R amp R OR REPLACE C0130 0131 F 5 2 2 5 5 4 4 4 4 2 2 2 2 GLASS INTERIOR TRIM AND SEATS 11 GLASS AND ATTACHING PARTS
67. ECTION PUMP REPLACE POLIGY P T TIMING FUEL INJECTION PUMP DIESEL ADJUST POLIGY E ENGINE J 77 CAB STYLE VIN CODE J 78 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER TF 4 FRP FUEL RAIL PRESSURE SCV SUCTION CONTROL VALVE J5990 REPLACE INC SUPPLY PUMP REMOVALAND REINSTALL TIME ADD A Fitted 2003 Cab Model 4 6 0 FRP FUEL RAIL PRESSURE SCV SUCTION CONTROL VALVE J5995 1 REPLACE ON VEHICLE VALVE PCV REPLACE J6000 3 3 POLICY E 4 SENSOR AIR CLEANER TEMPERATURE REPLACE J6200 POLICY E ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download PIPE EGR R amp 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 4JJ1 4JK1 Engine B Diagnosis Time Diagnosis Time amp Data Recording Module DRM Download D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger COOLER EGR VALVE REPLACE J6275 ADD 4JJ1 4JK1 Engine B Intercooler of Upside Installation Type 4JJ1 4JK1 Engine C 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger BYPASS VALVE AND OR GASKET EGR REPLACE ENGINE J 79 CAB STYLE OPERATION DESCRIPTION OPERATION u SOLENOID BYPASS CONTROL EGR REPLACE 5 ADD A Diagnosis Time Diagnosis Time amp Data Recording Module DRM Download
68. EL INSTRUMENT CLUSTER REPLACE ee METER BOARD ASSEMBLY REPLACE 2 2 POLICY A ELECTRICAL N 23 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER COIL ASSEMBLY SRS AIR BAG REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SRS AIR BAG REPLACE POLIGY A DRIVER PASSENGER ADD A Fitted 2003 Cab Pick Up Model N5821 Only 5 Diagnosis Time C Diagnosis Time amp Data Recording Module DRM Download SRS AIR BAG SIDE REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download C To Replace Each Additional SRS AIR BAG ROOF REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download C To Replace Each Additional SENDING AND DIAGNOSTIC MODULE SRS REPLACE ADD A For Wagon Model B Diagnosis Time C Fitted 2012 Cab Model D Diagnosis Time amp Data Recording Module DRM Download CONTROL UNIT ALARMER REPLACE ADD A For Wagon Model N 24 ELECTRICAL ELECTRICAL OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONTROL UNIT REAR FOG LAMP REPLACE G SENSOR REPLACE ADD A Diagnosis Time For Wagon Model C Fitted 2003 Cab Pick Up Model D Front Bumper Side One E Front Bumper Side Both F Diagnosis Time amp Data Recording Module DRM CONTROL MODULE PIM POWER TRAIN INTERFACE MO
69. EPLACE REGULATOR REAR DOOR WINDOW MANUAL R amp R OR REPLACE GLASS INTERIOR TRIM AND SEATS C 13 GLASS AND ATTACHING PARTS CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER REGULATOR REAR DOOR WINDOW POWER R amp R OR REPLACE ADD A For Pick Up Model Fitted 2003 Cab Model For Wagon Model ADD A For Pick Up Model Fitted 2003 Cab Model For Wagon Model GLASS REAR DOOR STATIONARY REPLACE GLASS SIDE ACCESS PANEL ALIGN GLASS SIDE ACCESS PANEL R amp 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 GLASS QUARTER STATIONARY RESEAL GLASS QUARTER STATIONARY R amp R OR REPLACE GLASS QUARTER SWING OUT REPLACE ING Transfer necessary parts HINGE QUARTER GLASS SWING OUT REPLACE RIGHT UPPER LEFT UPPER RIGHT LOWER LEFT LOWER ADD 0 Replace Both LATCH QUARTER GLASS SWING OUT REPLACE 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 ING Water test GLASS BACK WINDOW REPLACE ING R amp R rubber channel where nec water test and extra man s assistance ADD For Wagon Model GLASS INTER
70. ER MOTOR REPLACE HEATER ONLY D1000 2 WITH A C D1002 2 2 FILTER BLOWER UNIT REPLACE O E RELAY A C REPLACE SENSOR SUN REPLACE HEATING AND AIR CONDITIONING D 5 HEATING AND AIR CONDITIONING CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SWITCH COMPRESSOR CUT OFF REPLACE DUAL PRESSURE ADD A Discharge Charge A C System SWITCH THERMOSTATIC CONTROL REPLACE ADD A Discharge Charge A C System MOTOR AND OR FAN R amp R OR REPLACE BLOWER HEATER ONLY BLOWER WITH A C A C CONDENSER NOZZLE ASSEMBLY DEFROSTER REPLACE RIGHT LEFT CENTER DEFLECTOR GRILLE AIR REPLACE ADD A Fitted 2012 Cab Model RIGHT CENTER LEFT CENTER DUCT ASSEMBLY VENTILATION REPLACE RIGHT LEFT CENTER REAR D 6 HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING OPERATION DESCRIPTION CASE HEATER REPLACE ING R amp R instrument panel assembly and cross beam ADD A Discharge Charge A G System CASE EVAPORATOR R amp R OR REPLACE ADD A Discharge Charge A G System HOSES HEATER WITHOUT AIR CONDITIONING REPLACE HOSES HEATER WITH AIR CONDITIONING REPLACE CORE HEATER R amp R ADD A Discharge Charge A G System CORE HEATER REPLACE ADD A Discharge Charge A G System A C SYSTEM LEAK TEST DISCHARGED SYSTEM NOTE This labor operation to be used when necessary to partially charge 1 Ib max the A C system to locate a leak
71. EXTERIOR TRIM 5 LTGL1B05 6 BUMPERS DOORS AND EXTERIOR TRIM B7390 7 ZZ lt ISUZU EZE 6 I ISUZU OM 7 ERESSEER E 72 Dh 5 4390 O BRED 24390 2 INTERCOOLER 7 72 LTGL1B06 BUMPERS DOORS AND EXTERIOR TRIM B 7 BUMPER AND FRONT END CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER rere HNITE Gees srl SHEET NONSLIP REAR BUMPER REPLACE ADD A To Replace Bumper Back Bar Either Right or Left BUMPER ASSEMBLY REAR ALIGN B0860 Dt BUMPER AND OR STEP ASSEMBLY REAR REPLACE ADD A For Steel Bumper Type REINFORCEMENT ASSEMBLY REAR BUMPER REPLACE B0890 SIDE GUARD BUMPER REAR REPLACE B0891 2 B0892 2 GRILLE ASSEMBLY REPLACE ONE PIECE B1308 2 2 HOOD ASSEMBLY ENGINE R amp R OR REPLACE B1490 HOOD ASSEMBLY ALIGN B1500 3 3 ING Adjust bumper and or latch 5 8 BUMPERS DOORS AND EXTERIOR TRIM BUMPER AND FRONT END CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER kald i Wl ee ee HINGE HOOD REPLACE SKIRT FRONT FENDER INNER REPLACE ADD A For Wagon Model B Fitted 2012 Cab Model ADD A For Wagon Model B Fitted 2012 Cab Model ADD A For Wagon Model B Fitted 2012
72. For HVF6 engine CYLINDER CLUTCH MASTER R amp R OR REPLACE K0600 POLIGY T ING Bleed system ADD To Recondition Clutch Master Cylinder B HFV6 Engine C Fitted 2012 Cab LHD Model D Fitted 2012 Cab RHD Model CYLINDER CLUTCH DAMPER R amp R OR REPLACE POLICY T INC Bleed system TRANSAXLE AND TRANSMISSION K 9 CLUTCH amp CONTROLS CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CYLINDER SLAVE R amp R OR REPLACE POLIGY T ING Bleed system ADD To Recondition Slave Cylinder LINE CLUTCH HYDRAULIC MASTER CYLINDER TO SLAVE CYLINDER REPLACE POLICY T PIPE BEARING CLUTCH RELEASE REPLACE INC R amp R trans adjust clutch free travel and or linkage for all series ADD 6V 1 Engine B To Replace Clutch Disc and or Pressure Plate C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger A 6V 1 Engine B To Replace Clutch Disc and or Pressure Plate C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger CYLINDER CLUTCH ACTUATOR R amp R OR REPLACE NOTE For HFV6 engine ADD A For 4x4 Model DISC AND OR PRESSURE PLATE CLUTCH REPLACE POLICY A T INC R amp R trans adjust clutch free travel and or linkage for all series ADD To Replace Clutch Fork Shaft and or Bushings CONTINUED K 10 TRANSAXLE AND TRANSMISSION CLUTCH amp CONTROLS
73. For Wagon Model N0443 Only ADD A For Wagon Model N0444 Only DOME ONE ONE INSTRUMENT PANEL WARNING ONE ONE OR ALL LICENSE ONE ONE LICENSE TWO TWO CONTINUED OPERATION NUMBER CAB STYLE VIN CODE 3 3 2 2 3 ELECTRICAL 15 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER CONT D PARK AND TURN SIGNAL RH ONE OR ALL ADD A For Wagon Model N0685 Only A For Wagon Model N0686 Only PARK AND TURN SIGNAL BOTH TWO OR ALL A For Wagon Model N0687 Only POSITION INDICATOR ONE ONE SIDE MARKER FRONT RH ONE SIDE MARKER FRONT LH ONE STOP TAIL AND TURN SIGNAL RH ONE OR ALL For Pick Up Model N0765 Only STOP TAIL AND TURN SIGNAL LH ONE OR ALL A For Pick Up Model N0766 Only STOP TAIL AND TURN SIGNAL BOTH TWO OR ALL A For Pick Up Model 0767 Only A For Wagon Model N0769 Only MAP RH ONE MAP LH ONE FOG RH ONE A For Wagon Model N0852 Only A For Wagon Model N0853 Only ADD A For Wagon Model N0854 Only CONTINUED 16 ELECTRICAL ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D LUGGAGE COMPARTMENT ONE ONE 2 2 REAR FOG LIGHT LEFT 2 2 LENS AND OR GASKET LAMP REPLACE NOTE Per ONE LAMP HOUSING NAMES of LAMP HOUSINGS LENSES LUGGAGE COMPARTMENT ONE ONE DOME ONE ONE LICENSE ONE ONE LICENSE TWO TWO STOP TAIL AND TURN SIGNAL
74. H1 Engine with A C C 4JJ1 4JK1 Engine BEARING GENERATOR REPLACE ING R amp R generator separate end frame and R amp R rotor ADD With A C EXC 4JJ1 4JK1 Engine ADD With A C EXC 4JJ1 4JK1 Engine ADD With EXC 4JJ1 4JK1 Engine OPERATION NUMBER ENGINE J 67 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER T DIODE CHARGING SYSTEM JUMPER REPLACE J4050 1 4 1 4 NOTE EXC HFV6 engine ING R amp R and disassemble generator as necessary ADD 4JA1 4JH1 Engine with 3 REGULATOR VOLTAGE TEST AND REPLACE J4060 1 4 1 4 POLICY T NOTE EXC HFV6 engine INC R amp R and disassemble generator as necessary ADD A 4JA1 4JH1 Engine with A C 3 GENERATOR ASSEMBLY DISASSEMBLE INSPECT TEST AND REASSEMBLE POLICY T NOTE EXC HFV6 engine INC R amp R generator assembly DIESEL J4080 ADD To Replace Rotor Drive End Frame Pulley Fan and or Front Bearing B To Replace Stator C To Replace Diode Trio D To Recondition Complete 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 J4081 A To Replace Rotor Drive End Frame Pulley Fan and or Front Bearing B To Replace Stator C To Replace Diode Trio D To Recondition Complete INC All of the above additions NOTE All of the above addition
75. HT FRONT LEFT FRONT To Replace Additional Two Bolts To Replace Additional Four Bolts C To Replace All Bolts D With ABS CONTINUED STEERING SUSPENSION WHEELS AND TIRES E 9 WHEELS AND TIRES CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D E For 4x4 Model RIGHT REAR LEFT REAR ADD A To Replace Additional Two Bolts To Replace Additional Four Bolts C To Replace All Bolts HANGER ASSY HOLD DOWN SPARE TIRE R amp R OR REPLACE JACK AND OR HANDLE REPLACE E 10 STEERING SUSPENSION WHEELS AND TIRES OPERATION DESCRIPTION OPERATION NUMBER CUSHION PAD AND OR BOLT BODY R amp R OR REPLACE MOUNT POSITION ONE ADD To Replace Additional Two Cushions B To Replace Additional Four Cushions C Replace All Cushions 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
76. IGHT 4 x 2 OUTER LEFT 4 x 2 OUTER RIGHT 4 x 4 OUTER LEFT 4 x 4 OUTER BOTH 4 x 2 OUTER BOTH 4 x 4 INNER AND OUTER RIGHT 4 x 2 INNER AND OUTER LEFT 4 x 2 INNER AND OUTER RIGHT 4 x 4 INNER AND OUTER LEFT 4 x 4 INNER AND OUTER BOTH 4 x 2 INNER AND OUTER BOTH 4 x 4 lt yee Q RONDE N k N N k S N N 7 7 9 9 0 4 7 7 9 9 0 4 7 7 9 9 m ix SEAL FRONT WHEEL BEARING REPLACE POLICY P INC Clean inspect and repack inner and outer bearings Replace bearings if necessary RIGHT 4 x 2 LEFT 4 x 2 RIGHT 4 x 4 LEFT 4 x 4 BOTH 4 x 2 BOTH 4 x 4 STEERING SUSPENSION WHEELS AND TIRES E 13 FRONT SUSPENSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER HUB ASSEMBLY FRONT WHEEL REPLACE ING R amp R wheel clean and pack inner and outer bearings replace seal fill oiler cap ADD A For 4x4 Model B With ABS C For Wagon Model A For 4x4 Model With ABS C For Wagon Model A For 4x4 Model With ABS C For Wagon Model AUTO LOCKING HUB REPLACE ADD To Replace Manual Locking Hub KNUCKLE ASSEMBLY STEERING REPLACE POLICY T INC R amp R wheel hub and steering knuckle Adjust and lubricate front wheel bearings and set toe in RIGHT 4 x 2 LEFT 4 x 2 RIGHT 4 x 4 LEFT 4 x 4 BOTH
77. IGN 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 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 ILLUSTRATION INDEX PAINT A 1 A 2 PAINT 2500 A2501 LTGL1A01 LTGL1A02
78. IOR TRIM AND SEATS C 15 WEATHER STRIPS AND FINISHER CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER WEATHER STRIP FRONT DOOR ALIGN OR REPLACE WEATHER STRIP REAR DOOR ALIGN OR REPLACE ADD A For Wagon Model ADD For Wagon Model WEATHER STRIP SIDE ACCESS PANEL ALIGN OR REPLACE 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 For Wagon Model CONTINUED C 16 GLASS INTERIOR TRIM AND SEATS INTERIOR TRIM CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D ADD A For Wagon Model SUNSHADE AND OR SUPPORT R amp R OR REPLACE LOCK GLOVE COMPARTMENT INSTRUMENT PANEL REPLACE ADD To Code Cylinder HINGE AND OR STRIKER GLOVE COMPARTMENT INSTRUMENT PANEL ADJUST OR REPLACE BOX GLOVE COMPARTMENT INSTRUMENT PANEL REPLACE INC D amp C door assembly ASH TRAY INSTRUMENT PANEL R amp R OR REPLACE C2200 ASH TRAY DOOR TRIM PAD R amp R OR REPLACE REAR RIGHT C2250 2 2 REAR LEFT C2251 2 2 TRIM COVER INSTRUMENT LOWER DRIVER REPLACE C2350 KNEE BOLSTER REPLACE DRIVER ADD A For Wagon Model PASSENGER CLUSTER CENTER INSTRUMENT PANEL R amp R OR REPLACE ADD A Fitted 2003 Cab Model
79. IRROR FRONT REPLACE C3400 2 2 C3401 2 2 SHEET WATERPROOF FRONT DOOR REPLACE C3420 3 C3421 3 3 SHEET WATERPROOF REAR DOOR REPLACE C3450 3 3 C3451 3 3 TRIM ASSEMBLY REAR DOOR R amp R OR REPLACE C3540 2 2 C3541 2 2 TRIM ASSEMBLY SIDE ACCESS PANEL R amp R OR REPLACE C3543 2 C3544 2 GLASS INTERIOR TRIM AND SEATS C 19 INTERIOR TRIM OPERATION DESCRIPTION OPERATION VIN CODE NUMBER PLATE AND OR INSERT REAR DOOR SILL REPLACE 2 2 2 2 TRIM ASSEMBLY BC PILLAR R amp R OR REPLACE UPPER RIGHT UPPER LEFT LOWER RIGHT LOWER LEFT TRIM ASSEMBLY QUARTER UPPER R amp R OR REPLACE A For Regular Cab B With Center Jack Cover C For Extend Cab Fitted 2003 Cab Model D For Wagon Model TRIM ASSEMBLY QUARTER LOWER R amp R OR REPLACE ADD A For Regular Cab B With Center Jack Cover TRIM COVER CAB BACK R amp R OR REPLACE ADD A For Regular Cab TRIM ASSEMBLY BACK DOOR SINGLE DOOR TYPE R amp R OR REPLACE C 20 GLASS INTERIOR TRIM AND SEATS INTERIOR TRIM CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CARPET OR VINYL MAT REPLACE ADD A For Pick Up Model Fitted 2003 Cab Model B For Wagon Model C For Crew Cab Model Fitted 2012 Cab Model LUGGAGE ASSIST GRIP FRONT R amp R OR REPLACE ASSIST GRIP REAR R amp R OR REPLACE ONE OR ALL COAT HANGER FRONT AND OR REAR R amp R OR REPLACE ONE OR ALL GLASS INTERIOR TRIM AND
80. ISUZU LIGHT DUTY VEHICLE TF amp UC NEW CAB MODEL LABOR TIME GUIDE FOREWORD These Labor Time allowances are published by ISUZU for the purpose of imple menting 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 adjust ments 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 J apan INTRODUCTION This Labor Time Guide is designed for more convenient and accurate use The guide is identi cal in page format to all Labor Time Guides pro duced 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
81. J0853 ADD With A C B For 4x4 Model C To Replace All Valve Lifter CONTINUED J 42 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D D For A T E 4JA1 Engine Fitted 2012 Cab Model A With A G 8 For A T A With A C 8 For A T A With A G 8 For A T SEAL CAMSHAFT OIL REPLACE ADD 6V 1 Engine To Replace Second Camshaft Oil Seal CAMSHAFT INTAKE REPLACE POLIGY P T 7 1 ADD To Replace Left Bank Intake Camshaft CAMSHAFT EXHAUST REPLACE POLICY P T 7 1 ADD A To Replace Left Bank Exhaust Camshaft ENGINE J 43 CAB STYLE OPERATION DESCRIPTION OPERATION VIN GODE NUMBER CAMSHAFT EXHAUST REPLACE 4JJ1 4JK1 0864 ADD To Replace Intake Camshaft B Intercooler of Upside Installation Type 4JJ1 4JK1 Engine C Fitted 2012 Cab Model TENSIONER ASSEMBLY AND OR GASKET TIMING CHAIN REPLACE 4JJ1 4JK1 0865 ADD With B Fitted 2012 Cab Model CHAIN TIMING REPLACE 4JJ1 4JK1 0866 ADD With A C 5 To Replace Sprocket Cam Drive C To Replace Sprocket Supply Pump D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine LEVER TIMING CHAIN REPLACE 4JJ1 4JK1 0867 ADD With A C 5 To Replace Guide C Intercooler of Upside Installation Type 4JJ1 4JK1 Engine CAP OIL FILLER REPLACE J0900 TUBE DIPSTICK REPLACE J0930 ADD 4JA1 4JH1 Engine
82. JK1 Engine Fitted 2012 Cab Model G For A T Model 4JJ1 4JK1 Engine Fitted 2012 Cab Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger J For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger K For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger L For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger A For 4x4 Model B For A T Pick Up Model C For A T Wagon Model 9 48 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER BEARING CRANKSHAFT MAIN REPLACE POLIGY P T ING R amp R engine assembly oil pan and flywheel housing plastic type gauge bearing ONE BEARING C24 E ADD A To Replace Main Bearings One Additional To Replace Main Bearings Two Additional C To Replace All Main Bearings D To Replace Connecting Rod Bearings One Additional E To Replace Connecting Rod Bearings Two Additional F To Replace All Connecting Rod Bearings G For 4x4 Pick Up Model H For 4x4 Wagon Model J For A T Pick Up Model K For A T Wagon Model L For Pick Up Model with A C Engine Remove Work only M For Wagon Model with A C Engine Remove Work only N For 4x4 Model A N A To Replace Main Bearings One Additional 8 To Replace Main Bearings Two Additional C To Replace All Main Bearings D To Replace Connecting Rod Bearings One Add
83. K1 Engine D HFV6 Engine COOLER ENGINE OIL REPLACE POLICY P T INC Drain and refill ADD A To Repair Core B To Replace Core C 4JJ1 4JK1 Engine Fitted 2003 Cab Model D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine E 4JJ1 4JK1 Engine Fitted 2012 Cab Model F 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger G For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger SHROUD RADIATOR FAN REPLACE ADD A Fitted 2012 Cab Model RESERVOIR RADIATOR COOLANT REPLACE ONE PIECE TWO PIECE TYPE UPPER TWO PIECE TYPE LOWER TWO PIECE TYPE BOTH OPERATION NUMBER ENGINE J 63 J 64 ENGINE OPERATION DESCRIPTION CLAMP RADIATOR HOSE REPLACE ADD A To Replace Clamp One Additional Two Additional Three Additional D To Replace Clamp Four Additional To Replace Clamp C To Replace Clamp HOSE ENGINE COOLANT REPLACE POLIGY T ING Drain and refill radiator as necessary ADD HFV6 Engine ADD 4JH1 or 6V 1 Engine COOLING FAN REPLACE POLICY T INC R amp R fan clutch assembly if any ADD A 6V 1 Engine B C24 E Engine C 4JJ1 4JK1 Engine D HFV6 Engine E 4JA1 Engine Fitted 2012 Cab Model CLUTCH ASSEMBLY COOLING FAN REPLACE ADD A 6V 1 Engine B C24 E Engine C 4JJ1 4JK1 Engine Fitted 2003 Cab Model D 4JJ1 4JK1 Engine Fitted 2012 Cab Model E 4JA1 Engine Fitted 2012 Cab Model
84. L1228 ADD A EXC 4JJ1 4JK1 Engine B For Wagon Model C Fitted 2012 Cab Model FUEL WAXING KIT INSTALL L1250 PE TANK FUEL REPLACE L1280 ING Drain and refill tank Transfer gage and filler neck as necessary ADD EXC 4JJ1 4JK1 Engine B For Wagon Model C Fitted 2012 Cab Model HANGER AND OR CLAMP EXHAUST SYSTEM REPLACE ADD To Replace Additional Hanger and or Clamp B To Replace Two Additional Hanger and or Clamp SEAL EXHAUST PIPE REPLACE POLICY E ADD A With Skid Plate 6V 1 Engine PIPE RIGHT FRONT EXHAUST REPLACE POLICY E NOTE For HFV6 engine FUEL AND EXHAUST L 5 FUEL AND EXHAUST CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER PIPE LEFT FRONT EXHAUST REPLACE POLIGY E NOTE For HFV6 engine PIPE FRONT EXHAUST REPLACE POLIGY E NOTE EXC HFV6 engine ADD C24 E Engine ADD A For 4x4 Model PIPE CENTER EXHAUST REPLACE ADD CONVERTER EXHAUST CATALYTIC REPLACE POLIGY E T ING Check system for leaks ADD EXC 4JJ1 4JK1 6V 1 Engine 8 4JJ1 4JK1 Engine Fitted 2003 Cab Model C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger SENSOR TEMPERATURE CATALYTIC CONVERTER IN REPLACE ADD A Diagnosis Time Diagnosis Time amp Data Recording Module DRM
85. Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger G 4JA1 Engine with EGR System Fitted 2012 Cab Model H 4JJ1 4JK1 Engine Fitted 2003 Cab Model 5 9 5 7 2 9 5 2 9 6V 1 Engine Left B 6V 1 Engine for 4x4 Model Right MANIFOLD AND OR GASKET INTAKE REPLACE POLICY P ADD A 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model B 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model C Intercooler of Upside Installation Type 4JJ1 4JK1 Engine D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F 4JA1 Engine with EGR System Fitted 2012 Cab Model G 4JJ1 4JK1 Engine CONTINUED ENGINE J 31 CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TF CONT D 40210 1 6 COMMON AND OR GASKET INLET REPLACE J0220 1 4 MANIFOLD INTAKE UPPER R amp R OR REPLACE POLIGY P 0221 MANIFOLD INTAKE LOWER R amp R OR REPLACE POLICY P J0224 PUMP AND OR GASKET VACUUM REPLACE DIESEL J0240 ADD A With A C EXC 4JJ1 4JK1 Engine B 4JJ1 4JK1 Engine Fitted 2003 Cab Model C 4JJ1 4JK1 Engine Fitted 2012 Cab Model FLEXIBLE PIPE VACUUM PUMP REPLACE DIESEL J0245 3 2 2 HOSE ONE VACUUM REPLACE J0250 ADD To Replace Hose One Additional TANK VACUUM REPLACE J0260 2 2 2 COVER ENGINE REPLACE J0290 J
86. N ELECTRICAL ELECTRICAL 1 0150 110 10260 N0281 10261 10282 10265 N1520 10266 N1521 LTGL1NO1 N 2 ELECTRICAL REAR STEP BUMPER gt N1176 N1177 N1477 1065 7 10658 EXC REAR STEP BUMPER N1176 N1177 N1477 ot 1065 7 N0658 LTGL1N02 ELECTRICAL 3 LTGL1N03 N 4 ELECTRICAL LTGL1N04 ELECTRICAL N 5 LTGL1N05 OD CD N 111 lt I gt 12114 N 6 ELECTRICAL N2242 N2249 N2240 N2247 N2248 4JA1 4JH1 N2315 LTGL1N06 ELECTRICAL N 7 N2345 LTGL1N07 N 8 ELECTRICAL RELAY ENGINE MAIN ECM N2800 A C CONDEMSOR N2912 STARTER N2810 HAZARD TURN SIGNAL N2920 HEAD LIGHT N2820 GLOW PLUG N2922 TAIL LIGHT N2830 HEATER N2932 DIMMER N2850 HAZARD RIGHT N2933 FOG LAMP N2856 HAZARD LEFT N2934 REAR FOG N2857 THERMO A C N2937 HORN N2880 FUEL PUMP N2960 A C COMPRESSOR N2910 LTGL1NO8 ELECTRICAL N 9 N2930 gg AN N2980 PI POWER WINDOW N2990 Nr REAR
87. N VIN CODE NUMBER TRANSMISSION CONTROL MODULE R amp R OR REPLACE POLIGY P ADD A Diagnosis Time B Program TCM C Diagnosis Time amp Data Recording Module DRM Download SENSOR TURBIN SPEED REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download VALVE BODY TRANSMISSION R amp R OR REPLACE POLIGY P ING K6500 R amp R transmission oil pan ADD To Replace Separator Plate or Gaskets To Replace Solenoids One or All ING Diagnosis C To Clean and Recondition Valve Body Main Case PARKING PAWL SHAFT ROD OR SPRING REPLACE POLICY P INC Drain and refill R amp R prop shaft center bearing speedometer drive gear and cable ADD A For 4x4 Model ATF THERMO SENSOR REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download TRANSAXLE AND TRANSMISSION K 21 AUTOMATIC TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER AUTOMATIC TRANSMISSION ASSEMBLY REPLACE POLICY A P T ADD A To Replace Torque Converter B To Flush Cooling Line C For 4 x 4 Model D 6VE1 Engine E HFV6 Engine F 4JJ1 4JK1 Engine Fitted 2012 Cab Model G 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger H For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger TORQUE CONVERTER ASSEMBLY REPLACE POLICY A P T INC K7000 R R automatic transmission assembly
88. OP REPLACE POLICY E DIESEL J5345 3 4 PEDAL ACCELERATOR REPLACE J5350 FILTER FUEL ELEMENT REPLACE J5420 ADD A Fitted 2003 Cab Model PUMP AND OR GASKET FUEL REPLACE POLIGY T INTANK ELECTRIC J5431 REGULATOR FUEL PRESSURE REPLACE 4 5 GASOLINE ADD 6V 1 Engine PIPES amp HOSES FUEL FEED AND RETURN FUEL PIPE FUEL RAIL REPLACE J5640 MS INJECTOR FUEL GASOLINE REPLACE ADD A To Replace Each Additional Injector B To Replace All Injector C Diagnosis Time J 74 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER UC RAIL FUEL INJECTOR REPLACE RAIL ASSEMBLY COMMON FUEL INJECTION DIESEL R amp R OR REPLACE ADD A Fitted 2003 Cab Model SENSOR MASS AIR FLOW REPLACE NOTE For HFV6 engine ADD A Diagnosis Time INTERCOOLER COMPONENTS REPLACE INTERCOOLER ASSEMBLY ADD 4JA1 4JH1 Engine 8 Intercooler of Upside Installation Type 4JJ1 4JK1 Engine TURBO TO INTERCOOLER INLET PIPE ADD 4JA1 4JH1 Engine ADD 4JA1 4JH1 Engine ADD 4JA1 4JH1 Engine ADD A To Replace Third Piece Rubber Hose B 4JA1 4JH1 Engine TURBOCHARGER ASSEMBLY LOW PRESSURE REPLACE J5857 3 5 TURBOCHARGER ASSEMBLY HIGH PRESSURE REPLACE J5858 ENGINE J 75 CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TURBOCHARGER ASSEMBLY REPLACE POLICY A EXC UC MODEL POLICY
89. REAR ENGINE OIL PRESSURE ADD A HFV6 Engine N2220 Only ADD A For Pick Up Model N2230 Only ADD A For Pick Up Model N2240 Only REAR WIPER WASHER REAR DEFOGGER ADD A For Wagon Model N2243 Only FOG LAMP POWER MIRROR HAZARD WARNING REAR FOG LAMP REAR A C MAIN LIGHTING ADD With SRS N2290 Only ADD A With SRS ADD A For Pick Up Model N2315 Only IGNITION NEUTRAL A T POWER 3RD START VACUUM CONTINUED ELECTRICAL N 19 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D CLUTCH NEUTRAL M T NEUTRAL T F PARKING BRAKE LIGHT PARKING BRAKE LIGHT STICK TYPE STOP LIGHT ADD A Fitted 2012 Cab Model N2440 Only TURN SIGNAL COMBINATION WINDSHIELD WIPER WASHER COMBINATION ADD A With SRS 4x4 INDICATOR LIGHT TCS ESC OFF RELAY REPLACE INC Replace fuse where necessary ENGINE MAIN ECM STARTER HEAD LIGHT TAIL LIGHT DIMMER FOG LAMP REAR FOG HORN WIPER A C COMPRESSOR A C CONDENSOR HAZARD TURN SIGNAL GLOW PLUG ACCESSORY SOCKET HEATER HAZARD RIGHT HAZARD LEFT THERMO A C N HD N v 3 N N N 3 N N 03 CONTINUED N 20 ELECTRICAL ELECTRICAL OPERATION DESCRIPTION OPERATION CODE NUMBER CONT D FUEL PUMP POWER WINDOW REAR DEFOGGER MOTOR REPLACE POLICY A POWER WINDOW F
90. REPLACE REAR RIGHT REAR LEFT REAR BOTH SELF ADJUSTER BRAKE R amp R OR REPLACE REAR RIGHT REAR LEFT REAR BOTH BRAKES H 7 BRAKES OPERATION DESCRIPTION OPERATION VIN CODE 7 7 1 2 NUMBER T F CYLINDER BRAKE WHEEL R amp R OR REPLACE POLIGY T ING Time to recondition adjust bearings bleed brakes REAR RIGHT 7 REAR LEFT 7 REAR BOTH 1 2 SHIELD REAR BRAKE DUST R amp R OR REPLACE DRUM RIGHT ADD A For Wagon Model ADD A For Wagon Model ADD A For Wagon Model RESERVOIR BRAKE MASTER CYLINDER REPLACE INC Air bleed brake system CYLINDER ASSEMBLY BRAKE MASTER R amp 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 CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER HOSE BRAKE REPLACE POLICY T INC Air bleed brake system FRONT RIGHT FRONT LEFT FRONT BOTH REAR CENTER PIPE BRAKE REPLACE POLICY T INC Air bleed brake system MASTER CYL TO CONNECTOR CONNECTOR TO FRONT WHEEL FLEX HOSE RIGHT CONNECTOR TO FRONT WHEEL FLEX HOSE LEFT AXLE HOUSING JUNCTION TO REAR WHEEL RIGHT AXLE HOUSING JUNCTION TO REAR WHEEL LEFT VACUUM TANK REPLACE ADD A For Two Batteries Specification BOOSTER ASSEMBLY VACUUM POWER BRAKE R amp R POLICY T INC Air bleed brake system MASTER VAC MODEL ADD A To Recondition Booster B Fitted 2012 Cab
91. RONT RIGHT ADD A For Wagon Model ADD A For Wagon Model ADD A Fitted 2003 Cab Pick Up Model ADD A Fitted 2003 Cab Pick Up Model ACTUATOR ASSY DOOR LOCK R amp R OR REPLACE FRONT RIGHT ADD A For Pick Up Model ADD For Pick Up Model ADD A For Pick Up Model ADD A For Pick Up Model BACK DOOR ELECTRICAL N 21 ELECTRICAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER MOTOR WIPER R amp R ING Replace fuse where necessary WINDSHIELD ADD A Fitted 2012 Cab Model MOTOR WIPER REPLACE WINDSHIELD ADD A Fitted 2012 Cab Model BLADE WIPER REPLACE WINDSHIELD BACK GLASS ARM WIPER REPLACE ING One or both WINDSHIELD BACK GLASS LINK WINDSHIELD WIPER OPERATING REPLACE ADD A Fitted 2003 Cab Model ADD A Fitted 2003 Cab Model HOSES NOZZLES WASHER AND OR WIPER STOPS REPLACE ING One or all WINDSHIELD ADD A Fitted 2012 Cab Model CONTINUED 22 ELECTRICAL ELECTRICAL OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 3 CONT D BACK GLASS CONTAINER AND COVER WASHER REPLACE WINDSHIELD 1 0 ADD For Wagon Model BACK GLASS 1 0 PUMP ASSEMBLY WASHER R amp R OR REPLACE ING One or both WINDSHIELD ADD For Wagon Model BACK GLASS LIGHTER ASSEMBLY CIGARETTE REPLACE ADD A Fitted 2003 Cab Model SOCKET ACCESSORY REPLACE FRONT CONSOLE LUGGAGE ROOM LENS AND OR BEZ
92. Stage Turbocharger H For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger FLYWHEEL MANUAL TRANSMISSION REPLACE POLIGY P ING R amp R transmission ADD A To Replace Clutch Pilot Bearing B To Replace Ring Gear C For 4x4 Model D For Pick Up Model A To Replace Clutch Pilot Bearing B To Replace Ring Gear C For 4x4 Model A To Replace Clutch Pilot Bearing B To Replace Ring Gear C For 4x4 Model Fitted 2003 Cab Model D For Pick Up Model Fitted 2003 Cab Model E 4JJ1 4JK1 Engine Fitted 2012 Cab Model F For 4x4 Model 4JJ1 4JK1 Engine Fitted 2012 Cab Model G 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger H For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger A To Replace Clutch Pilot Bearing B To Replace Ring Gear CONTINUED ENGINE J 57 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D C For 4x4 Model 8 D For Pick Up Model 5 MOUNT ENGINE REPLACE POLICY P FRONT RIGHT ADD A 4JJ1 4JK1 Engine Fitted 2003 Cab Model B HFV6 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger F 4JA1 Engine Fitted 2012 Cab Model A 4JJ1 4JK1 Engine Fitted 2003 Cab Model B HFV6 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D For 4x4 Model Fitted 2
93. T TRANSMISSION REPLACE POLICY P INHIBITOR SWITCH TRANSMISSION REPLACE POLICY P T INC D amp C shift arm cable transmission side ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM BOLTS CONVERTER TO FLYWHEEL REPLACE POLICY P ADD A HFV6 Engine DRIVEN GEAR AND OR GASKET SPEEDOMETER REPLACE POLICY P TRANSAXLE AND TRANSMISSION K 19 AUTOMATIC TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SENSOR VEHICLE SPEED REPLACE ADD A Diagnosis Time 8 Diagnosis Time amp Data Recording Module DRM Download SENSOR SPEED REVOLUTION REPLACE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download OIL SEAL EXTENSION HOUSING FLANGE YOKE REPLACE POLIGY P ING Drain and refill ATF OIL PRESSURE TEST K6400 DRAIN PLUG AND OR GASKET R amp R OR REPLACE K6490 OIL PAN AND OR GASKET TRANSMISSION R amp R OR REPLACE POLICY P TRANSMISSION ADD To Replace Oil filter B To Replace Solenoids One or All EXC Pressure Control Solenoid INC Diagnosis SOLENOID SHIFT LOCK REPLACE K6508 CONTROLLER SHIFT LOCK SOLENOID REPLACE HARNESS AND OR CONNECTOR VALVE BODY REPLACE MAIN CASE ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download K 20 TRANSAXLE AND TRANSMISSION AUTOMATIC TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATIO
94. TIGHTEN NOTE This operation is to be used on chassis items only For body items refer to operation C9990 of the seats section CAB STYLE VIN CODE UC STEERING SUSPENSION WHEELS AND TIRES E 11 FRONT SUSPENSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TOE IN FRONT SUSPENSION ADJUST PE FRONT SUSPENSION CHECK AND OR ALIGN ING 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 amp R OR REPLACE POLIGY P Except Bushing NOTE Maximum time not to exceed operation number E2147 3 3 3 3 4 4 SHAFT FRONT STABILIZER REPLACE POLICY P INC R amp R links and bushings INSULATOR AND OR BRACKET FRONT STABILIZER SHAFT AT FRAME REPLACE NUT FRONT WHEEL HUB REPLACE ADD To Replace Both B For 4x4 Model BEARING FRONT WHEEL ADJUST ADD A For 4x4 Model CAP FRONT WHEEL HUB DUST REPLACE E 12 STEERING SUSPENSION WHEELS AND TIRES FRONT SUSPENSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER BEARING FRONT WHEEL REPLACE POLICY T P INC R amp R wheel clean and pack inner and outer bearings replace seal fill oiler cap NOTE Maximum time not to exceed operation number E2267 amp E2268 INNER RIGHT 4 x 2 INNER LEFT 4 x 2 INNER RIGHT 4 x 4 INNER LEFT 4 x 4 INNER BOTH 4 x 2 INNER BOTH 4 x 4 OUTER R
95. Up Model D With A C for Wagon Model E Intercooler of Upside Installation Type 4JJ1 4JK1 Engine F 4JJ1 4JK1 Engine Fitted 2012 Cab Model G 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger H For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger J 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model K 4JA1 Engine with EGR System Fitted 2012 Cab Model 6V 1 Engine Right B 6V 1 Engine Both C With A C for Wagon Model OPERATION DESCRIPTION OPERATION NUMBER VALVE RECONDITION OR REPLACE POLIGY P ING R amp R rocker cover rocker arms push rods cylinder head recondition valve seat and replace valve seal and make all necessary adjustments ADD ONE CYL HFV6 To Recondition Valves One Cyl Right Bank B To Recondition All Valves Right Bank C To Recondition All Valves Left Bank D To Recondition All Valves Both Bank E With A C for Wagon Model To Recondition All Valves 4JJ1 4JK1 Engine B 4JJ1 4JK1 Engine Fitted 2003 Cab Model C 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model D With A C for Pick Up Model E With A C for Wagon Model F Intercooler of Upside Installation Type 4JJ1 4JK1 Engine G 4JJ1 4JK1 Engine Fitted 2012 Cab Model H 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger J For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger K 4JA1 4JH1 Engine with EGR Cooler
96. V 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger W For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger X For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger Y For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger Z AJA1 Engine Fitted 2012 Cab Model ADD A For Pick Up Model with A C CONTINUED ENGINE J 53 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D 8 For Wagon Model with A C C For 4x4 Model D To Replace Rod and or Pin Only One E To Replace Rod and or Pin Only Two Replace Cylinder Head G To Recondition or Replace All Valve H To Replace Piston Rod and or Rings One J To Replace Piston Rod and or Rings Two K For A T Pick Up Model L For A T Wagon Model M To Replace Rod and or Pin only All 6V 1 Engine N To Replace Piston Rod and or Rings All 6V 1 Engine P For 4x4 Pick Up Model Q For 4x4 Wagon Model To Replace Rod and or Pin Only One To Replace Rod and or Pin Only Two C To Replace Rod and or Pin Only All D To Replace Cylinder Head One Bank E To Replace Cylinder Head Both Bank To Recondition or Replace All Valve G To Replace Piston Rod and or Rings One H To Replace Piston Rod and or Rings Two 9 To Replace Piston Rod and or Rings All K With Auto Trans L For 4x4 Model 9 54 ENGIN
97. WHEELS AND TIRES FRONT SUSPENSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D UPPER BOTH ADD A Fitted 2003 Cab Model LOWER RIGHT LOWER LEFT ADD A Fitted 2003 Cab Model B Fitted 2012 Cab 4x4 Model ADD A Fitted 2003 Cab Model B Fitted 2012 Cab 4x4 Model BUSHINGS AND OR SHAFT FRONT CONTROL ARM REPLACE POLICY T UPPER RIGHT UPPER LEFT ADD A Fitted 2003 Cab Model ADD A Fitted 2003 Cab Model LOWER RIGHT LOWER LEFT ADD A Fitted 2003 Cab Model B Fitted 2012 Cab 4x4 Model ADD A Fitted 2003 Cab Model B Fitted 2012 Cab 4x4 Model STEERING SUSPENSION WHEELS AND TIRES E 17 FRONT SUSPENSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SHOCK ABSORBER FRONT REPLACE POLICY A RIGHT ADD A Fitted 2003 Cab 4x2 Model EXC High Ride B Fitted 2012 Cab 4x2 Model C Fitted 2012 Cab 4x4 Model A Fitted 2003 Cab 4x2 Model EXC High Ride B Fitted 2012 Cab 4x2 Model C Fitted 2012 Cab 4x4 Model Fitted 2003 Cab 4x2 Model EXC High Ride B Fitted 2012 Cab 4x2 Model C Fitted 2012 Cab 4x4 Model COVER FRONT SHOCK ABSORBER REPLACE ADD A Fitted 2012 Cab 4x2 Model B Fitted 2012 Cab 4x4 Model ADD A Fitted 2012 Cab 4x
98. ace Main Drive Gear Bearing Retainer and or Gasket or Seal C To Replace Main Drive Gear Bearing INC The above add condition To Recondition Main Shaft E To Replace Case Extension And Seal F To Replace Speedometer Drive Gear G To Replace Case H 6V 1 Engine J HFV6 Engine K Fitted 2012 Cab Model A To Replace Front Oil Seal B To Replace Main amp Counter Gear and or Bearing C To Replace Output Shaft amp Bearing and or Seal D To Replace Front Case E To Replace Rear Case F Fitted 2012 Cab Model A To Replace Front Oil Seal B To Replace Main amp Counter Gear and or Bearing C To Replace Output Shaft amp Bearing and or Seal D To Replace Front Case E To Replace Rear Case F Fitted 2012 Cab Model K 14 TRANSAXLE AND TRANSMISSION MANUAL TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER TRANSMISSION ASSEMBLY REPLACE POLICY A P T INC Separate transfer case assembly ADD A For 4x4 Model ADD A 6V 1 Engine B HFV6 Engine C Fitted 2012 Cab Model ADD A 6V 1 Engine B HFV6 Engine C Fitted 2012 Cab Model TRANSAXLE AND TRANSMISSION K 15 AUXILIARY TRANSMISSION CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER ACTUATOR TRANSFER 2W 4W SHIFT REPLACE EN SEAL OIL ACTUATOR SHAFT REPLACE SEAL TRANSFER CASE OIL REPLACE POLIGY P FRONT REAR FRONT INPUT CONTROL UNIT TRANSFER
99. amp Data Recording Module DRM Download SENSOR IAT MAT INTAKE AIR TEMPERATURE MANIFOLD AIR TEMPERATURE REPLACE ADD A Diagnosis Time 8 Diagnosis Time amp Data Recording Module DRM Download CAB STYLE VIN CODE ENGINE J 81 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER UC SENSOR 0 2 EXHAUST OXYGEN REPLACE POLICY E ADD A 6V 1 Engine B HFV6 Engine C To Replace Each Additional Sensor D Diagnosis Time SENSOR ACCEL POSITION REPLACE NOTE Include clean all connector pins ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SENSOR THROTTLE POSITION REPLACE ADD A Diagnosis Time SENSOR CAMSHAFT ANGLE REPLACE NOTE EXC HFV6 engine ADD A 6V 1 Engine B 4JJ1 4JK1 Engine C Diagnosis Time D Diagnosis Time amp Data Recording Module DRM Download SENSOR AIR FLOW REPLACE NOTE EXC HFV6 Engine ADD A Diagnosis Time B Diagnosis Time amp Data Recording Module DRM Download SENSOR KNOCK REPLACE NOTE EXC HFV6 engine ADD A Diagnosis Time 9 82 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONTROLLER EGR REPLACE ADD A Diagnosis Time 8 Diagnosis Time amp Data Recording Module DRM Download SENSOR ENGINE SPEED REPLACE ADD A Diagnosis Time SENSOR EGR TEMPERATURE IN REPLACE ADD A Diagnosis
100. amp Spring LSD seen 5 HOUSING ASSEMBLY REAR AXLE REPLACE POLIGY P T ING R amp R propeller shaft transfer all parts bleed brakes and make all necessary adjustments AXLE AND DIFFERENTIAL F 7 AXLE AND DIFFERENTIAL CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER HOUSING ASSEMBLY FRONT AXLE REPLACE ADD A Fitted 2003 Cab Model DRAIN OR REFILL PLUG AND OR GASKET FRONT OR REAR AXLE REPLACE FRONT AXLE REAR AXLE VENTILATOR AXLE REPLACE ING Hose assembly H BRAKES BRAKES 1 H0042 2 gt 0161 m H0167 H0120 1 10121 H0122 2 Gog 76 7 N 10160 LTGL1HO1 H 2 BRAKES amp H1240 H1240 i D H0960 LTGL1HO2 BRAKES 3 S MBR RH H2495 A WAV LTGL1H03 1 4 BRAKES 12800 12860 FLOOR LEVER TYPE H2887 2 H2886 H2640 LTGL1H04 BRAKES 5 BRAKES CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER UC PADS DISC BRAKE R amp R OR REPLACE BOTH FRONT CALIPER ASSEMBLY R amp R POLICY T INC R amp R brake pads from caliper Clean and inspect caliper and bleed brakes FRONT RIGHT FRONT LEFT ADD A To Recondition Ca
101. ditional To Replace Main Bearings Two Additional C To Replace All Main Bearings D To Replace Connecting Rod Bearings One Additional E To Replace Connecting Rod Bearings Two Additional F To Replace All Connecting Rod Bearings G For 4x4 Pick Up Model H For 4x4 Wagon Model J For A T Pick Up Model K For A T Wagon Model L For Pick Up Model with A C Engine Remove Work only M For Wagon Model with A C Engine Remove Work only N For 4x4 Model J 50 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER BEARING CONNECTING ROD REPLACE POLICY P T ING R amp R oil pan oil pump plastic type gauge bearings clean and inspect oil pump and pan 6V R amp R front axle housing complete ONE BEARING C24 E A To Replace Connecting Rod Bearings One Additional B To Replace Connecting Rod Bearings Two Additional C To Replace All Connecting Rod Bearings D For 4x4 Pick Up Model E For 4x4 Wagon Model F For A T Pick Up Model G For A T Wagon Model H For Pick Up Model with A C Engine Remove Work only J For Wagon Model with A C Engine Remove Work only A To Replace Connecting Rod Bearings One Additional B To Replace Connecting Rod Bearings Two Additional C To Replace All Connecting Rod Bearings D For 4x4 Wagon Model E For A T Pick Up Model F For A T Wagon Model G For Pick Up Model with A C Engine Remove Work only H Fo
102. ead F To Recondition or Replace All Valves G For A T Model A For 4x4 Pick Up Model B For 4x4 Wagon Model C To Boring D To Replace Cylinder Head One Bank CONTINUED ENGINE J 59 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D E To Replace Cylinder Head Both Bank To Recondition or Replace All Valves G For A T Model H With Auto Trans With A C B For 4x4 Pick Up Model C For 4x4 Wagon Model D To Boring E To Replace Cylinder Head F To Replace Cylinder Head 4JJ1 4JK1 Engine G To Recondition or Replace All Valves H 4JJ1 4JK1 Engine J For A T Model K With EGR Cooler 4JA1 4JH1 Engine L Intercooler of Upside Installation Type 4JJ1 4JK1 Engine M 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger N For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger P For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger Q For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger R 4JA1 Engine Fitted 2012 Cab Model With A C B For 4x4 Pick Up Model C For 4x4 Wagon Model D To Boring E To Replace Cylinder Head To Recondition or Replace All Valves G For A T Model J 60 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER ENGINE PARTIAL BASIC REPLACE POLICY A P T INC R amp R engine assembly ADD A With A
103. ed 2003 Cab Model B 4JJ1 4JK1 Engine Fitted 2012 Cab Model HOUSING AND OR GASKET TIMING PULLEY REPLACE INC R amp R engine assembly 4J Engine ADD A With A C B For 4x4 Model C For A T D Intercooler of Upside Installation Type 4JJ1 4JK1 Engine E 4JJ1 4JK1 Engine F 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger G 4JA1 Engine Fitted 2012 Cab Model H For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger J For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger K For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger With A C B For 4x4 Model C For A T BELT CAMSHAFT DRIVE REPLACE POLICY P T INC Adjust J0800 J0807 ENGINE J 41 CAB STYLE OPERATION DESCRIPTION OPERATION PULLEY IDLER TIMING REPLACE POLIGY P T J0817 TENSIONER ASSEMBLY TIMING BELT REPLACE J0818 J0828 GEAR IDLER TIMING REPLACE J0823 ADD 4JJ1 4JK1 Engine Fitted 2003 Cab Model 8 4JJ1 4JK1 Engine Fitted 2012 Cab Model GEAR CRANKSHAFT TIMING REPLACE POLICY P T J0832 J0833 ADD 4JJ1 4JK1 Engine 8 4JA1 Engine Fitted 2012 Cab Model GEAR CAMSHAFT TIMING REPLACE POLICY P T J0843 CAMSHAFT REPLACE POLICY P T NOTE EXC 4JJ1 4JK1 and HFV6 engines INC R amp R radiator harmonic balancer cover and seal Replace camshaft gear if necessary Adjust valves
104. escription 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 amp R as a single action word R amp R notation indicates the part or assem bly 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 opera tion REPAIR OR REPLACE R amp 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 Opera tion 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 recondi tion a
105. g these is the duty of the dealership service management and or service writer Symptom Diagnosis The process of finding the source of a problem based on a detailed symptom Symptom diagnosis is com plete when the problem has been found Repair Diagnosis The checks tests and measurements needed in the repair to find the cause of failure or identify faulty parts Examples Are cleaning and inspection of all parts such as gears and clutch plates use of common testers such as an ohm meter 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 sub mit a complete detailed description of the work performed The statement followed Shop Manual Procedure is generally not a sufficient explana tion of the procedure followed Generally a tech nician 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 infor
106. itional E To Replace Connecting Rod Bearings Two Additional F To Replace All Connecting Rod Bearings G For 4x4 Pick Up Model H For 4x4 Wagon Model J For Pick Up Model with A C Engine Remove Work only K For Wagon Model with A C Engine Remove Work only L For 4x4 Model M With Auto Trans o N N ADD A To Replace Main Bearings One Additional CONTINUED ENGINE J 49 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D 8 To Replace Main Bearings Two Additional C To Replace All Main Bearings D To Replace Connecting Rod Bearings One Additional E To Replace Connecting Rod Bearings Two Additional F To Replace All Connecting Rod Bearings G For 4x4 Model 4JJ1 4JK1 Engine H For A T Pick Up Model 9 For A T Wagon Model K For Pick Up Model with A C Engine Remove Work only L For Wagon Model with A C Engine Remove Work only M 4JJ1 4JK1 Engine For 4x4 Model 4JA1 4JH1 Engine P Intercooler of Upside Installation Type 4JJ1 4JK1 Engine Q 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger R 4JA1 Engine Fitted 2012 Cab Model S For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger T For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger U For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger ONE BEARING 6V A To Replace Main Bearings One Ad
107. liper Assembly One ADD A To Recondition Caliper Assembly One B To Recondition Caliper Assembly All CALIPER ASSENBLY REPLACE POLICY T INC R amp R brake pads from caliper Clean and inspect caliper and bleed brakes FRONT RIGHT FRONT LEFT FRONT BOTH DISC ASSEMBLY R amp R OR REPLACE INC D amp C caliper assembly and visually inspect Check rotor lateral runout and parallelism Transfer seals bearings and races Clean and repack wheel bearing as necessary FRONT RIGHT 4x2 FRONT LEFT 4x2 FRONT RIGHT 4x4 FRONT LEFT 4x4 FRONT BOTH 4x2 FRONT BOTH 4x4 ADD A To Reface Disc One B To Reface Disc Two C With ABS 6 BRAKES BRAKES CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER SHIELD FRONT BRAKE DUST R amp R OR REPLACE ADD A For 4x4 Model ADD A For 4x4 Model DRUM BRAKE R amp 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 REAR LEFT REAR BOTH ADD A To Reface Drum One 8 To Reface Drum Two SHOES AND LININGS DRUM BRAKE R amp R OR REPLACE INC R amp 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 REAR LEFT REAR BOTH SPRINGS BRAKE SHOE RETURN AND OR HOLD DOWN
108. m 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 review will be conducted of the Labor Time Guide text and pro cedure 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 Ve hicle Identification Number VIN is used to iden tify 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 Abbrevia tions Description Abbrevia tions Description AIC ADD ADJ AIR ASSY AUTO CONT D CV JOINT CYL D amp C DIFF DOHC ECM EFE EGR Air Conditioning Addition Adjust Air Injector Reactor Assembly Automatic Continued Constant Velosity Cylinder Disconnect And Connect Differential Double Overhead Camshaft Electronic Control Module Early Fuel Evaporation Exhaust Gas Recirculation EXC INC OHC P S R amp R TRANS TPS TURBO T V VIN W W O
109. mp R automatic transmission assembly K7020 R amp R torque converter ADD A For 4x4 Model B 6VE1 Engine C 4JJ1 4JK1 Engine Fitted 2012 Cab Model D 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger E For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger FUEL AND EXHAUST FUEL AND EXHAUST L 1 FUEL TANK LTGL1L01 L 2 FUEL AND EXHAUST LTGL1L02 FUEL AND EXHAUST L 3 FUEL AND EXHAUST CAB STYLE OPERATION DESCRIPTION OPERATION 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 FUEL TANK AREA PIPES 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 NECK PIPE FUEL TANK FILLER REPLACE L1065 L 4 FUEL AND EXHAUST FUEL AND EXHAUST CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER NECK HOSE AND OR VENT HOSE FUEL TANK FILLER REPLACE REAR TANK L1068 ADD A For Wagon Model B Fitted 2012 Cab Model GAUGE UNIT ASSEMBLY FUEL TANK REPLACE
110. n 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 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 The time allowances published have been determined by performing the operation a suffi cient number of times to establish an average time or to determine that a fair and equitable time has been developed Standard technicians hand tools and dealer essential and available tools are used in performing time studies No power oper ated wrenches are used for time studies Pro cedures outlined in Service Manuals other Ser vice Publications and good shop practices are used as a guide when performing the work necessary to establish time allowa
111. nces The time allowance includes the actual time required to perform the operation plus an addi tional allowance to provide for operating varia bles Time allowances do not include time to remove and replace special equipment other than manufacturer options and accessories 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 encoun tered An authorization is required for the addi tional time DIAGNOSIS TIME Repair diagnosis time is included in all established labor time operations where it is required of the technician to perform the opera tion It is the responsibility of qualified superviso ry 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 Definin
112. ne assembly R amp R cylinder head assembly oil pan and flywheel housing plastic type gauge bearings J1200 ADD A For Pick Up Model with A C B For Wagon Model with A C C To Replace Rod and or Pin Only One D To Replace Rod and or Pin Only Two E To Replace Rod and or Pin Only All F To Replace Cylinder Head G To Recondition or Replace All Valve H To Replace Piston Rod and or Rings One CONTINUED 9 52 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D J To Replace Piston Rod and or Rings Two To Replace Piston Rod and or Rings All L For A T Pick Up Model M For A T Wagon Model N For 4x4 Pick Up Model P For 4x4 Wagon Model A For Pick Up Model with A C B For Wagon Model with A C C For 4x4 Model 4JA1 4JH1 Engine D To Replace Rod and or Pin Only One E To Replace Rod and or Pin Only Two To Replace Rod and or Pin Only All G To Replace Cylinder Head H To Recondition or Replace All Valve J To Replace Piston Rod and or Rings One K To Replace Piston Rod and or Rings Two L To Replace Piston Rod and or Rings All M To Replace Cylinder Liner One N To Replace Cylinder Liner Two P To Replace Cylinder Liner All Q 4JJ1 4JK1 Engine R For A T Pick Up Model S For A T Wagon Model T For 4x4 Wagon Model 4JJ1 4JK1 Engine U Intercooler of Upside Installation Type 4JJ1 4JK1 Engine
113. odel F 4JA1 Engine with EGR System Fitted 2012 Cab Model GASKET CYLINDER HEAD REPLACE POLICY P T INC R amp R rocker cover loosen rocker arms diesel only and remove push rods diesel only D amp C exhaust pipe and make all necessary adjustments J0502 ADD A With A C for Wagon Model B Right Bank C Both Bank A 4JJ1 4JK1 Engine Fitted 2003 Cab Model 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model C With A C for Pick Up Model D With A C for Wagon Model E Intercooler of Upside Installation Type 4JJ1 4JK1 Engine F 4JJ1 4JK1 Engine Fitted 2012 Cab Model G 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger H For 4x4 Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger J 4JA1 4JH1 Engine with EGR Cooler Fitted 2003 Cab Model K 4JA1 Engine with EGR System Fitted 2012 Cab Model CONTINUED 9 34 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER CONT D ADD 6V 1 Engine Right B With A C for Wagon Model HEAD CYLINDER REPLACE POLICY P T INC R amp R rocker cover loosen rocker arms diesel only and remove push rods diesel only D amp C exhaust pipe and make all necessary adjustments ADD A With A C for Wagon Model B Left Bank C Both Bank A 4JA1 4JH1 Engine without EGR Cooler Fitted 2003 Cab Model B 4JJ1 4JK1 Engine Fitted 2003 Cab Model C With A C for Pick
114. r Wagon Model with A C Engine Remove Work only J With Auto Trans K For 4x4 Model A To Replace Connecting Rod Bearings One Additional B To Replace Connecting Rod Bearings Two Additional C To Replace All Connecting Rod Bearings D For 4x4 Model 4JA1 4JH1 Engine E For 4x4 Pick Up Model 4JJ1 4JK1 Engine F For 4x4 Wagon Model 4JJ1 4JK1 Engine CONTINUED ENGINE J 51 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D G For A T Pick Up Model H For A T Wagon Model J For Pick Up Model with A C Engine Remove Work only K For Wagon Model with A C Engine Remove Work only L 4JJ1 4JK1 Engine M Intercooler of Upside Installation Type 4JJ1 4JK1 Engine N 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger P For 4x4 M T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger Q For 4x2 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger For 4x4 A T Model 4JK1 Engine Fitted 2012 Cab Model 2 Stage Turbocharger ONE BEARING 6V To Replace Connecting Rod Bearings One Additional B To Replace Connecting Rod Bearings Two Additional C To Replace All Connecting Rod Bearings D For 4x4 Wagon Model E For A T Pick Up Model F For A T Wagon Model G For Pick Up Model with A C Engine Remove Work only H For Wagon Model with A C Engine Remove Work only CRANKSHAFT REPLACE POLICY P T INC R amp R engi
115. s include time to inspect and test the components on the bench upon installation of a new part CONTINUED J 68 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER 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 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 ADD A 6V 1 Engine B HFV6 Engine WIRES SPARK PLUG REPLACE POLICY T ONE OR TWO ALL PLUGS SPARK REPLACE POLICY T ONE OR TWO ADD A HFV6 Engine CONTINUED ENGINE J 69 CAB STYLE OPERATION DESCRIPTION OPERATION NUMBER CONT D ADD A HFV6 Engine COIL IGNITION REPLACE POLICY E T ADD C24 E Engine COIL ELECTRONIC IGNITION CONTROL REPLACE POLICY E T NOTE For HFV6 engine ADD To Replace All Coils B Diagnosis Time SENSOR CAMSHAFT POSITION REPLACE POLICY E T NOTE For HFV6 engine ADD A Diagnosis Time SENSOR CRANKSHAFT POSITION REPLACE POLICY E T NOTE For HFV6 engine ADD A Diagnosis Time SENSOR KNOCK REPLACE POLICY E T NOTE For HFV6 engine ADD A To Replace Both Banks B Diagnosis Time 70 ENGINE CAB STYLE OPERATION DESCRIPTION OPERATION VIN CODE NUMBER

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