CODES 6C-01 6C-02 6C-03 6G-01 6G-02 6G-03 6K-01 6K-02 6L-01 6L-02 6L-03 7A-01 7A-02 7A-03 7C-01 7C-02 7D-01 7D-02 7D-03 7E 7E-01 7E-02
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3 SECTION CODE INDEX SEC. CODES ASS. DESCRIPTION SEC. CODES ASS. DESCRIPTION 1A B 3C 3D 3E 3F 4 4A 1A-01 1A HEATER AND VENTILATION Heating control Heater and ventilator BUMPER, ENGINE HOOD AND FRONTAL Bumper Engine hood Frontal STEERING, SUSPENSION AND WHEELS Steering 3B-01 Tie rod and rods 3B-02 Power-steering system Steering wheel 3C-01 Steering wheel and columns 3D-01 3D-02 3E-01 3E-02 3F-01 4A-01 4A-02 4A-03 Front suspension Front springs Front shock absorber Rear suspension Rear springs Rear shock absorber Wheels Wheels and tyres PROPELLER SHAFTS Front drive shaft Front shaft assembly Front wheel hub assembly King pin assembly 6C 6G 6K 6L 7 7A 7C 7D 6C-01 6C-02 6C-03 6G-01 6G-02 6G-03 6K-01 6K-02 6L-01 6L-02 6L-03 7A-01 7A-02 7A-03 7C-01 7C-02 7D-01 7D-02 7D-03 Feeding and emission control Fuel feeding Air overfeeding Sensors, thermistors and engine control switches Engine electrical system Generator and battery Starting motor Thermo-starting and E.C.M. control unit Engine exhaust system Exhaust maninfold Muffler Engine lubrication Oil pump Oil filter and cooler Turbocharger lubrication TRANSMISSION Gear box Transmission case Internal organs Gear shifting control Clutch Hydraulic components Mechanical components Transfer Transfer case Internal organs Transfer selector lever 4B 4B-01 4B-02 Rear drive shaft Rear shaft assembly Rear wheel hub assembly 7E 7E-01 7E-02 Front and rear differential Front differential gear Rear differential gear 4C C Propeller shafts Propeller shaft BRAKE SYSTEM Parking brake and disc brake components Hydraulic circuit and servobrake ENGINE AND ITS SYSTEMS BODY ELECTRICAL SYSTEM Wiring and relays Switches Indicators Headlamp Other lamps 6A 6A-01 6A-02 6A-03 6A-04 6A-05 6A-06 6A-07 6A-08 6A-09 6A-10 6A-11 6A-12 Engine assembly Stripped engine Complete engine Cylinder block Oil pan Cylinder head Crankshaft Pistons and connecting rods Engine flywheel Camshaft and timing belt Auxiliary organs group Engine front mounting Fuel injection BODY AND FRAME Body panels Roof and moldings Doors and locks Trims and door regulators Windows glass Seats and seat belts Inner garnishes Rubber and weatherstrip profiles Chassis frame assembly 6B 6B-01 6B-02 6B-03 6B-04 Engine cooling Water pump, thermostat and heat excharger tubing Fan and control belts Water radiator and degasing box Water hoses
4 FOREWORD This Flat Rate Manual contains the operations and times assigned to repair SANTANA vehicles related in model code list in GENERAL section. The times assigned will be employed to calculate the labour cost of those repairs done during the warranty period of the vehicle. The use of these time assignments as a guide for those services paid by the customer, is subject to the dealer's criteria. SANTANA MOTOR, S. A.
5 ILLUSTRATION INDEX 1A B C-01 3D E F-01 4A B-01-02
6 4C A A A-05 6A A-09 6A-10-11
7 6A-12 6B B C-01 6C-02 6C-03 6G K L
8 7A C C E
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10 CONTENTS GENERAL Page 1 HEATER AND VENTILATION 1A BUMPER, ENGINE HOOD AND FRONTAL 02 STEERING, SUSPENSION AND WHEELS 3 PROPELLER SHAFT 4 BRAKE SYSTEM 05 ENGINE AND ITS SYSTEMS 6 TRANSMISSION 7 BODY ELECTRICAL SYSTEM 08 BODY AND FRAME 09
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12 GENERAL CONTENTS PAG 1. HOW TO READ THIS MANUAL HOW TO USE THIS MANUAL CONDITION FOR ESTABLISHING FLAT RATE TIMES REPAIR TIME MODEL CODE LIST... 8 Page 1-1-
13 1. HOW TO READ THIS MANUAL 6A ENGINE 6 ENGINE AND ITS SYSTEMS Section number Indicates section number and the product it refers to (consult index on back cover). Section code Indicates section code, referring to a concrete par of the product or to a system (consult index on back cover). Assembly components code Indicates assembly components code of the product (consult index on back cover). Position The position number corresponds with illustration. Operation code The operation code is formed by six characters that indicate: -2-
14 Basic operation code : 5 1 6A Basic operation code Section code Component assembly code Correlative operation number - "OTHER" operation code : A "OTHER" operation code Section code Components assembly code The two zeros in this position form the "OTHER" operation code. This code is used in those operations not contemplated in this manual, adjudicating as real repair time used and detailing the operation. 6 C/V Code variation This code indicates additional time conceded to a determined operation because of repair time difference existence, due to the different model equipment or exclusive time of a model. The C/V code, is represented by the letters (A) (B) (C) and (D) which indicate the following: A : Additional time for equipping air conditioner or sliding glass on laterals B : Additional time for equipping mechanical injection engine or this engine exclusive C : Additional time for equipping electronic injection engine (Common Rail) or this engine exclusive D : Additional time for equipping sliding glass on laterals -3-
15 7 8 Repair times Repair times are expressed in hours or in tenths of an hour Operation denomination - Describes what the operation consists of in the time given. - Specific situation, the state of the product and installation level of product, the repair time given corresponds to the described operation in total. When situation is specified, the state or installation level of the product, complementary operation time must be added to the basic operation. - When removal or installation (D/M) and substituting, the same time is given, except if a different time for each case is specified. - Some operations may present doubts as to if repair time given includes certain steps of the operation such as adjustments, timings, diagnosis, etc. In these cases, doubts are solved with "INCLUDES", "EXCLUDES" clarifications, or with (*). If the "INCLUDE", "EXCLUDE" CLARIFICATIONS or the (*) are not mentioned, it is understood that all the steps of the operation are included until its final mounting or product functioning. 9 Symbols " " " - " * - When the symbol appears " " in the repair time column, it means there is no established time for this operation. * - When the "-" symbol appears in the repair time column, it means that this operation does not correspond or does not exist for this model. -4-
16 2. HOW TO USE THIS MANUAL When you have done a repair, substitution, adjustment, etc..., consult this manual to apply correct operation code and repair time given; see examples 1, 2 or 3. When filling in the application form, bear the following in mind: - Make sure you note down basic operation code, the description and repair time given to each of the operations. - Reasonably choose the complementary operations which intervene in the reparation, substitution, etc., done. - When using the "OTHER" code (00), note down "real time"; this will correspond to invested time on repair, substitution, etc. done. In the "Break down description" space of the form, specify real service done. Example 1: (When doing a service which contains complementary operation and additional time because of C/V) Model code: AL01 (mechanical injection) Basic operation: CONNECTING ROD CRANKPINS DIAMETER MEASURE (FOUR) Complementary Operations: D / M CONNECTING ROD AND PISTON ASSEMBLY (SET) Additional time: ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE Step 1. Look for CRANKSHAFT in the SECTION CODES AND ASSEMBLY INDEX, or look for CRANKSHAFT in the ILLUSTRATIONS INDEX. Step 2. Open page 6A-06, look for connecting rod crankpin number and the operation that has been done. Step 3. Look for complementary operations. Step 4. Look for additional time because of C/V (code variation) Basic operation: Complementary operation: CONNECTING ROD CRANKPINS DIAMETER MEASURE (FOUR) D/M CONNECTING ROD AND PISTON ASSEMBLY (SET) 6A0618 6A Additional time: ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE A B Operation code: 6A0618 6A0710 A B Operation time: =
17 Example 2: (When a service is done that does not contain complementary operation and does contain additional time) Model code: AL01 (mechanical injection) Basic operation: D / M CRANKSHAFT PULLEY Additional time: ADDITIONAL TIME WITH AIR CONDITIONER Step 1. Look for CRANKSHAFT in the SECTION AND ASSEMBLY CODES INDEX, or look for CRANKSHAFT PULLEY directly in the ILLUSTRATIONS INDEX. Step 2. Open page 6A-06, look for crankshaft pulley position number and the operation which has been done. Step 3. Look for additional time operation. Basic Operation: Complementary Operation: D/M CRANKSHAFT PULLEY 6A Additional time: ADDITIONAL TIME WITH AIR CONDITIONER A Operation code: 6A0622 A Operation Time: =
18 Example 3: (When the OTHER "00" has to be used) Model code: AL01 (mechanical injection) Basic operation: CRANKSHAFT PULLEY ALIGNMENT CHECK Step 1. Look for CRANKSHAFT in the SECTION AND ASSEMBLY CODES INDEX, or look for CRANKSHAFT PULLEY directly in the ILLUSTRATIONS INDEX Step 2. Open page 6A-06, look for crankshaft pulley position number and the operation which has been done. Basic operation: CRANKSHAFT PULLEY ALIGNMENT CHECK?? If there is no operation that corresponds to the service done, note down real time using the "00" OTHER code Operation code:... 6A0600 Operation time: Full time When using the "00" OTHER code, describe the break down and the corrective measures in the "Break down Description" space of the form -7-
19 3. CONDITION FOR ESTABLISHING FLAT RATE TIMES Definition of flat rate time The flat rate time in this manual refer to the time required to perform warranty related services and repair. It consists of the following. Composition: Flat rate time Set up time Net working time Margin time Set up time The time required for set-up, such as: - Preparing parts, hand tools, special tools, etc. - Preparing necessary equipment - Preparing necessary measuring instruments - Moving the vehicle to and from hoist or wordstall area. Net working time The actual time spent on the repair/replacement service. This includes inspection, adjustment and road test as well as simple diagnosis. Margin time The time accompanying the actual working time and time spent for the following: - Relieving fatigue. - Cleaning the service shop. - Others suchas cleaning and toggins of parts. The specified margin time corresponds to 20% of the net working time. Working conditions The following conditions are prerequisites for deternining the net working time: - The hand tools, special tools and equipment are as specified in Service Manual. - Tools, equipment, power sources and other supplies are ready to be used. - The technician is experienced with SANTANA vehicles. - The work is performed at what is considered to be a normal word pace. 4. TIMES The flat rate time in this manual for perform warranty releated services and repair, are expressed in hours and tenths hour. Examples 0.1 hour = 6 minutes = = = = = = = = = 60 To convert minutes to the nearest hour and tenths of an horu devide munutes by 60 Example: 1 hour and 20 minutes (80 minutes) = (1.3 hours) To convert hours and tenths of hour to minutes multiply hours and tenths by 60 Example: 1 hour and 0.3 (1.3) 1.3 x 60 = 78 minutes (1 hour and 18 minutes) 5. MODEL CODE LIST MODEL CODE AL01 AL02 AL03 MODEL 5 DOORS LONG PS-10 HARD ROOF 3 DOORS LONG PS CANVAS AWNING 3 DOORS LONG VEHICLE
20 1A HEATER AND VENTILATION... 1A HEATING CONTROL... 1A-01 HEATER AND VENTILATOR... 1A-02
21 1A HEATER AND VENTILATION HEATING CONTROL 1A-01 HEATER AND VENTILATOR 1A-02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Heating control panel 1 Heating control lever assembly 2 Heater switch 3 Control assembly and heater driving cables 4 Air inlet assembly 5 Fan and protector 6 Heater assembly 7 Ventilator duct 8 Demister duct 9 Ventilation nozzle 10
22 HEATER AND VENTILATION 1A POS BASIC OPERATION CODE C/V 1A-01. HEATING CONTROL 1A-02. HEATER AND VENTILATOR MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 1A0101 HEATING CONTROL PANEL SUBSTITUTION 2 1A0102 HEATING CONTROL LEVER ASSEMBLY SUBSTITUTION - Control cables adjustment A0103 HEATING SWITCH SUBSTITUTION (HEATING CONTROL LEVERS ASSEMBLY DISMOUNTED) A0104 HEATING DRIVER CABLE SUBSTITUTION (ONE) (HEATING CONTROL LEVERS ASSEMBLY DISMOUNTED) 4 1A0105 CONTROL ASSEMBLY ADJUSTMENT AND HEATING DRI- VER CABLES A0100 OTHER * * * 5 1A0201 AIR INLET ASSEMBLY SUBSTITUTION A0202 FAN AND PROTECTOR ASSEMBLY SUBSTITUTION - Control cables adjustment A0203 HEATER ASSEMBLY SUBSTITUTION A VENTILATOR DUCT RH OR LH SUBSTITUTION (SEPARATED GLOVE BOX) 9 1A0205 DEMISTER DUCT SUBSTITUTION (ONE) (SEPARATED GLOVE BOX) A0206 VENTILATION NOZZLE SUBSTITUTION (ONE) 0.1 1A0200 OTHER * * *
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24 02 BUMPER, GRILLE AND ENGINE HOOD BUMPER ENGINE HOOD GRILLE
25 BUMPER, GRILLE AND ENGINE HOOD BUMPER ENGINE HOOD GRILLE COMPONENTS POS COMPONENTS POS COMPONENTS POS Front bumper 1 Cover outer bumper 2 Cover center bumper 3 Rear bumper 4 Cushion lateral bumper 5 Cushion center bumper 6 Hood assembly 7 Hood hinge 8 Opener driver cable 9 Lock assembly 10 Hood stay 11 Front grille 12 Fender assy 13 Superior profile 14 Front frame assembly 15 Central profile 16 Headlamp 17
26 BUMPER, GRILLE AND ENGINE HOOD POS BASIC OPERATION CODE C/V BUMPERS ENGINE HOOD GRILLE MODEL CODES AND REPAIR TIME AL01 AL02 AL FRONT BUMPER ASSEMBLY SUBSTITUTION COVER OUTER BUMPER SUBSTITUTION (ONE) COVER CENTER BUMPER SUBSTITUTION (ONE) REAR BUMPER ASSEMBLY SUBSTITUTION CUSHION LATERAL BUMPER SUBSTITUTION (ONE) CUSHION CENTER BUMPER SUBSTITUTION (ONE) OTHER * * * HOOD ASSEMBLY SUBSTITUTION - Element transfer - Hood lock adjustment D / M HOOD ASSEMBLY - Hood lock adjustment HOOD HINGE SUBSTITUTION (ONE) (BONNET ASSEMBLY DISMOUNTED) HOOD OPENER DRIVER CABLE ASSEMBLY SUBSTITUTION HOOD LOCK ASSEMBLY SUBSTITUTION - Hood lock adjustment HOOD STAY SUBSTITUTION OTHER * * * FRONT GRILLE SUBSTITUTION RIGHT FENDER ASSY SUBSTITUTION - Element transfer
27 BUMPER, GRILLE AND ENGINE HOOD BUMPER ENGINE HOOD GRILLE COMPONENTS POS COMPONENTS POS COMPONENTS POS Front bumper 1 Cover outer bumper 2 Cover center bumper 3 Rear bumper 4 Cushion lateral bumper 5 Cushion center bumper 6 Hood assembly 7 Hood hinge 8 Opener driver cable 9 Lock assembly 10 Hood stay 11 Front grille 12 Fender assy 13 Superior profile 14 Front frame assembly 15 Central profile 16 Headlamp 17
28 BUMPER, GRILLE AND ENGINE HOOD POS BASIC OPERATION CODE C/V GRILLE MODEL CODES AND REPAIR TIME AL01 AL02 AL D / M RIGHT FENDER ASSY LEFT FENDER SUBSTITUTION - Element transfer D / M LEFT FENDER ASSEMBLY SUPERIOR PROFILE ASSEMBLY SUBSTITUTION FRONT FRAME WELDERING ASSEMBLY SUBSTITUTION CENTRAL PROFILE ASSEMBLY SUBSTITUTION R/H HEADLAMP PANEL SUBSTITUTION - Headlamp measure L/H HEADLAMP PANEL SUBSTITUTION - Headlamp measure OTHER 1.3 * * *
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30 STEERING, SUSPENSION AND WHEELS STEERING... 3B STEERING WHEEL... 3C FRONT SUSPENSION... 3D REAR SUSPENSION... 3E WHEELS... 3F
31 .
32 STEERING... 3B 3B TIE ROD AND RODS... 3B-01 POWER-STEERING SYSTEM... 3B-02
33 3B STEERING 3 STEERING, SUSPENSION AND WHEELS TIE ROD AND RODS 3B.01 POWER-STEERING SYSTEM 3B.02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Control rod 1 Union rod 2 Tie rod 3 Power-steering oil tank 4 Filter 5 Intake pipe 6 Pressure hose 7 Return hose 8 Power-steering pump 9 Steering gear box 10 Oil tank bracket 11 Suction hose elbow 12 Pitman arm 13
34 3 STEERING, SUSPENSION AND WHEELS STEERING 3B POS BASIC OPERATION CODE C/V 3B-01. TIE ROD AND RODS 3B-02. POWER-STEERING SYSTEM MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 3B0101 CONTROL ROD AND TIE ROD SUBSTITUTION (TWO) - Steering measure B0102 UNION ROD AND TIE ROD SUBSTITUTION (TWO) - Steering measure B0103 CONVERGENCE MEASURE B0104 TIE ROD SUBSTITUTION (ONE) EXCLUDES: - Convergence adjustment or turning radius B0100 OTHER * * * 4 3B0201 POWER-STEERING OIL TANK SUBSTITUTION (*) B0202 POWER-STEERING OIL LEVEL INSPECTION B0203 POWER-STEERING OIL SUBSTITUTION (*) 5 3B0204 POWER-STEERING OIL FILTER SUBSTITUTION B0205 INTAKE PIPE SUBSTITUTION (*) B0206 PRESSURE HOSE SUBSTITUTION (*) B0207 RETURN HOSE SUBSTITUTION (*) B0208 POWER-STEERING PUMP SUBSTITUTION (*) B0209 POWER-STEERING PRESSURE CHECK IN THE P/S CIRCUIT B0210 STEERING GEAR BOX SUBSTITUTION (*) B0211 TURNING RADIUS MEASURE (RIGHT AND LEFT SIDES) B0212 OIL TANK BRACKET SUBSTITUTION 12 3B0213 SUCTION HOSE ELBOW SUBSTITUTION (*) (*) INCLUDES FILLING, DRAINING OR HYDRAULIC SYSTEM LEVEL ADJUSTMENT
35 3B STEERING 3 STEERING, SUSPENSION AND WHEELS TIE ROD AND RODS 3B.01 POWER-STEERING SYSTEM 3B.02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Control rod 1 Union rod 2 Tie rod 3 Power-steering oil tank 4 Filter 5 Intake pipe 6 Pressure hose 7 Return hose 8 Power-steering pump 9 Steering gear box 10 Oil tank bracket 11 Suction hose elbow 12 Pitman arm 13
36 3 STEERING, SUSPENSION AND WHEELS STEERING 3B-02 POS BASIC OPERATION CODE C/V 3B-02. POWER-STEERING SYSTEM MODEL CODES AND REPAIR TIME AL01 AL02 AL B0214 PITMAN ARM SUBSTITUTION Turning radius measure (left and right sides) B0200 OTHER * * *
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38 STEERING WHEEL... 3C 3C STEERING WHEEL AND COLUMNS... 3C-01
39 3C-01 STEERING WHEEL 3 STEERING, SUSPENSION AND WHEELS STEERING WHEEL AND COLUMNS 3C.01 COMPONENTS POS COMPONENTS POS COMPONENTS POS Steering wheel 1 Upper and lower cover 2 Steering column 3 Column upper bracket 4 Column lower bracket 5 Steering lower column 6
40 3 STEERING, SUSPENSION AND WHEELS STEERING WHEEL 3C-01 POS BASIC OPERATION CODE C/V 3C-01. STEERING WHEEL AND COLUMNS MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 3C0101 STEERING WHEEL SUBSTITUTION - Steering wheel repositioning C0102 STEERING WHEEL OPENWORK 2 3C0103 UPPER AND LOWER COVER SUBSTITUTION (ONE) C0104 STEERING COLUMN SUBSTITUTION - Steering wheel repositioning C0105 COLUMN UPPER BRACKET SUBSTITUTION C0106 COLUMN LOWER BRACKET SUBSTITUTION C0107 STEERING LOWER COLUMN SUBSTITUTION - Steering wheel repositioning C0100 OTHER * * *
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42 FRONT SUSPENSION... 3D 3D FRONT SPRINGS... 3D-01 FRONT SHOCK ABSORBER... 3D-02
43 3D FRONT SUSPENSION 3 STEERING, SUSPENSION AND WHEELS FRONT SPRINGS 3D.01 FRONT SHOCK ABSORBER 3D.02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Front spring 1 Front shock absorber 4 Bush 2 Spring bumper 3
44 3 STEERING, SUSPENSION AND WHEELS FRONT SUSPENSION 3D POS BASIC OPERATION CODE C/V 3D-01. FRONT SPRINGS 3D-02. FRONT SHOCK ABSORBER MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 3D0101 FRONT SPRING ASSEMBLY SUBSTITUTION (ONE SIDE) D0102 FRONT SPRING REPAIR D0103 SPRING BUSH OR CHASSIS SUBSTITUTION (ONE) (REMOVAL SPRING) 3 3D0104 SPRING BUMPER SUBSTITUTION (ONE) 3D0100 OTHER * * * 4 3D0201 SHOCK ABSORBER SUBSTITUTION (ONE) D0200 OTHER * * *
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46 REAR SUSPENSION... 3E 3E REAR SPRINGS... 3E-01 REAR SHOCK ABSORBER... 3E-02
47 3E REAR SUSPENSION 3 STEERING, SUSPENSION AND WHEELS REAR SPRINGS 3E.01 REAR SHOCK ABSORBER 3E.02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Rear spring 1 Rear shock absorber 4 Bush 2 Rear stopper 3
48 3 STEERING, SUSPENSION AND WHEELS REAR SUSPENSION 3E POS BASIC OPERATION CODE C/V 3E-01. REAR SPRINGS 3E-02. REAR SHOCK ABSORBER MODEL CODE AND REPAIR TIME AL01 AL02 AL03 1 3E0101 REAR SPRING ASSEMBLY SUBSTITUTION (ONE SIDE) E0102 REAR SPRING REPARIR E0103 SPRING BUSH OR CHASSIS SUBSTITUTION (ONE) (REMOVAL SPRING) 3 3E0104 REAR STOPPER SUBSTITUTION (ONE) 3E0100 OTHER * * * 4 3E0201 REAR SHOCK ABSORBER SUBSTITUTION (ONE) E0200 OTHER * * *
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50 WHEELS... 3F 3F WHEEL AND TYRES... 3F-01
51 3F-01 WHEELS 3 STEERING, SUSPENSION AND WHEELS WHEEL AND TYRES 3F.01 COMPONENTS POS COMPONENTS POS COMPONENTS POS Wheel 1 Tyre 2 Wheel 3
52 3 STEERING, SUSPENSION AND WHEELS WHEELS 3F-01 POS BASIC OPERATION CODE C/V 3F-01. WHEEL AND TYRES MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 3F0101 WHEEL SUBSTITUTION (ONE) (*) F0102 TYRE SUBSTITUTION (ONE) (*) F0103 WHEEL SUBSTITUTION (ONE) EXCLUDES: - Wheel balancing 3F0100 OTHER * * * (*) INCLUDES WHEEL BALANCING
53
54 PROPELLER SHAFT... 4 FRONT DRIVE SHAFT... 4A REAR DRIVE SHAFT... 4B 4 PROPELLER SHAFTS... 4C
55 .
56 FRONT DRIVE SHAFT... 4A FRONT SHAFT ASSEMBLY... 4A-01 4A FRONT WHEEL HUB ASSEMBLY... 4A-02 KING PIN ASSEMBLY... 4A-03
57 4A FRONT DRIVE SHAFT 4 PROPELLER SHAFTS FRONT SHAFT ASSEMBLY 4A-01 FRONT WHEEL HUB ASSEMBLY 4A-02 KING PIN ASSEMBLY 4A-03 COMPONENTS POS COMPONENTS POS COMPONENTS POS Front axle assembly 1 Front axle housing 2 King pin assembly 3 Oil seal 4 Axle shaft join 5 Front wheel hub 6 Front hub bearing 7 Front hub oil seal 8 Spindle 9 Free wheel assembly 10 Bolt stud 11 King pin 13 Steering knuckle 14 King pin bearing 15 Steering knuckle 16 Housing oil seal 17 Left pitman arm 18 Shaft drive flange 12 Right pitman arm 19
58 4 PROPELLER SHAFTS FRONT DRIVE SHAFT 4A POS BASIC OPERATION CODE C/V 4A-01. FRONT SHAFT ASSEMBLY 4A-02. FRONT WHEEL HUB ASSEMBLY MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 4A0101 D / M FRONT SHAFT ASSEMBLY A0102 FRONT AXLE HOUSING SUBSTITUTION (*) - Transfer elements A0103 D / M KING PIN ASSEMBLY (LEFT) A0104 D / M KING PIN ASSEMBLY (RIGHT) A0105 LEFT OIL SEAL SUBSTITUTION (*) A0106 RIGHT OIL SEAL SUBSTITUTION (*) A0107 OIL SEALS OF BOTH SIDES SUBSTITUTION (*) AXLE SHAFT JOIN SUBSTITUTION (ONE) (*) AXLE SHAFT JOIN SUBSTITUTION (TWO) (*) A0100 OTHER * * * 6 4A0201 D / M FRONT WHEEL HUB (ONE SIDE) A0202 FRONT WHEEL HUB SUBSTITUTION (ONE SIDE) - Transfer elements or installation new ones A0203 FRONT WHEEL HUB ADJUSTMENT (ONE SIDE) A0204 FRONT HUB BEARING SUBSTITUTION (ONE) A0205 FRONT HUB BEARING SUBSTITUTION (TWO) A0206 FRONT HUB OIL SEAL SUBSTITUTION (ONE SIDE) (*) INCLUDES FILLING OR OIL LEVEL ADJUSTMENT AND/OR STEERING MEASURES
59 4A FRONT DRIVE SHAFT 4 PROPELLER SHAFTS FRONT SHAFT ASSEMBLY 4A-01 FRONT WHEEL HUB ASSEMBLY 4A-02 KING PIN ASSEMBLY 4A-03 COMPONENTS POS COMPONENTS POS COMPONENTS POS Front axle assembly 1 Front axle housing 2 King pin assembly 3 Oil seal 4 Axle shaft join 5 Front wheel hub 6 Front hub bearing 7 Front hub oil seal 8 Spindle 9 Free wheel assembly 10 Bolt stud 11 King pin 13 Steering knuckle 14 King pin bearing 15 Steering knuckle 16 Housing oil seal 17 Left pitman arm 18 Shaft drive flange 12 Right pitman arm 19
60 4 PROPELLER SHAFTS FRONT DRIVE SHAFT 4A POS BASIC OPERATION CODE C/V 4A-02. FRONT WHEEL HUB ASSEMBLY 4A-03. KING PIN ASSEMBLY MODEL CODES AND REPAIR TIME AL01 AL02 AL03 9 4A0207 D / M SPINDLE ASSEMBLY (ONE SIDE (*) A0208 D / M SPINDLE ASSEMBLY (TWO SIDES) (*) A0209 SPINDLE SUBSTITUTION OR REPARATION (SEPARATED SPINDLE) A0210 FREE WHEEL ASSEMBLY SUBSTITUTION (ONE SIDE) A0211 FREE WHEEL ASSEMBLY REPARATION (ONE SIDE) A0212 BOLT STUD SUBSTITUTION (ONE) (SEPARATED WHEEL HUB) 11 4A0213 BOLT STUD SUBSTITUTION (SET) (SEPARATED WHEEL HUB) A0214 SHAFT DRIVE FLANGE SUBSTITUTION (ONE SIDE) A0200 OTHER * * * 13 4A0301 KING PIN SUBSTITUTION (ONE) (*) EXCLUDES: - King pin turning resistance measure A0302 TURNING RESISTANCE OF LEFT KING PIN (CHECK) (*) EXCLUDES: - D/M or king pin substitution A0303 TURNING RESTANCE OF RIGHT KING PIN (CHECK) (*) EXCLUDES: - D/M or king pin substitution A0304 LEFT STEERING KNUCKLE SUBSTITUTION (*) A0305 RIGHT STEERING KNUCKLE SUBSTITUTION (*) A0306 LEFT KING PIN BEARING SUBSTITUTION (ONE) (*) (*) INCLUDES FILLING OR OIL LEVEL ADJUSTMENT AND/OR STEERING MEASURES
61 4A FRONT DRIVE SHAFT 4 PROPELLER SHAFTS FRONT SHAFT ASSEMBLY 4A-01 FRONT WHEEL HUB ASSEMBLY 4A-02 KING PIN ASSEMBLY 4A-03 COMPONENTS POS COMPONENTS POS COMPONENTS POS Front axle assembly 1 Front axle housing 2 King pin assembly 3 Oil seal 4 Axle shaft join 5 Front wheel hub 6 Front hub bearing 7 Front hub oil seal 8 Spindle 9 Free wheel assembly 10 Bolt stud 11 King pin 13 Steering knuckle 14 King pin bearing 15 Steering knuckle 16 Housing oil seal 17 Left pitman arm 18 Shaft drive flange 12 Right pitman arm 19
62 4 PROPELLER SHAFTS FRONT DRIVE SHAFT 4A-03 POS BASIC OPERATION CODE C/V 4A-03. KING PIN ASSEMBLY MODEL CODES AND REPAIR TIME AL01 AL02 AL A0307 LEFT KING PIN BEARINGS SUBSTITUTION (TWO) (*) A0308 RIGHT KING PIN BEARINGS SUBSTITUTION (ONE) (*) A0309 RIGHT KING PIN BEARINGS SUBSTITUTION (TWO) (*) A0310 LEFT KING PIN BEARING HOUSING SUBSTITUTION (STEERING KNUCKLE) (*) A0311 RIGHT KING PIN BEARING HOUSING SUBSTITUTION (STEERING KNUCKLE) (*) A0312 LEFT HOUSING OIL SEAL SUBSTITUTION (*) A0313 RIGHT HOUSING OIL SEAL SUBSTITUTION (*) A0314 LEFT PITMAN ARM SUBSTITUTION (*) A0315 RIGHT PITMAN ARM SUBSTITUTION (*) 1.0 4A0300 OTHER * * * (*) INCLUDES FILLING OR OIL LEVEL ADJUSTMENT AND/OR STEERING MEASURES
63
64 REAR DRIVE SHAFT... 4B REAR SHAFT ASSEMBLY... 4B-01 REAR WHEEL HUB ASSEMBLY... 4B-02 4B
65 4B REAR DRIVE SHAFT 4 PROPELLER SHAFTS REAR SHAFT ASSEMBLY 4B-01 REAR WHEEL HUB ASSEMBLY 4B-02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Rear shaft assembly 1 Rear shaft housing 2 King pin 3 Wheel hub assembly 4 Rear hub bearing 5 Oil seal 6 Spindle 7 Stud bolt 8 Shaft drive flange 9
66 4 PROPELLER SHAFTS REAR DRIVE SHAFT 4B POS BASIC OPERATION CODE C/V 4B-01. REAR SHAFT ASSEMBLY 4B-02. REAR WHEEL HUB ASSEMBLY MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 4B0101 D / M REAR SHAFT ASSEMBLY (*) B0102 REAR SHAFT HOUSING SUBSTITUTION (*) - Transfer elements B0103 KING PIN SUBSTITUTION (ONE) B0100 OTHER * * * 4 4B0201 D / M WHEEL HUB ASSEMBLY (ONE SIDE) B0202 WHEEL HUB ASSEMBLY SUBSTITUTION (ONE SIDE) - Transfer components or installation new ones B0203 WHEEL HUB ASSEMBLY ADJUSTMENT (ONE SIDE) B0204 REAR HUB BEARING SUBSTITUTION (ONE) B0205 REAR HUB BEARING SUBSTITUTION B0206 OIL SEAL SUBSTITUTION (ONE SIDE) B0207 SPINDLE SUBSTITUTION (ONE SIDE) (*) B0208 SPINDLE SUBSTITUTION (BOTH SIDES) (*) B0209 STUD BOLT SUBSTITUTION (ONE) (SEPARATED WHEEL HUB) 8 4B0210 STUD BOLT SUBSTITUTION (WHEEL SET) 0.9 (SEPARATED WHEEL HUB) B0211 SHAFT DRIVE FLANGE SUBSTITUTION (ONE) B0200 OTHER * * * (*) INCLUDES FILLING OR OIL LEVEL ADJUSTMENT AND/OR STEERING MEASURES
67
68 PROPELLER SHAFTS... 4C PROPELLER SHAFT... 4C-01 4C
69 4C-01 PROPELLER SHAFTS 4 PROPELLER SHAFTS PROPELLER SHAFT 4C-01 COMPONENTS POS COMPONENTS POS COMPONENTS POS Propeller front shaft 1 Propeller rear shaft 2
70 4 PROPELLER SHAFTS PROPELLER SHAFTS 4C-01 POS BASIC OPERATION CODE C/V 4C-01. PROPELLER SHAFT MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 4C0101 PROPELLER FRONT SHAFT SUBSTITUTION C0102 PROPELLER FRONT SHAFT REPARATION C0103 PROPELLER REAR SHAFT SUBSTITUTION C0104 PROPELLER REAR SHAFT REPARATION 1.0 4C0100 OTHER * * *
71
72 BRAKE SYSTEM PARKING BRAKE & DISC BRAKE COMPONENTS HYDRAULIC CIRCUIT & SERVOBRAKE
73 05-01 BRAKE SYSTEM PARKING BRAKE & DISC BRAKE COMPONENTS PARKING BRAKE & DISC BRAKE COMPONENTS COMPONENTS POS COMPONENTS POS COMPONENTS POS Transmission brake 1 Switch transmission brake 2 Parking brake cable 3 Link assembly 4 Expansion unit 5 Brake plate 6 Brake drum 7 Brake shoes set 8 Regulation unit 9 Parking cable brake assembly 11 Brake bracket 12 Brake disc 13 Brake assembly 14 Friction pads set 15 Front brake pistons 16 Rear brake disc 17 Rear brake assembly 18 Rear brake pistons 19 Springs 10
74 BRAKE SYSTEM POS BASIC OPERATION CODE C/V PARKING BRAKE & DISC BRAKE COMPONENTS MODEL CODES AND REPAIR TIME AL01 AL02 AL TRANSMISSION BRAKE MEASURE SWITCH BRAKE TRANSMISSION SUBSTITUTION (*) SWHITCH BRAKE TRANSMISSION REPARATION (*) PARKING BRAKE CABLE SUBSTITUTION (*) LINK ASSEMBLY SUBSTITUTION (*) EXPANSION UNIT SUBSTITUTION (*) BRAKE PLATE SUBSTITUTION (*) BRAKE DRUM SUBSTITUTION (*) BRAKE SHOES DRUM SUBSTITUTION OR REVISION (*) REGULATION UNIT SUBSTITUTION (*) SPRINGS SUBSTITUTION (*) PARKING CABLE BRAKE ASSEMBLY SUBSTITUTION (*) BRAKE BRACKET SUBSTITUTION (ONE) FRONT BRAKE DISC SUBSTITUTION (ONE) FRONT BRAKE ASSEMBLY SUBSTITUTION (ONE) (**) FRONT BRAKE ASSEMBLY SUBSTITUTION (TWO) FRICTION PADS SET SUBSTITUTION (ONE WHEEL) FRONT BRAKE PISTONS REPARATION (ONE SIDE) (**) FRONT BRAKE PISTONS REPARATION (TWO SIDES) (**) REAR BRAKE DISC SUBSTITUTION (ONE) (*) INCLUDES ADJUST FROM CONTROL TO THE TRANSMISSION (**) INCLUDES PURGED PARTIAL OF CONTROLS
75 05-01 BRAKE SYSTEM PARKING BRAKE & DISC BRAKE COMPONENTS PARKING BRAKE & DISC BRAKE COMPONENTS COMPONENTS POS COMPONENTS POS COMPONENTS POS Transmission brake 1 Switch transmission brake 2 Parking brake cable 3 Link assembly 4 Expansion unit 5 Brake plate 6 Brake drum 7 Brake shoes set 8 Regulation unit 9 Parking cable brake assembly 11 Brake bracket 12 Brake disc 13 Brake assembly 14 Friction pads set 15 Front brake pistons 16 Rear brake disc 17 Rear brake assembly 18 Rear brake pistons 19 Springs 10
76 BRAKE SYSTEM POS BASIC OPERATION CODE C/V PARKING BRAKE & DISC BRAKE COMPONENTS MODEL CODES AND REPAIR TIME AL01 AL02 AL REAR BRAKE ASSEMBLY SUBSTITUTION (ONE) (**) REAR BRAKE ASSEMBLY SUBSTITUTION (TWO) (**) REAR BRAKE PISTON REPARATION (ONE SIDE) (**) REAR BRAKE PISTON REPARATION (TWO SIDES) (**) OTHER * * * (**) INCLUDES PURGED PARTIAL OF CONTROLS
77 05-02 BRAKE SYSTEM HYDRAULIC CIRCUIT & SERVOBRAKE HYDRAULIC CIRCUIT & SERVOBRAKE HYDRAULIC CIRCUIT & SERVOBRAKE COMPONENTS POS COMPONENTS POS COMPONENTS POS Brake pedal bracket 1 Pedal assembly and bracket 2 Brake master cylinder 3 Servo brake 4 Hydraulic circuit 5 Vacuum pump 6 Hole 7 Vacuum reservoir tank 8 Front, brake flexible hose 9 Brake 3 way joint 10 Brake five way joint 11 Brake 2 way joint 12 LSP valve assembly 13 2 way valve to front brake pipe 14 5 way valve to front brake pipe 15 5 way valve to LSP valve pipe 16 LSP valve to rear side pipe 17 3 way valve to rear brake pipe 18 Master cylinder to 5 way valve pipe 19 Master cylinder to 2 way valve pipe 20 LSP crossmember 21
78 BRAKE SYSTEM POS BASIC OPERATION CODE C/V HYDRAULIC CIRCUIT & SERVOBRAKE MODEL CODES AND REPAIR TIME AL01 AL02 AL BRAKE PEDAL BRACKET SUBSTITUTION - Measures and drain PEDAL ASSEMBLY AND BRACKET SUBSTITUTION - Measures and drain BRAKE MASTER CYLINDER SUBSTITUTION (*) SERVO BRAKE SUBSTITUTION - Measures SERVO BRAKE MEASURE SERVO BRAKE MEASURE CHECK HYDRAULIC SYSTEM COMPLETE DRAIN HYDRAULIC SYSTEM PARTIAL DRAIN BRAKE LIQUID SUBSTITUTION VACUUM PUMP SUBSTITUTION Vacuum circuit check VACUUM PUMP CHECK HOSE SUBSTITUTION (ONE) VACUUM RESERVOIR TANK SUBSTITUTION FRONT BRAKE FLEXIBLE HOSE SUBSTITUTION (COMPLE- TE SET) (*) FRONT BRAKE FLEXIBLE HOSE SUBSTITUTION (ONE) (*) FRONT BRAKE FLEXIBLE HOSE SUBSTITUTION (NEXT) BRAKE 3 WAY JOINT SUBSTITUTION (*) BRAKE 3 WAY JOINT SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT (*) INCLUDES FILLING, DRAIN OR HYDRAULIC SYSTEM LEVEL ADJUSTMENT
79 05-02 BRAKE SYSTEM HYDRAULIC CIRCUIT & SERVOBRAKE HYDRAULIC CIRCUIT & SERVOBRAKE HYDRAULIC CIRCUIT & SERVOBRAKE COMPONENTS POS COMPONENTS POS COMPONENTS POS Brake pedal bracket 1 Pedal assembly and bracket 2 Brake master cylinder 3 Servo brake 4 Hydraulic circuit 5 Vacuum pump 6 Hole 7 Vacuum reservoir tank 8 Front, brake flexible hose 9 Brake 3 way joint 10 Brake five way joint 11 Brake 2 way joint 12 LSP valve assembly 13 2 way valve to front brake pipe 14 5 way valve to front brake pipe 15 5 way valve to LSP valve pipe 16 LSP valve to rear side pipe 17 3 way valve to rear brake pipe 18 Master cylinder to 5 way valve pipe 19 Master cylinder to 2 way valve pipe 20 LSP crossmember 21
80 BRAKE SYSTEM POS BASIC OPERATION CODE C/V HYDRAULIC CIRCUIT & SERVOBRAKE MODEL CODES AND REPAIR TIME AL01 AL02 AL BRAKE FIVE WAY JOINT SUBSTITUTION (*) BRAKE FIVE WAY JOINT SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT BRAKE TWO WAY JOINT SUBSTITUTION (*) BRAKE TWO WAY JOINT SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT LSP VALVE ASSEMBLY SUBSTITUTION (*) LSP VALVE ASSEMBLY MEASURE LSP VALVE ASSEMBLY SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT WAY VALVE TO FRONT BRAKE PIPE SUBSITUTION (*) WAY VALVE TO FRONT BRAKE PIPE SUBSITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT WAY VALVE FRONT BRAKE PIPE SUBSTITUTION (*) WAY VALVE TO FRONT BRAKE PIPE SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT WAY VALVE TO LSP VALV. PIPE SUBSTITUTION (ONE) (*) WAY VALVE TO LSP VALVE PIPE SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT LSP VALVE TO REAR SIDE PIPE SUBSTITUTION (*) LSP VALVE TO REAR SIDE PIPE SUBSTITUTION AFTER 0.4 ANOTHER INTERVENTION IN THE CIRCUIT WAY VALVE TO REAR BRAKE PIPE SUBSTITUTION (*) WAY VALVE TO REAR BRAKE PIPE SUBSTITUTION AFTER 0.4 ANOTHER INTERVENTION IN THE CIRCUIT MASTER CYLINDER TO FIVE WAY VALVE PIPE 0.7 SUBSTITUTION (*) (*) INCLUDES FILLING, DRAIN OR HYDRAULIC SYSTEM LEVEL ADJUSTMENT
81 05-02 BRAKE SYSTEM HYDRAULIC CIRCUIT & SERVOBRAKE HYDRAULIC CIRCUIT & SERVOBRAKE HYDRAULIC CIRCUIT & SERVOBRAKE COMPONENTS POS COMPONENTS POS COMPONENTS POS Brake pedal bracket 1 Pedal assembly and bracket 2 Brake master cylinder 3 Servo brake 4 Hydraulic circuit 5 Vacuum pump 6 Hole 7 Vacuum reservoir tank 8 Front, brake flexible hose 9 Brake 3 way joint 10 Brake five way joint 11 Brake 2 way joint 12 LSP valve assembly 13 2 way valve to front brake pipe 14 5 way valve to front brake pipe 15 5 way valve to LSP valve pipe 16 LSP valve to rear side pipe 17 3 way valve to rear brake pipe 18 Master cylinder to 5 way valve pipe 19 Master cylinder to 2 way valve pipe 20 LSP crossmember 21
82 BRAKE SYSTEM POS BASIC OPERATION CODE C/V HYDRAULIC CIRCUIT & SERVOBRAKE MODEL CODES AND REPAIR TIME AL01 AL02 AL MASTER CYLINDER TO FIVE WAY VALVE PIPE 0.4 SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT MASTER CYLINDER TO 2 WAY VALVE PIPE (*) MASTER CYLINDER TO 2 WAY VALVE PIPE SUBSTITUTION AFTER ANOTHER INTERVENTION IN THE CIRCUIT LSP CROSSMEMBER SUBSTITUTION 0.5 -LSPV valve measure OTHER * * * (*) INCLUDES FILLING, DRAIN OR HYDRAULIC SYSTEM LEVEL ADJUSTMENT
83
84 ENGINE AND ITS SYSTEMS... 6 ENGINE ASSEMBLY... 6A ENGINE COOLING... 6B FEEDING AND EMISSION CONTROL... 6C ENGINE ELECTRICAL SYSTEM... 6G ENGINE EXHAUST SYSTEM... 6K 6 ENGINE LUBRICATION... 6L
85 .
86 ENGINE ASSEMBLY... 6A STRIPPED ENGINE... 6A-01 COMPLETE ENGINE... 6A-02 CYLINDER BLOCK... 6A-03 OIL PAN... 6A-04 CYLINDER HEAD... 6A-05 6A CRANKSHAFT... 6A-06 PISTONS AND CONNECTING RODS... 6A-07 FLYWHEEL ENGINE... 6A-08 CAMSHAFT AND TIMING... 6A-09 AUXILIARY ORGAN GROUP... 6A-10 FRONT ENGINE MOUNTING... 6A-11 FUEL INJECTION... 6A-12
87 6A ENGINE 6 ENGINE AND ITS SYSTEMS STRIPPED ENGINE 6A-01 COMPLETE ENGINE 6A-02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Stripped engine 1 Complete engine 2
88 6 ENGINE AND ITS SYSTEMS ENGINE 6A POS BASIC OPERATION CODE C/V 6A-01. STRIPPED ENGINE 6A-02. COMPLETE ENGINE MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 6A0101 D / M STRIPPED ENGINE - D / M complete engine - Transfer components - Timing setting - Flywheel engine setting - Injection pump setting - Valve measure EXCLUDES: 6A0100 A B - Diagnostic operations ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE 2 6A0201 D / M COMPLETE ENGINE - Necessary measures, levels and drain - Electrical servicing - External washing of engine on the vehicle EXCLUDES: A B OTHER - Diagnostic operations ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE * * * A0202 REMOVAL AND ENGINE MEASURES (SEPARATED ENGINE) - Diagnostic operations - Removal of main parts - Washing of dismounted parts - Diameter measure of casings - Diameter measure of crankpins - Measure of pistons - Diameter measure of camshaft holder and camheight - D / M engine on bench - Loose parts control EXCLUDES: A B - Removal of pistons and connecting rods ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INYECTION ENGINE
89 6A ENGINE 6 ENGINE AND ITS SYSTEMS STRIPPED ENGINE 6A-01 COMPLETE ENGINE 6A-02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Stripped engine 1 Complete engine 2
90 6 ENGINE AND ITS SYSTEMS ENGINE 6A-02 POS BASIC OPERATION CODE C/V 6A-02. COMPLETE ENGINE MODEL CODES AND REPAIR TIME AL01 AL02 AL03 2 6A0203 REMOVAL,CLEAN,VERIFICATION, MEASURE AND INSTALATION OF ENGINE (SEPARATED ENGINE) - Diagnostic operations - D / M of main parts - Washing of dismounted parts - Diameter measure of casings - Diameter measure of crankpins - Measure of pistons - Diameter measure of camshaft and cam height supports - D / M engine on bench - Loose parts control - Clearance control between crankpins and bushes with calibrated thread - Control and measure of valve set EXCLUDES: A B - Removal of pistons and connecting rods ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE 2 6A0204 NORMAL ENGINE REPARATION (SEPARATED ENGINE) A B - Diagnostic operations - D / M of engine on bench - Removal and instalation of engine - Washing of dismounted parts - Pistons and segments substitution - Measure and balancing of piston and connecting rods weight - Valve and seating rectification - Revision and tare of injectors - Control of clearance between crankpins and bearings with calibrated thread EXCLUDES: - Engine on bench test - Measures after road test ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE
91 6A ENGINE 6 ENGINE AND ITS SYSTEMS STRIPPED ENGINE 6A-01 COMPLETE ENGINE 6A-02 COMPONENTS POS COMPONENTS POS COMPONENTS POS Stripped engine 1 Complete engine 2
92 6 ENGINE AND ITS SYSTEMS ENGINE 6A-02 POS BASIC OPERATION CODE C/V 6A-02. COMPLETE ENGINE MODEL CODES AND REPAIR TIME AL01 AL02 AL03 2 6A0205 GENERAL ENGINE REPARATION (SEPARATED ENGINE) - Operations included in normal reparation 6A Connecting rod bearings and main bearing substitution - Auxiliary organs group reparation - Cylinder head planning - Cramkshaft rectification - Rectification of cylinders - Revision and tare of injector pump (mechanical injection) - Revision of oil pump and water pump - Revision of generator and engine starting - Revision of turbo-charger - Revision of depressor - Revision of high pressure pump (Common Rail) EXCLUDES: - Hydraulic Cylinder head test and substitution of caps - Rectification superior surface of block - Rectification steering wheel and indented crown wheel A B - Water and oil gallery caps substitution ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE A0206 ENGINE TO BRAKE TEST (SEPARATED ENGINE) A0207 MEASURES AFTER ENGINE REPARATION (ENGINE IN VEHICLE) - Accelerator control measure (mechanical injection) - Verification and adjustment of hose and brake line sealing - Eventual measure of valve clearance - Adjustment with analyser (Common Rail) C ADDITIONAL TIME COMMON RAIL ENGINE A0208 EXTERNAL WASHING ENGINE ON VEHICLE 0.5 6A0200 OTHER * * *
93 6A ENGINE 6 ENGINE AND ITS SYSTEMS CYLINDER BLOCK 6A-03 OIL PAN 6A-04 OIL PAN 6A-04 COMPONENTS POS COMPONENTS POS COMPONENTS POS Upper block 1 Lock plug 2 Lower block 3 Engine flat gasket 4 Oil pan 8 Oil flat gasket 9 Oil pan screw 10 Threaded plug 11 Oil filter plug 18 Oil level tube 19 Oil dipstick 20 Oil nozzle Cylinder ball Engine cover and flat gasket Engine breather assembly 12 Breather 13 Rubber sleeve 14 Rubber sleeve 15 O ring 16 Oil filter neck 17
94 6 ENGINE AND ITS SYSTEMS ENGINE 6A POS BASIC OPERATION CODE C/V 6A-03. CYLINDER BLOCK 6A-04. OIL PAN MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 6A0301 PLAN BLOCK UPPER BASE (NAKED BLOCK) A0302 NAKED BLOCK WASHING A0303 WATER OR LOCK PLUG CAP SUBSTITUTION (NAKED BLOCK) A0304 D / M LOWER BLOCK TO ELIMINATE LOSS (SEPARATED ENGINE) A0305 ENGINE FLAT GASKET SUBSTITUTION (SEPARATED ENGINE) A0306 OIL NOZZLE SUBSTITUTION (ONE) (SEPARATED INFERIOR BLOCK) 6 6A0307 D / M CYLINDER WALL (NAKED BLOCK) A0308 CASING WALL BABOONING AND EMERYING (NAKED BLOCK) A0309 CYLINDER CASING MEASURE (ONE) (SEPARATED CONNECTING ROD AND PISTON) A0310 CYLINDER CASING MEASURE (SET) (SEPARATED CONNECTING RODS AND PISTONS) A0311 ENGINE COVER AND FLAT GASKET SUBSTITUTION A0312 ENGINE COVER AND FLAT GASKET SUBSTITUTION (SEPARATED ENGINE) A0300 OTHER * * * 8 6A0401 D / M OIL PAN A0402 D / M OIL PAN (SEPARATED ENGINE) A0403 REVIEW OIL PAN THREAD CAP (EMPTIED OIL) A0404 OIL PAN FLAT GASKET SUPPORT PLAN CONTROL (SEPARATED HOUSING)
95 6A ENGINE 6 ENGINE AND ITS SYSTEMS CYLINDER BLOCK 6A-03 OIL PAN 6A-04 OIL PAN 6A-04 COMPONENTS POS COMPONENTS POS COMPONENTS POS Upper block 1 Lock plug 2 Lower block 3 Engine flat gasket 4 Oil pan 8 Oil flat gasket 9 Oil pan screw 10 Threaded plug 11 Oil filter plug 18 Oil level tube 19 Oil dipstick 20 Oil nozzle Cylinder ball Engine cover and flat gasket Engine breather assembly 12 Breather 13 Rubber sleeve 14 Rubber sleeve 15 O ring 16 Oil filter neck 17
96 6 ENGINE AND ITS SYSTEMS ENGINE 6A-04 POS BASIC OPERATION CODE C/V 6A-04. OIL PAN MODEL CODES AND REPAIR TIME AL01 AL02 AL03 9 6A0405 OIL FLAT GASKET SUBSTITUTION A0406 RE-TIGHTEN OIL PUMP SCREW 11 6A0407 D / M OIL THREADED PLUG A0408 D / M ENGINE BREATHER ASSEMBLY A0409 D / M OIL BREATHER A0410 D / M RUBBER SLEEVE (ONE) A0411 D / M RUBBER SLEEVE TO ATMOSPHERE A0412 CONDENSER UNION TO BLOCK O RING SUBSTITUTION A0413 D / M OIL FILTER NECK A0414 D / M OIL FILTER NECK AND JOINT SUBSTITUTION A0415 D / M OIL LEVEL TUBE A0416 D / M OIL DIPSTICK A0400 OTHER * * *
97 6A-05 ENGINE 6 ENGINE AND ITS SYSTEMS CYLINDER HEAD 6A-05 CYLINDER HEAD 6A-05 COMPONENTS POS COMPONENTS POS COMPONENTS POS Cylinder head 1 Cylinder head gasket 2 Engine valve spring assembly 11 Valve guides 12 Lock plug 3 Injector housing 4 Head cover gasket and cylinder Engine flat gasket and cover Cylinder head cover Valve and seat assembly Valve seat Valves
98 6 ENGINE AND ITS SYSTEMS ENGINE 6A-05 POS BASIC OPERATION CODE C/V 6A-05. HEAD CYLINDER MODEL CODES AND REPAIR TIME AL01 AL02 AL03 1 6A0501 HEAD CYLINDER, ENGINE OIL AND FILTER SUBSTITUTION - Washing - Hydraulic test - Cap substitution, if necessary - Transfer components - Timing adjustment A B - Valve set measure ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE 1 6A0502 D / M CYLINDER HEAD - Timing adjustment EXCLUDES: - Measure and testing of valve set A B - Washing ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE A0503 D / M CYLINDER HEAD (SEPARATED ENGINE) INCLUDES AND EXCLUDES: - The same as operation 6A0502 B ADDITIONAL TIME MECHANICAL INJECTION ENGINE A0504 TRANSFER CYLINDER HEAD COMPONENTS (SEPARATED CYLINDER HEAD) A0505 CYLINDER HEAD PLANNING (SEPARATED CYLINDER HEAD AND DISMOUNTED COMPONENTS) A0506 HYDRAULIC TEST (SEPARATED CYLINDER HEAD) A0507 COMPRESSION CONTROL - Perform of two tests A0508 COMPRESSION CONTROL (SEPARATED INJECTORS) A0509 CYLINDER HEAD WASHING (SEPARATED CYLINDER HEAD)
99 6A-05 ENGINE 6 ENGINE AND ITS SYSTEMS CYLINDER HEAD 6A-05 CYLINDER HEAD 6A-05 COMPONENTS POS COMPONENTS POS COMPONENTS POS Cylinder head 1 Cylinder head gasket 2 Engine valve spring assembly 11 Valve guides 12 Lock plug 3 Injector housing 4 Head cover gasket and cylinder Engine flat gasket and cover Cylinder head cover Valve and seat assembly Valve seat Valves
100 6 ENGINE AND ITS SYSTEMS ENGINE 6A-05 POS BASIC OPERATION CODE C/V 6A-05. CYLINDER HEAD MODEL CODES AND REPAIR TIME AL01 AL02 AL03 2 6A0510 CYLINDER HEAD GASKET, ENGINE OIL AND FILTER SUBSTITUTION -The same as for OP. 6A0502 -Washing -Hydraulic test A B -Eventual substitution of caps ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE 3 6A0511 LOCK PLUG SUBSTITUTION (ONE) (SEPARATED CYLINDER HEAD) A0512 INJECTOR HOUSING RECTIFICATION (ONE) (SEPARATED CYLINDER HEAD AND INJECTOR) 4 6A0513 INJECTOR HOUSING RECTIFICATION (SET) (SEPARATED CYLINDER HEAD AND INJECTOR) A0514 D / M HEAD COVER GASKET AND CYLINDER A0515 D / M ENGINE FLAT GASKET AND COVER A0516 D / M ENGINE FLAT GASKET AND COVER (SEPARATED ENGINE) A0517 D / M CYLINDER HEAD COVER A0518 VALVE AND SEAT ASSEMBLY RECTIFICATION - Checking and adjustment of valve set - Valve sealing control - Descaling of cinder - Valve spring control EXCLUDES: - Valve guide substitution A B - Diagnostic operations ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE A0519 VALVE AND SEAT ASSEMBLY RECTIFICATION (SEPARATED ENGINE) INCLUDES AND EXCLUDES: - The same as for OP. 6A0518 B ADDITIONAL TIME MECHANICAL INJECTION ENGINE
101 6A-05 ENGINE 6 ENGINE AND ITS SYSTEMS CYLINDER HEAD 6A-05 CYLINDER HEAD 6A-05 COMPONENTS POS COMPONENTS POS COMPONENTS POS Cylinder head 1 Cylinder head gasket 2 Engine valve spring assembly 11 Valve guides 12 Lock plug 3 Injector housing 4 Head cover gasket and cylinder Engine flat gasket and cover Cylinder head cover Valve and seat assembly Valve seat Valves
102 6 ENGINE AND ITS SYSTEMS ENGINE 6A-05 POS BASIC OPERATION CODE C/V 6A-05. CYLINDER HEAD MODEL CODES AND REPAIR TIME AL01 AL02 AL03 8 6A0520 VALVE SUBSTITUTION AND SEAT RECTIFICATION - Compression control - Checking and adjustment of valve set - Washing - Cinder descaling - Valve sealing control - Valve spring control EXCLUDES: -Valve guide substitution A B -Diagnostic operations ADDITIONAL TIME WITH AIR CONDITIONER ADDITIONAL TIME MECHANICAL INJECTION ENGINE 8 6A0521 VALVE SEALING CONTROL (SEPARATED CYLINDER HEAD) A0522 VALVE SEAT RECTIFICATION (ONE) (SEPARATED VALVE) - Valve sealing control - Cinder descaling EXCLUDES: - Rectification and descaling of valves - Valve guide substitution A0523 NEXT VALVE SEAT RECTIFICATION (SEPARATED VALVE) INCLUDES AND EXCLUDES: - The same as for OP. 6A A0524 VALVE SEAT RECTIFICATION (SET) (SEPARATED VALVES) INCLUDES AND EXCLUDES: - The same as for OP. 6A A0525 VALVE SEAT SUBSTITUTION (ONE) (SEPARATED VALVES) - Rectification of valve seating EXCLUDES: - Rectification and descaling of valves - Valve guide substitution A0526 NEXT VALVE SEAT SUBSTITUTION (SEPARATED VALVE) INCLUDES AND EXCLUDES: - The same as for OP. 6A
Rail 001 112 2 Canvas, folding top 001 101 3 Rear panel 001 102 4 Stip in window, left 001 106 dto. right 001 107
U 411 1 Rear view mirror, round, metall 13cm Ø 002 045 2 Raised airintake 002 060 3 Side panelling, front, left 002 030 Side panelling, front, right 002 031 4 Panelling left 002 051 dto. right 002 052
1/29/2008 DR70. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 43
DR70 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 43 CYLINDER & CYLINDER HEAD 1 DR70-001 883099044472 CYLINDER 1 1 2 DR70-002 883099044489 GASKET, CYLINDER 1 1 3 DR70-003 883099044496
1/29/2008 DR50. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 45
DR50 Toll Free: 888-863-2252 PART NUMBERS PRICES ARE SUBJECT TO CHANGE 1 of 45 CYLINDER & CYLINDER HEAD Part UPC Number Description Baja Description 1 DR50-001 842645074424 CYLINDER 1 1 2 DR50-002 842645074431
BR150 Pmi Baja Reaction 150cc Go Kart (VIN PREFIX L4VM)
Page 1 of 21 Product Information Baja Web > Product Information > Parts Lists > GOKART > BR150 Pmi Baja Reaction 150cc Go Kart (VIN PREFIX L4VM) BR150 Pmi Baja Reaction 150cc Go Kart (VIN PREFIX L4VM)
DR50 Hensim Dirt Runner 49cc Dirt Bike (VIN PREFIX LLCH or LUAH)
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DR90. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51
DR90 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51 CYLINDER & CYLINDER HEAD 1 DR90-001 842645048166 CYLINDER 1 1 2 DR90-002 842645048173 GASKET, CYLINDER 1 1 3 DR90-003
1/29/2008 DR125 / DR150. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PARTS AND PRICES ARE SUBJECT TO CHANGE 1 of 55
DR125 / DR150 Toll Free: 888-863-2252 PARTS AND PRICES ARE SUBJECT TO CHANGE 1 of 55 CYLINDER HEAD ASSY. 1 125-001 883099006937 CYLINDER HEAD COVER 1 1 2 125-002 883099006944 BOLT M6X28 2 3 3 125-003 883099006951
DR90. Baja Motorsports Inc. P.O. Box 61150 Phoenix, AZ 85082 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51
DR90 Toll Free: 888-863-2252 PART NUMBERS AND PRICES ARE SUBJECT TO CHANGE 1 of 51 CYLINDER & CYLINDER HEAD Part UPC Number Description Baja Description 1 DR90-001 842645048166 CYLINDER 1 1 2 DR90-002
COVERING MILLIONS Preferred Protection Plan, a Service Group Company www.sgifs.com PO Box 26830, Austin, TX 78755-0800.
COVERING MILLIONS Preferred Protection Plan, a Service Group Company www.sgifs.com PO Box 26830, Austin, TX 78755-0800. 1-877-565-0816 PPP-308 0903 rev 0408 BENEFITS New and Pre-Owned Vehicles Preferred
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SAYFA: 1 10100 10102 10103 355 353 06 15 355 353 03 15 346 353 08 15 AXLE GEAR AXLE GEAR AXLE (WITH BUSHING TYPE) (WITH BUSHING TYPE) (WITH BUSHING TYPE) 2521 2517-2521-2622 10104 10105 10106 308 350 00
MERCEDES FIRST EDITION - 2013
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DR125 and DR150 Hensim Dirt Runner 125cc and 150cc Dirt Bike (VIN PREFIX LLCH or LUAH)
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