Labour Time Guide Serie N 21-01-2019

LIGHT DUTY VEHICLE
(N**, QKR)
LABOR TIME GUIDE
FOREWORD
These Labor Time allowances are published by ISUZU for the purpose of im-
plementing 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. L4G-LE-99L1

Printed in Japan
INTRODUCTION
This Labor Time Guide is designed for more POLICY CODES

convenient and accurate use. The guide is identical
The policy codes are shown under the par-
in page format to all Labor Time Guides pro-duced
ticular operation description.(ex. POLICY: P,A)
by ISUZU. In addition to the uniform page layout,
Each letter indicates below meaning.
the Operation Description and Numbering System
is now standard for all ISUZU vehicles. P– Power Train Related Operation. Used only for
the countries which have specific warranty
condition for Power Train parts.
PAGE LAYOUT A– Operation which requires to submit Authori-
To aid in the use of the Time Guide, the layout zation Request(AR)
has been structured in reading sequence. Reading E– Emission Related Operation. Used only for
from left to right are the “Operation Description” the countries which have specific warranty
and its qualifiers, followed by the “Operation condition for Emission parts.
Numbers”. On the right hand side of the page is an
area designating the vehicles by series with their
appropriate times.
OPERATION DESCRIPTION
MAJOR OPERATIONS REPLACE (as a single action word)

Operations having a labor operation number The “REPLACE” notation is used when the
(A1234) are classified as Major Operations. A ma- part or an assembly is subject to replacement only.
jor operation time allowance is sufficient to do the A part is required on the warranty claim.
work described as a single operation.
R&R (as a single action word)
Operations within each section are generally
“R&R” notation indicates the part or assem-
arranged in the following manner – Front to Rear,
bly is repairable and can be removed, repaired,
Top to Bottom, Right to Left. Sitting in the driver’s
and reinstalled. All labor operations so noted are
seat, Right-Hand components are to the Driver’s
followed by “ADD” statements which cover all
Right, Left-Hand to the Driver’s Left.
possible repair conditions. This can be a labor only
operation.
ADD CONDITIONS REPAIR
Additional time allowances which may be ALIGN (as a single action word)
required for performing a Major Operation or ADJUST
supplement a Major Operation are included in the TIGHTEN
“ADD” sections under vehicle designation. Each The above notation indicate the work (repair)
“add” is preceded by a letter designation (A, B, C, to be performed. This can be a labor only opera-
~) which should be placed on the dealer repair or- tion.
der under the 5-Position Major Operation Number
if the “ADD” is performed. These letters are not to REPAIR OR REPLACE
appear on the Warranty Claim. R&R OR REPLACE
The above notations indicate the part or as-
sembly can be repaired, aligned or adjusted on the
ACTION WORDS vehicle or removed, repaired, and/or reinstalled or
Each labor operation description has been re- replaced, depending on the extent of failure. This
vised to clearly identify the repair that is allowable can be a labor only operation when no part or as-
on that component. These notations, plus the de- sembly is required.
scription of same, are provided below:
RECONDITION Some repair operation time allowances are
developed from data which indicates that most
When this term is used with a Major Oper-
repairs can be performed in the published time. It
ation, it means to remove an assembly from the
is reasonable to assume that additional time may
vehicle, disassemble, clean and inspect all parts,
be required when unusual conditions are encoun-
rebuild the assembly with the same or new parts,
tered. An authorization is required for the addition-
reinstall and adjust. When this term is used in an
al time.
ADD Operation, it does not include Remove and
Reinstall but only that work necessary to recondi-
tion an assembly once it is removed from the vehi-
DIAGNOSIS TIME
cle.
“Repair diagnosis” time is included in all
established labor time operations where it is re-
INCLUDES quired of the technician to perform the operation.
It is the responsibility of qualified supervisory
The Includes which follow some of the de-
personnel to assist technicians in “customer prob-
scriptions are provided to assist in knowing wheth-
lem analysis” and “symptom diagnosis”. Service
er or not certain items or functions are included
personnel should be contacted for assistance in
within the operation. These are not all encompass-
circumstances requiring extensive diagnosis. Time
ing because to place all such data in the Guide
for extensive diagnosis will require authorization if
would make it difficult to use. If there are any
deemed allowable.
questions as to whether something is included or
not, the Request for Review form may be used to Following are definitions of the terms used in
question or recommend changes. the preceding statement:
“Customer Problem Analysis” – The process
NOTES of translating the customer’s problems to a symp-
tom. Examples are: A/C insufficient cooling, brakes
Throughout the Time Guide, various notes pull, engine diesels, hesitates, surges, etc. It also
will be inserted to assist in the use of the Guide. includes those failures which are readily apparent
to the normal senses of sight, touch, sound and
smell. Defining these is the duty of the dealership
service management and/or service writer.
TIME ALLOWANCES “Symptom Diagnosis” – The process of find-
All time allowances as indicated in hours and ing the source of a problem based on a detailed
tenths of hours published in this guide (except for symptom. Symptom diagnosis is complete when
a few Repair Operations) are based on studies of the problem has been found.
the actual time required to complete the operation. “Repair Diagnosis” – The checks, tests and
No connection with technicians’ wages is implied measurements needed in the repair to find the
since they are dependent upon the dealer techni- cause of failure, or identify faulty parts.
cian pay plan in use.
Examples Are:
The time allowances published have been
determined by performing the operation a suffi- • cleaning and inspection of all parts such as
cient number of times to establish an average time gears and clutch plates;
or to determine that a fair and equitable time has • use of common testers such as an ohmmeter,
been developed. Standard technicians’ hand tools voltampere meter or timing light that are in-
and dealer essential and available tools are used cluded in the service manual procedure.
in performing time studies. No power operated
wrenches are used for time studies. Procedures
outlined in Service Manuals, other Service Publica-
tions and good shop practices are used as a guide
when performing the work necessary to establish
time allowances.
The time allowance includes the actual time
required to perform the operation plus an addi-
tional allowance to provide for operating variables.
Time allowances do not include time to remove
and replace special equipment other than manu-
facturer options and accessories.
REQUEST FOR REVIEW
Any questions relating to suggested new or The “Request for Review” form is primarily
existing operations and/or time allowances in this intended for your use to inform us of a problem
time guide should be submitted on a “Request for affecting the ability of technicians to perform an
Review” form. These forms can be found at the operation within the published time allowance. The
end of this Manual. When completing this form, request should be forwarded to the address indi-
it is important that vehicle identification data af- cated on the form.
fecting or influencing the operation in question be
All inquiries received at the home office will
provided. It is also important to submit a complete
be acknowledged and reviewed. A review will be
(detailed) description of the work performed. The
conducted of the Labor Time Guide text and proce-
statement “followed Shop Manual Procedure” is
dure as outlined by the model year service manual
generally not a sufficient explanation of the pro-
and dealer bulletins, restudies will be conducted
cedure followed. Generally, a technician performs
as required.
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.
VEHICLES MODEL YEAR
Refer to below illustrations for vehicles model.
1995 Cab Model (N series) 2005 Cab Model (N series including QKR)
2008 Cab Model (N series)

VEHICLE AND ENGINE IDENTIFICATION
The Engine Code designation from the Vehicle

Identification Number (VIN) is used to identify the
appropriate engine mechanical sections within this
publication. Refer to the VIN chart for engine iden-
tification codes.
ABBREVIATIONS
Abbreviations will be used through the Labor Time Guide. Below is a list of abbreviations
and their meaning.
Abbreviations Description Abbreviations Description
A/C Air Conditioning EXC Except

ADD Addition INC Includes
ADJ Adjust I/P Instrument Panel
AIR Air Injector Reactor MAN Manual
ASSY Assembly NEC Necessary
AUTO Automatic OHC Overhead Camshaft
CONT'D Continued P/S Power Steering
CV-JOINT Constant Velosity R&R Remove and Reinstall
CYL Cylinder TRANS Transmission
D&C Disconnect And Connect TPS Throttle Position Sensor
DIFF Differential TURBO Turbocharger
DOHC Double Overhead Camshaft T.V. Throttle Valve
ECM Electronic Control Module VIN Vehicle Identification Number
EFE Early Fuel Evaporation W/ With
EGR Exhaust Gas Recirculation W/O Without
REQUEST FOR REVIEW FORM
DEALERSHIP INFORMATION
A REVIEW OF LABOR OPERATION
FRANCHISE NAME:
NUMBER WITH A
ISUZU DEALER CODE:
OPERATION DESCRIPTION OF
SUBMITTED BY:
IS REQUESTED BECAUSE: SERVICE MGR. SIGNATURE:
A New Labor Operation description is recommended DISTRIBUTOR USE ONLY

(Record your suggestion in technicians comments)
Published Time is insufficient YES NO
(Completion of step by step labor description on Does the labor listed on the reverse side follow
reverse side is required) the Isuzu Service Manual?
Is the repairing technician Isuzu trained?
Operation Description is incorrect
(Record you suggestion in tech comments) Did you verify the availability/condition of the
essential tools required for this repair?
Other — (Describe in Technicians Comments section)
Did you review this request with both the
Technicians Comments: technician and service manager?
SIGNATURE
recommendation/comments:
SIGNATURE
LABOR OP #
OPERATION DESCRIPTION
STEP DESCRIPTION OF BASIC STEPS TIME
NO. IN MIN.
STEP DESCRIPTION OF BASIC STEPS TIME

NO. IN MIN.
The actual time required to perform this labor operation in our shop is hr.
Vehicle Information
VIN # Engine Family Trans #
Rear Axle # Body Type Special Equip.
Additional Comments:
TROUBLE CODES
1 BROKEN 43 SHIFTS HARD
2 BROKEN WELD 44 SLIPS OUT OF GEAR
3 STRIPPED 45 WIND NOISE
4 TORN OR PUNCTURED 46 FLOODS
5 CRACKED 47 FLAT SPOT OR HESITATES
6 WORN 48 DISCOLORED
7 SCORED OR SCRATCHED 49 PITTED
8 POOR METAL FINISH 50 ELECTRICAL FAILURES
9 CHIPPED 51 NOT CONNECTED
10 SOILED OR STAINED 52 BINDS, STICKS
11 BENT 53 NOT DRILLED
12 FOREIGN MATERIAL 54 WRONG PART
13 OVERHEATED 55 POOR FIT
14 BURNED 56 INOPERATIVE
15 SEIZED 57 REGISTERS INCORRECTLY
16 PAINT - DIRT OR FOREIGN 58 PART IMPROPERLY INSTALLED
MATERIAL 59 PULLS
17 PAINT - DRY SPRAY, MOTTLING 60 ENGINE PING
SAGS, OFF-COLOR, ROUGH 61 INCORRECT PRESSURE
18 PAINT - FILM MARRED OR 62 IMPROPER CLEARANCE
SCRATCHED 63 FADE OR HARD PEDAL
19 PAINT - THIN OR RUBBED THROUGH 64 GLAZED
20 PAINT - CORROSION, CRAZING, 65 SLIPS
CRACKING, CHALKING 66 COLLAPSED
21 PAINT - POOR REPAIR 67 EXCESSIVE LUBRICATION OR OIL
22 PAINT - FILM SPOTTED SOAKED
23 PAINT - FINISH COMES OFF 68 INSUFFICIENT LUBRICATION
24 CHROME PLATING DEFECTIVE 69 POOR OIL MILEAGE
25 MISALIGNED 70 POOR GASOLINE MILEAGE
26 MISADJUSTED 71 PULLED LOOSE
27 LOOSE 72 SPLIT SEAMS
29 PART OMITTED 73 IMPROPERLY PADDED
30 POROSITY 74 FUMES
31 POOR MACHINING 75 RUSTED OR CORRODED
32 GLASS - POOR VISION 76 WRINKLED
33 WEAK 78 CARBON DEPOSIT
34 OUT OF BALANCE 79 POOR RELEASE
35 OUT OF ROUND 81 HARD RIDE
36 VIBRATES 82 SURGE
37 POOR ENGAGEMENT 83 HARD STARTING (COLD)
38 DOES NOT SEAT 84 HARD STARTING (HOT)
39 GRABS 85 SHEARED
40 NOISY 93 DISCHARGED
41 CHATTERS 95 SPECIAL POLICY
42 LEAKS 96 CAMPAIGN
A PAINT A
B
C
D
E
F
H
J
K
L
N
R
S
U
A - 2 PAINT
PAINT EXTERIOR
OPERATION DESCRIPTION OPERATION
MODEL & TIME
NUMBER
N**, QKR
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
POLICY: A
COLOR COAT; ONE PIECE A0028 ST
PANEL, FRONT END

POLICY: A
COLOR COAT; UPPER RIGHT CORNER A0142 ST
COLOR COAT; UPPER LEFT CORNER A0143 ST
COLOR COAT; LOWER RIGHT CORNER A0144 ST
COLOR COAT; LOWER LEFT CORNER A0145 ST
COLOR COAT; CENTER A0147 ST
GRILLE
POLICY: A
INC: R&R grille, emblem and headlight bezels.
COLOR COAT A0260 ST
PILLAR, WINDSHIELD
POLICY: A
COLOR COAT; RIGHT A0800 ST
COLOR COAT; LEFT A0801 ST
ROOF
POLICY: A
Except Spot Repair
COLOR COAT A0880 ST
PILLAR, CENTER
POLICY: A
PAINT A - 3
PAINT EXTERIOR
MODEL & TIME
NUMBER
N**, QKR
FRAME, FRONT DOOR WINDOW

POLICY: A
DOOR, FRONT
POLICY: A
INC: Door window frame, R&R mirror.
DOES NOT INC: Drivers ventilator on aluminum tilt series,
use spot repair for ventilator.
PANEL, CAB SIDE

POLICY: A
PANEL, CAB BACK

POLICY: A
Except Spot Repair
COLOR COAT A1360 ST
DOOR, REAR
POLICY: A
LOAD FLOOR
POLICY: A
COLOR COAT A2410 ST
TAILGATE, COMPLETE
POLICY: A
COLOR COAT A2920 ST
A - 4 PAINT
PAINT EXTERIOR
MODEL & TIME
NUMBER
N**, QKR
WHEELS
POLICY: A
COLOR COAT; FRONT RIGHT A3300 ST
COLOR COAT; FRONT LEFT A3301 ST
COLOR COAT; REAR RIGHT A3320 ST
COLOR COAT; REAR LEFT A3321 ST
BOX, BATTERY
POLICY: A
REFINISH A3450 ST
SUPPORT, STEP, DOOR OPENING

POLICY: A
B BODY EXTERIOR A
B
C
D
E
F
H
J
K
L
N
R
S
U
BUMPERS, DOORS AND EXTERIOR TRIM B - 5
BUMPER AND FRONT END

MODEL & TIME
NUMBER
N**, QKR
BUMPER ASSEMBLY, FRONT - REPLACE B0048 .5

POLICY: A
PROTECTOR, UNDER, FRONT - REPLACE B0220 .6

POLICY: A
BUMPER ASSEMBLY, FRONT - ALIGN B0260 .3
BAR, REAR BUMPER FACE - REPLACE B0800 .4

POLICY: A
BUMPER ASSEMBLY, REAR - ALIGN B0860 .4
HOOK - REPLACE
FRONT B1000 .3
REAR B1001 .2
GRILLE ASSEMBLY - REPLACE

POLICY: A
ONE PIECE B1308 .2
ADD:
A - 1995 Cab Model............................................................................................................. .2
INSULATION, ENGINE HOOD - REPLACE B1510 .4

POLICY: A
PANEL ASSEMBLY, (LID) FRONT CENTER - REPLACE B1770 .2

POLICY: A
GUARD, MUD - REPLACE B1830 .3

POLICY: A
ADD:
A - To Replace Both............................................................................................................ .2
B - 6 BUMPERS, DOORS AND EXTERIOR TRIM
BUMPER AND FRONT END

MODEL & TIME
NUMBER
N**, QKR
FLAP, MUD GUARD - REPLACE B1831 .2

POLICY: A
ADD:
A - To Replace Both............................................................................................................ .1
PLATE, FLAP - REPLACE B1832 .2

POLICY: A
ADD:
A - To Replace Both............................................................................................................ .1
COVER, NOISE - R&R OR REPLACE

ENGINE RIGHT B1907 .2
ENGINE LEFT B1908 .3
ENGINE BOTH B1909 .4
ENGINE & TRANSMISSION LOWER B1910 .5
TRANSMISSION RIGHT B1914 .8
TRANSMISSION LEFT B1915 .7
TRANSMISSION UPPER B1916 .4
CAB REAR B1919 .4
STEP, CAB ASSIST - REPLACE

POLICY: A
RIGHT UPPER B1920 .4
LEFT UPPER B1921 .4
REAR RIGHT B1924 .3
REAR LEFT B1925 .3
DOORS AND REAR COMPARTMENT

MODEL & TIME
NUMBER
N**, QKR
DOOR ASSEMBLY, FRONT - ALIGN

RIGHT B4000 .5
LEFT B4001 .5
DOOR ASSEMBLY, FRONT - R&R

POLICY: A
RIGHT B4005 .5
LEFT B4006 .5
HINGE, FRONT DOOR (BOLT ON) - REPLACE

INC: Adjust door lock striker plate and door assembly to door opening.
LEFT UPPER B4013 .6
RIGHT LOWER B4014 .6
LEFT LOWER B4015 .6
CHECK ASSEMBLY, FRONT DOOR - REPLACE

RIGHT B4070 .4
LEFT B4071 .4
HANDLE, FRONT DOOR OUTSIDE - REPLACE

POLICY: A
RIGHT B4120 .6
LEFT B4121 .6
CYLINDER, FRONT DOOR LOCK - R&R OR REPLACE

RIGHT B4180 .5
ADD:
A - 2008 Cab Model............................................................................................................. .2
LEFT B4181 .5
ADD:
A - 2008 Cab Model............................................................................................................. .2
STRIKER, FRONT DOOR LOCK - REPLACE

DOES NOT INC: Aligning door assembly to door opening.
RIGHT B4240 .3
(CONTINUED)

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
LEFT B4241 .3
LOCK, FRONT DOOR - R&R OR REPLACE

RIGHT B4260 .7
LEFT B4261 .7
HANDLE, FRONT DOOR INSIDE OPENING - R&R OR REPLACE

RIGHT B4280 .3
ADD:
A - EXC. 2008 Cab Model................................................................................................... .2
LEFT B4281 .3
ADD:
A - EXC. 2008 Cab Model................................................................................................... .2
CONTROL, FRONT DOOR LOCK REMOTE - REPLACE

RIGHT B4290 .5
ADD:
A - 2008 Cab Model............................................................................................................. .4
LEFT B4291 .5
ADD:
A - 2008 Cab Model............................................................................................................. .4
KNOB, FRONT DOOR INSIDE LOCKING - REPLACE

RIGHT B4350 .6
LEFT B4351 .6
ROD, FRONT DOOR INSIDE LOCKING - R&R OR REPLACE

RIGHT B4360 .6
LEFT B4361 .6
CABLE, FRONT DOOR INSIDE LOCKING - REPLACE

RIGHT B4362 .8
LEFT B4363 .8

MODEL & TIME
NUMBER
N**, QKR
DOOR ASSEMBLY, REAR - ALIGN

RIGHT B4400 .5
LEFT B4401 .5
DOOR ASSEMBLY, REAR - R&R

POLICY: A
RIGHT B4405 .5
LEFT B4406 .5
HINGE, REAR DOOR - REPLACE

LEFT UPPER B4413 .5
RIGHT LOWER B4414 .5
LEFT LOWER B4415 .5
HANDLE, REAR DOOR OUTSIDE - REPLACE

POLICY: A
RIGHT B4520 .5
LEFT B4521 .5
STRIKER, REAR DOOR LOCK - REPLACE

RIGHT B4640 .3
LEFT B4641 .3
LOCK, REAR DOOR - R&R OR REPLACE

RIGHT B4660 .5
LEFT B4661 .5
HANDLE, REAR DOOR INSIDE OPENING - R&R OR REPLACE

RIGHT B4680 .3
ADD:
A - EXC. 2008 Cab Model................................................................................................... .2
LEFT B4681 .3
ADD:
A - EXC. 2008 Cab Model................................................................................................... .2

MODEL & TIME
NUMBER
N**, QKR
RUBBER, BUMPER, SIDEGATE AND/OR TAILGATE - REPLACE

POLICY: A
ONE OR ALL B5850 .3
EXTERIOR TRIM
MODEL & TIME
NUMBER
N**, QKR
EMBLEM, GRILLE - REPLACE B7100 .3

POLICY: A
INC: R&R grille if necessary.
PLATE, MODEL DESIGNATION - REPLACE

POLICY: A
ONE B7390 .3
BODY
MODEL & TIME
NUMBER
N**, QKR
BODY - REPAIR B9990 ST

POLICY: A
C BODY INTERIOR A
B
C
D
E
F
H
J
K
L
N
R
S
U
GLASS, INTERIOR TRIM AND SEATS C - 3
GLASS AND ATTACHING PARTS

MODEL & TIME
NUMBER
N**, QKR
GLASS, WINDSHIELD - RESEAL C0020 .5

POLICY: A
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

POLICY: A
INC: Water test and extra man's assistance.
ONE PIECE C0034 2.0
MIRROR, INSIDE REAR VIEW - REPLACE C0040 .3
SUPPORT, INSIDE REAR VIEW MIRROR - R&R OR REPLACE C0050 .3

INC: Transfer or replacement of mirror to support.
GLASS, FRONT DOOR - ALIGN

RIGHT C0100 .5
LEFT C0101 .5
GLASS, FRONT DOOR - R&R

POLICY: A
INC: Necessary lubrication and adjustments.
RIGHT C0110 .7
ADD:
A - 1995 Cab Model............................................................................................................. .7
LEFT C0111 .7
ADD:
A - 1995 Cab Model............................................................................................................. .7
C - 4 GLASS, INTERIOR TRIM AND SEATS

MODEL & TIME
NUMBER
N**, QKR
GLASS, FRONT DOOR - REPLACE

POLICY: A
INC: Necessary lubrication and adjustments.
RIGHT C0114 .7
ADD:
A - 1995 Cab Model............................................................................................................. .7
LEFT C0115 .7
ADD:
A - 1995 Cab Model............................................................................................................. .7
CHANNEL, FRONT DOOR GLASS LOWER SASH - R&R OR REPLACE

RIGHT C0116 .5
ADD:
A - EXC. 2008 Cab Model................................................................................................... .3
LEFT C0117 .5
ADD:
A - EXC. 2008 Cab Model................................................................................................... .3
WAIST SEAL AND/OR RETAINER, FRONT DOOR WINDOW INNER -

R&R OR REPLACE
POLICY: A
RIGHT C0120 .3
ADD:
A - EXC. 2008 Cab Model................................................................................................... .3
LEFT C0121 .3
ADD:
A - EXC. 2008 Cab Model................................................................................................... .3
WAIST SEAL, FRONT DOOR WINDOW OUTER - R&R OR REPLACE

POLICY: A
RIGHT C0130 .2
ADD:
A - EXC. 2008 Cab Model................................................................................................... .1
LEFT C0131 .2
ADD:
A - EXC. 2008 Cab Model................................................................................................... .1

MODEL & TIME
NUMBER
N**, QKR
CHANNEL, FRONT DOOR WINDOW RUN - R&R OR REPLACE

INC: R&R door glass as necessary.
RIGHT C0140 .6
LEFT C0141 .6
HANDLE, FRONT DOOR WINDOW REGULATOR - REPLACE

RIGHT C0170 .3
LEFT C0171 .3
COVER, FRONT DOOR WINDOW REGULATOR HANDLE - REPLACE

ONE OR ALL C0179 .3
REGULATOR, FRONT DOOR WINDOW - R&R OR REPLACE

INC: D&C glass, prop in up position and transfer motor where necessary.
MANUAL; RIGHT C0180 .6
MANUAL; LEFT C0181 .6
POWER; RIGHT C0182 .7
POWER; LEFT C0183 .7
GLASS, REAR DOOR - R&R

POLICY: A
RIGHT C0310 .5
LEFT C0311 .5
GLASS, REAR DOOR - REPLACE

POLICY: A
RIGHT C0314 .5
LEFT C0315 .5
HANDLE, REAR DOOR WINDOW REGULATOR - REPLACE

RIGHT C0370 .3
LEFT C0371 .3
REGULATOR, REAR DOOR WINDOW - R&R OR REPLACE

MANUAL; RIGHT C0380 .4
MANUAL; LEFT C0381 .4
(CONTINUED)

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
POWER; RIGHT C0382 .4
POWER; LEFT C0383 .4
GLASS, BACK WINDOW - REPLACE C0660 .7

POLICY: A
INC: R&R rubber channel where necessary, water test and extra man's assistance.
WEATHERSTRIPS AND FINISHER

MODEL & TIME
NUMBER
N**, QKR
WEATHERSTRIP - ALIGN OR REPLACE

POLICY: A
FRONT DOOR; RIGHT C1060 .4
FRONT DOOR; LEFT C1061 .4
REAR DOOR; RIGHT C1120 .4
REAR DOOR; LEFT C1121 .4
FINISHER - ALIGN OR REPLACE

POLICY: A
FRONT DOOR; RIGHT C1603 .4
FRONT DOOR; LEFT C1604 .4
REAR DOOR; RIGHT C1610 .4
REAR DOOR; LEFT C1611 .4
INTERIOR TRIM
MODEL & TIME
NUMBER
N**, QKR
SUNSHADE AND/OR SUPPORT - R&R OR REPLACE

RIGHT C2020 .3
LEFT C2021 .3
LOCK, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE C2100 .2

ADD:
A - To Code Cylinder........................................................................................................... .4
B - EXC. 2008 Cab Model................................................................................................... .1
STRIKER, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE C2115 .2
HINGE AND/OR STRIKER, GLOVE COMPARTMENT INSTRUMENT C2120 .4

PANEL - ADJUST OR REPLACE
DOOR ASSEMBLY, GLOVE COMPARTMENT INSTRUMENT PANEL - C2140 .4

R&R OR REPLACE
POLICY: A
INC: Align compartment door latch catch.
BOX, GLOVE COMPARTMENT INSTRUMENT PANEL - REPLACE C2160 .4

POLICY: A
INC: D&C door assembly.
ADD:
A - 2008 Cab Model............................................................................................................. 1.2
ASH TRAY, INSTRUMENT PANEL - R&R OR REPLACE C2200 .3

POLICY: A
PAD, INSTRUMENT PANEL COVER - REPLACE C2475 1.6

POLICY: A
ADD:
A - EXC. 2008 Cab Model................................................................................................... 1.0
INTERIOR TRIM
MODEL & TIME
NUMBER
N**, QKR
PAD, INSTRUMENT PANEL COVER - REPAIR C2480 .5

POLICY: A
INSTRUMENT PANEL ASSEMBLY - R&R C2500 2.6

POLICY: A
NOTE: EXC. 2008 Cab Model
HEADLINING ASSEMBLY - REPAIR

ONE PIECE C3098 .6
HEADLINING ASSEMBLY - R&R OR REPLACE

ONE PIECE C3108 .6
ADD:
A - To Replace Headlining Equipped with Roof Ventilator and/or Header.......................... .1
B - 1995 Cab Model............................................................................................................. 3.5
C - 2008 Cab Model............................................................................................................ .5
D - With Header Shelf......................................................................................................... .3
HEADLINING ASSEMBLY, REAR END - R&R OR REPLACE C3130 .4
TRIM ASSEMBLY, FRONT DOOR - R&R OR REPLACE

POLICY: A
RIGHT; ONE PIECE C3348 .4
LEFT; ONE PIECE C3358 .4
PLATE AND/OR INSERT, FRONT DOOR SILL - REPLACE

POLICY: A
RIGHT C3360 .3
LEFT C3361 .3
TRIM ASSEMBLY, REAR DOOR - R&R OR REPLACE

POLICY: A
RIGHT C3540 .3
(CONTINUED)
INTERIOR TRIM
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
LEFT C3541 .3
SEATS AND SEAT TRIM

MODEL & TIME
NUMBER
N**, QKR
SLIDE ADJUSTER ASSEMBLY, FRONT SEAT MANUAL - R&R OR REPLACE

BUCKET SEAT, ONE SIDE; DRIVER C6011 .4
SEAT ASSEMBLY, FRONT - REPLACE

POLICY: A
BUCKET SEAT; PASSENGER C6820 .3
ADD:
A - 1995 Cab Model............................................................................................................. .3
BUCKET SEAT; DRIVER C6821 .3
ADD:
A - 1995 Cab Model............................................................................................................. .3
COVER AND/OR PAD, FRONT SEAT, CUSHION - R&R OR REPLACE

POLICY: A
BUCKET SEAT; PASSENGER C6870 1.1
BUCKET SEAT; DRIVER C6871 1.1
COVER AND/OR PAD, FRONT SEAT, BACK - R&R OR REPLACE

POLICY: A
BUCKET SEAT; PASSENGER C7050 1.1
BUCKET SEAT; DRIVER C7051 1.1
COVER AND/OR PAD, REAR SEAT, CUSHION - R&R OR REPLACE

POLICY: A
CUSHION; 1 PIECE TYPE C7253 .7
COVER AND/OR PAD, REAR SEAT, BACK - R&R OR REPLACE

POLICY: A
INC: Replace frame as necessary.
BACK; 1 PIECE TYPE C7278 .8
SEAT BELT, FRONT (BUCKLE SIDE) - REPLACE

POLICY: A
RIGHT C9020 .3
LEFT C9021 .3
SEATS AND SEAT TRIM

MODEL & TIME
NUMBER
N**, QKR
SEAT BELT, FRONT (RETRACTOR SIDE) - R&R OR REPLACE

POLICY: A
RIGHT C9040 .5
LEFT C9041 .5
BOTH C9047 .7
GUIDE AND/OR COVER, SEAT BELT - R&R OR REPLACE

POLICY: A
RIGHT C9050 .3
LEFT C9051 .3
SEAT BELT, FRONT CENTER - REPLACE C9100 .4

POLICY: A
SEAT BELT, REAR (BACKLE SIDE) - REPLACE

POLICY: A
RIGHT C9190 .4
LEFT C9191 .4
SEAT BELT, REAR (RETRACTOR SIDE) - REPLACE

POLICY: A
RIGHT C9200 .6
LEFT C9201 .6
SAFETY BELT, REAR CENTER - REPLACE

POLICY: A
BUCKLE SIDE C9206 .4
TONGUE SIDE C9207 .4
BOLTS, FASTENERS AND FITTINGS - TIGHTEN C9990 .4

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 A
B
C
D
E
F
H
J
K
L
N
R
S
U
HEATING AND AIR CONDITIONING D - 3
HEATING AND AIR CONDITIONING

MODEL & TIME
NUMBER
N**, QKR
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.
KNOB, CONTROL ASSEMBLY - REPLACE D0100 .3

INC: One or all.
BEZEL, CONTROL ASSEMBLY - REPLACE D0140 .3
SWITCH, A/C. ON-OFF - REPLACE D0240 .3
CONTROL ASSEMBLY - REPLACE

HEATER ONLY D0360 .6
WITH A/C. D0362 .6
AUTO A/C. D0363 .4
CABLES, AIR DISTRIBUTION - R&R OR REPLACE

INC: Fabricate new cable and adjust.
HEATER (NON A/C.) AIR INLET D0436 .7
HEATER (NON A/C.) TEMPERATURE D0437 .7
HEATER (NON A/C.) DEFROSTER D0438 .7
AIR CONDITIONING TEMPERATURE D0447 .7
AIR SOURCE SELECT D0448 .7
AIR SELECT D0449 .7
RESISTOR, BLOWER MOTOR - REPLACE

HEATER ONLY D1000 .4
WITH A/C. D1002 .4
FILTER, BLOWER UNIT - REPLACE D1010 .2
RELAY, A/C. - REPLACE

A/C. D1027 .3
SENSOR, SUN - REPLACE D1100 1.3

D - 4 HEATING AND AIR CONDITIONING

MODEL & TIME
NUMBER
N**, QKR
SWITCH, COMPRESSOR CUT-OFF - REPLACE

DUAL PRESSURE D1116 .3
ADD:
A - Discharge/Charge A/C. System..................................................................................... .6
B - To Leak Check A/C. System.......................................................................................... .4
SWITCH, THERMOSTATIC CONTROL - REPLACE D1140 .7

ADD:
B - 1995 Cab Model............................................................................................................. .5
C - To Leak Check A/C. System.......................................................................................... .4
MOTOR AND/OR FAN - R&R OR REPLACE

BLOWER (HEATER ONLY) D1320 .4
ADD:
A - 1995 Cab Model............................................................................................................. .3
B - 2008 Cab Model............................................................................................................. .2
BLOWER (WITH A/C.) D1322 .4
ADD:
A - 1995 Cab Model............................................................................................................. .3
B - 2008 Cab Model............................................................................................................. .2
A/C. CONDENSER D1323 1.1
NOZZLE ASSEMBLY, DEFROSTER - REPLACE

RIGHT D1420 1.3
LEFT D1421 1.3
CENTER D1426 1.3
ADD:
A - 1995 Cab Model (D1426 Only)...................................................................................... 1.2
DEFLECTOR (GRILLE), AIR - REPLACE

RIGHT D1440 .4
ADD:
A - 2005 Cab Model............................................................................................................. .8
LEFT D1441 .4
(CONTINUED)

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
RIGHT CENTER D1442 .4
ADD:
A - 2005 Cab Model (D1442 Only)...................................................................................... .8
LEFT CENTER D1443 .4
CASE, HEATER - REPLACE

INC: R&R instrument panel assembly and cross beam.
HEATER ONLY D2220 1.7
ADD:
A - 1995 Cab Model............................................................................................................. 1.2
CASE, EVAPORATOR - R&R OR REPLACE D2510 1.3

ADD:
A - 1995 Cab Model............................................................................................................. .5
B - Discharge/Charge A/C. System..................................................................................... .6
HOSES, HEATER (WITHOUT AIR CONDITIONING) - REPLACE

ONE D2746 .6
BOTH D2747 .7
HOSES, HEATER (WITH AIR CONDITIONING) - REPLACE

ALL HOSES D2787 .7
CORE, HEATER - R&R

ADD:
A - 1995 Cab Model............................................................................................................. 1.2
WITH A/C. D2802 1.8
ADD:
A - Discharge/Charge A/C. System (EXC. 2005 Cab Model).............................................. .6
B - 1995 Cab Model............................................................................................................. 1.2

MODEL & TIME
NUMBER
N**, QKR
CORE, HEATER - REPLACE

ADD:
A - 1995 Cab Model............................................................................................................. 1.2
WITH A/C. D2822 1.8
ADD:
A - Discharge/Charge A/C. System (EXC. 2005 Cab Model).............................................. .6
B - 1995 Cab Model............................................................................................................. 1.2
SEALS, REFRIGERANT O-RING - REPLACE

COMPRESSOR MANIFOLD D3040 .4
ADD:
CONDENSER D3041 .3
ADD:
CONDENSER OUTLET PIPE D3042 .3
ADD:
EXPANSION VALVE D3043 1.0
ADD:
B - 1995 Cab Model............................................................................................................. .6
C - 2008 Cab Model............................................................................................................ .6
D - To Leak Check A/C. System.......................................................................................... .4
EVAPORATOR D3044 .4
ADD:
FILTER DRYER D3048 .3
ADD:
(CONTINUED)

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
HOSES AND/OR LINES, REFRIGERANT - REPLACE

INC: Assemble service hose as necessary.
CONDENSER INLET D3081 .4
ADD:
COMPRESSOR DISCHARGE D3082 .4
ADD:
EVAPORATOR OUTLET D3084 .4
ADD:
COMPRESSOR SUCTION AND DISCHARGE HOSE ASSEMBLY D3088 .4
ADD:
COMPRESSOR SUCTION D3089 .4
ADD:
FILTER DRYER TO CONDENSER D3096 .4
ADD:
FILTER DRYER OUTLET D3097 .4
ADD:
ANY ONE PIPE EXPANSION VALVE INLET D3099 1.0
ADD:
(CONTINUED)

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - 1995 Cab Model............................................................................................................. .6
C - 2008 Cab Model............................................................................................................ .6
CONDENSER - REPLACE D3140 .6

ADD:
VALVE, EXPANSION - REPLACE D3220 1.0

ADD:
B - 1995 Cab Model............................................................................................................. .4
C - 2008 Cab Model............................................................................................................ .6
DRYER, IN-LINE FILTER - REPLACE D3250 .4

ADD:
CORE, EVAPORATOR - REPLACE D3320 .8

ADD:
B - 1995 Cab Model............................................................................................................. .4
C - 2008 Cab Model............................................................................................................ .9
PULLEY IDLER, A/C. - R&R D4020 .4

ADD:
A - With Crew Cab............................................................................................................... 1.0
BRACKET (S) , COMPRESSOR MOUNTING - R&R OR REPLACE

ALL D4237 .6

MODEL & TIME
NUMBER
N**, QKR
CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR - REPLACE D4240 .8

INC. R&R compressor assembly.
ADD:
B - EXC. 4HK1 Engine (Euro4 Specification) Fitted 2005/2008 Cab Models...................... .6
C - 4JJ1 Engine................................................................................................................... .2
COMPRESSOR ASSEMBLY - REPLACE D4440 .4

ADD:
C - 4JJ1 Engine................................................................................................................... .2
E WHEELS, SUSPENSION, STEERING A
B
C
D
E
F
H
J
K
L
N
R
S
U
STEERING, SUSPENSION, WHEELS AND TIRES E - 9
WHEELS AND TIRES

MODEL & TIME
NUMBER
N**, QKR
WHEEL - BALANCE
INC: R&R wheel and tire.
ONE E0200 .6
TWO E0201 .8
THREE E0202 1.1
FOUR E0203 1.3
WHEEL OR TIRE - REPLACE

POLICY: A
NOTE: Include separate tire from wheel, and wheel balance (static).
ONE E0411 .7
TWO E0412 1.0
THREE E0413 1.2
FOUR E0414 1.4
FIVE E0415 1.6
SIX E0416 1.7
WHEEL W/TIRE - R&R OR REPLACE

POLICY: A
NOTE: Does not include wheel balance (static).
INC: R&R wheel to hub. Dual wheels are considered as one wheel on
dual wheeled models.
ONE E0420 .5
TWO E0421 .8
THREE E0422 1.1
FOUR E0423 1.3
FIVE E0424 1.6
SIX E0425 1.8
BOLT, WHEEL MOUNTING - REPLACE

RIGHT FRONT E0474 .7
ADD:
A - To Replace Additional Two Bolts................................................................................... .3
B - To Replace Additional Four Bolts.................................................................................. .5
C - To Replace All Bolts...................................................................................................... .7
D - To Replace Additional Two Bolts (Disc Brake Type)..................................................... .1
(CONTINUED)
E - 10 STEERING, SUSPENSION, WHEELS AND TIRES
WHEELS AND TIRES

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
E - To Replace Additional Four Bolts (Disc Brake Type)..................................................... .2
F - To Replace All Bolts (Disc Brake Type)......................................................................... .2
LEFT FRONT E0475 .7
ADD:
RIGHT REAR E0484 1.1
ADD:
LEFT REAR E0485 1.1
ADD:
HOLD DOWN, SPARE TIRE - R&R OR REPLACE E0600 .3
JACK AND/OR HANDLE - REPLACE E0620 .3

FRAME
MODEL & TIME
NUMBER
N**, QKR
PAD AND/OR BOLT, BODY - R&R OR REPLACE E1040 .8

POLICY: A
CUSHION, PAD AND/OR BOLT, BODY - R&R OR REPLACE

POLICY: A
MOUNT POSITION ONE E1106 .8
ADD:
A - To Replace Additional Two Cushions............................................................................ .2
B - To Replace Additional Four Cushions........................................................................... .3
C - Replace All Cushions..................................................................................................... .4
LATCH, CAB HOLD DOWN - REPLACE E1300 .4
SUPPORT, CAB REAR - REPLACE E1330 .4
BAR, CAB TORSION - REPLACE

POLICY: A
NOTE: R&R cab assembly.
ONE PIECE E1358 1.8
ADD:
A - With A/C......................................................................................................................... .3
B - 2008 Cab Model............................................................................................................. 1.4
HOOK, CAB REAR HOLD DOWN SAFETY - REPLACE E1400 .3
BUSHING, MOUNTING LEVER - REPLACE

POLICY: A
RIGHT E1420 .8
ADD:
A - 2008 Cab Model............................................................................................................. 3.3
LEFT E1421 .8
ADD:
A - 2008 Cab Model............................................................................................................. 3.3
FRAME
MODEL & TIME
NUMBER
N**, QKR
CROSSMEMBER, FRAME - REPAIR E1760 .5

CROSSMEMBER, FRAME - REPLACE E1770 .5

FRAME ASSEMBLY - REPAIR E1860 .5

BOLTS, FASTENERS AND FITTINGS - TIGHTEN E1990 .6

NOTE: This operation is to be used on chassis items only. For body
items refer to operation C9990 of the seats section.
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
TOE-IN, FRONT SUSPENSION - ADJUST E2000 .7
FRONT SUSPENSION - CHECK AND/OR ALIGN E2020 1.6

INC: Adjust camber, caster, toe-in and trim height where applicable.
ROD, FRONT STRUT - REPLACE

RIGHT E2100 .7
LEFT E2101 .7
BOTH E2107 1.1
BUSHINGS, FRONT STRUT ROD - REPLACE

POLICY: A
RIGHT E2120 .7
LEFT E2121 .7
BOTH E2127 1.1
SHAFT, FRONT STABILIZER - REPLACE E2160 .5

INC: R&R links and bushings.
NUT, FRONT WHEEL HUB - REPLACE E2200 .4

ADD:
A - To Replace Both............................................................................................................ .3
BEARING, FRONT WHEEL - ADJUST

RIGHT E2220 .5
LEFT E2221 .5
BOTH E2227 .7
CAP, FRONT WHEEL HUB DUST - REPLACE

POLICY: A
RIGHT E2230 .3
LEFT E2231 .3
BOTH E2237 .3
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
BEARING, FRONT WHEEL - REPLACE

NOTE: Maximum time not to exceed operation number E2267 & E2268.
INC: R&R wheel, clean and pack inner and outer bearings,
replace seal, fill oiler cap.
INNER RIGHT (4x2) E2240 1.3
INNER LEFT (4x2) E2241 1.3
INNER RIGHT (4x4) E2242 1.4
INNER LEFT (4x4) E2243 1.4
INNER BOTH (4x2) E2247 2.4
INNER BOTH (4x4) E2248 2.6
OUTER RIGHT (4x2) E2250 1.3
OUTER LEFT (4x2) E2251 1.3
OUTER RIGHT (4x4) E2252 1.4
OUTER LEFT (4x4) E2253 1.4
OUTER BOTH (4 x2) E2257 2.4
OUTER BOTH (4x4) E2258 2.6
INNER AND OUTER RIGHT (4x2) E2260 1.3
INNER AND OUTER LEFT (4x2) E2261 1.3
INNER AND OUTER RIGHT (4x4) E2262 1.4
INNER AND OUTER LEFT (4x4) E2263 1.4
INNER AND OUTER BOTH (4x2) E2267 2.4
INNER AND OUTER BOTH (4x4) E2268 2.6
SEAL, FRONT WHEEL BEARING - REPLACE

INC: Clean, inspect and repack inner and outer bearings. Replace
bearings as necessary (2001 and before models).
RIGHT (4x2) E2280 1.3
ADD:
A - To Clean Or Replace Brake Shoes One Wheel............................................................. .3
LEFT (4x2) E2281 1.3
ADD:
RIGHT (4x4) E2282 1.1
ADD:
(CONTINUED)
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
LEFT (4x4) E2283 1.1
ADD:
BOTH (4x2) E2287 2.4
ADD:
BOTH (4x4) E2291 1.9
ADD:
HUB ASSEMBLY, FRONT WHEEL (DISC BRAKE TYPE) - REPLACE

ONE E2317 1.1
ADD:
A - To Replace Additional Hub Assembly (One)................................................................. .9
HUB ASSEMBLY, FRONT WHEEL - REPLACE

NOTE: If Problems are discovered inspection, the hub assembly
must be replaced (2002 Model).
INC: R&R wheel, clean and pack inner and outer bearings,
replace seal, fill oiler cap (2001 and before models).
RIGHT E2320 .8
ADD:
A - For 4x4 Model................................................................................................................ .3
LEFT E2321 .8
ADD:
A - For 4x4 Model................................................................................................................ .3
BOTH E2327 1.6
ADD:
A - For 4x4 Model................................................................................................................ .6
AUTO LOCKING HUB - REPLACE

RIGHT E2360 .6
LEFT E2361 .6
BOTH E2367 1.1
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
KNUCKLE ASSEMBLY, STEERING - REPLACE

INC: R&R wheel, hub, steering knuckles, king pins and thrust bearings.
Adjust and lubricate front wheel bearings, adjust brakes and set toe-in
DOES NOT INC: Rebush steering knuckles.
RIGHT (4x2) E2520 2.2
LEFT (4x2) E2521 2.2
RIGHT (4x4) E2522 1.5
ADD:
A - Front Leaf Spring (4x4).................................................................................................. 1.0
LEFT (4x4) E2523 1.5
ADD:
BOTH (4x2) E2527 3.1
BOTH (4x4) E2528 2.7
ADD:
KNUCKLE OIL SEAL - REPLACE

RIGHT E2551 1.5
ADD:
LEFT E2552 1.5
ADD:
BOTH E2557 2.7
ADD:
STOP, STEERING KNUCKLE - ADJUST OR REPLACE

RIGHT E2560 .4
LEFT E2561 .4
BOTH E2567 .6
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
BUSHINGS, STEERING KNUCKLE - REPLACE

POLICY: A
INC: R&R wheels, hubs, steering knuckles, king pins and thrust bearings.
Replace bushings and fit pins. Adjust brakes, front wheel bearings and toe-in.
RIGHT E2760 2.4
LEFT E2761 2.4
BOTH E2767 4.3
BALL JOINT, CONTROL ARM - REPLACE

POLICY: A
UPPER RIGHT E2920 1.2
UPPER LEFT E2921 1.2
UPPER BOTH E2927 2.2
LOWER RIGHT E2930 1.6
LOWER LEFT E2931 1.6
LOWER BOTH E2937 2.6
KING PINS AND THRUST BEARINGS - REPLACE

POLICY: A
INC: R&R wheel, hub, steering knuckles, king pins and thrust bearings.
Adjust and lubricate front wheel bearings, adjust brakes and set toe-in.
DOES NOT INC: Rebush steering knuckles.
RIGHT E2960 2.0
ADD:
A - To Replace Tie Rod End Each...................................................................................... .3
B - To Replace Wheel Cylinder........................................................................................... .7
C - To Replace Front Brake Shoes Each Side.................................................................... .3
D - To Rebush Steering Knuckle Each Side Brass Bushing Only....................................... .5
E - For 4x4 Model................................................................................................................ .3
LEFT E2961 2.0
ADD:
E - For 4x4 Model................................................................................................................ .3
(CONTINUED)
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
BOTH E2967 3.6
ADD:
E - For 4x4 Model................................................................................................................ .6
BOLT, FRONT LEAF SPRING CENTER - REPLACE

INC: R&R spring assembly.
RIGHT E3100 1.8
LEFT E3101 1.8
BOTH E3107 3.4
SPRING ASSEMBLY, FRONT LEAF - R&R

POLICY: A
RIGHT E3120 1.7
ADD:
A - To Replace Center Bolt Each........................................................................................ .4
B - To Rebush Front Spring Hanger Each........................................................................... .5
C - To Rebush Front Spring Eye-Hanger End Each............................................................ .4
D - To Rebush Front Spring Eye-Shackle End Each........................................................... .5
LEFT E3121 1.7
ADD:
BOTH E3127 3.0
ADD:
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
SPRING ASSEMBLY, FRONT LEAF - REPLACE

POLICY: A
RIGHT E3130 1.7
LEFT E3131 1.7
BOTH E3137 3.0
LEAVES, FRONT SPRING - REPLACE

POLICY: A
RIGHT E3140 1.9
LEFT E3141 1.9
BOTH E3147 3.6
BUSHING, FRONT SPRING EYE - REPLACE

POLICY: A
INC: R&R spring assembly.
FRONT RIGHT E3180 .8
FRONT LEFT E3181 .8
REAR RIGHT E3190 .8
REAR LEFT E3191 .8
SHACKLE AND/OR PIN, FRONT SPRING - REPLACE

INC: Shackle end only.
RIGHT E3200 1.0
LEFT E3201 1.0
BOLT, FRONT SPRING EYE HANGER END - REPLACE

RIGHT E3220 .6
LEFT E3221 .6
BOTH E3227 1.0
U-BOLT, FRONT SPRING - REPLACE

INC: Both U-bolts.
RIGHT E3240 .6
LEFT E3241 .6
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
BAR, FRONT TORSION - ADJUST E3300 .7

NOTE: Use operation E2020 instead of this one, if front end alignment
is necessary.
BAR, FRONT TORSION - REPLACE

POLICY: A
INC: Adjust trim height.
RIGHT E3320 1.0
LEFT E3321 1.0
BOTH E3327 1.6
ARM, TORSION BAR PIVOT - REPLACE

INC: Adjust trim height.
RIGHT E3330 1.0
LEFT E3331 1.0
BOTH E3337 1.6
ARM ASSEMBLY, FRONT CONTROL - REPLACE

BUSHINGS AND/OR SHAFT, FRONT CONTROL ARM - REPLACE

POLICY: A
FRONT SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
AXLE, I-BEAM - REPLACE E3600 4.6

ADD:
A - To Replace Wheel Cylinder One Side........................................................................... .6
B - To Replace Wheel Cylinder Both Side.......................................................................... .5
C - To Replace Front Brake Shoes One Side..................................................................... .3
D - To Replace Front Brake Shoes Both Side..................................................................... .5
E - To Rebush Steering Knuckles One Side....................................................................... .5
F - To Rebush Steering Knuckles Both Side....................................................................... 1.0
SHOCK ABSORBER, FRONT - REPLACE

POLICY: A
RIGHT E3800 .4
LEFT E3801 .4
BOTH E3807 .6
CUSHION RUBBER BRACKET, LATERAL LEAF SPRING - REPLACE E3839 .4
LATERAL LEAF SPRING - REPLACE E3840 3.4
CUSHION RUBBER, LOWER, LATERAL LEAF SPRING - REPLACE

POLICY: A
RIGHT E3845 .3
LEFT E3846 .3
BOTH E3847 .4
CUSHION RUBBER, UPPER, LATERAL LEAF SPRING - REPLACE

POLICY: A
RIGHT E3848 3.4
LEFT E3849 3.4
BOTH E3850 3.4
SUPPORT RUBBER, LATERAL LEAF SPRING - REPLACE

POLICY: A
RIGHT E3851 .8
LEFT E3852 .8
BOTH E3853 1.4
REAR SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
BAR, REAR STABILIZER - REPLACE E4160 .6

POLICY: A
INSULATOR AND/OR SUPPORT, REAR STABILIZER BAR - REPLACE

POLICY: A
RIGHT E4180 .5
LEFT E4181 .5
BOTH E4187 .7
BEARINGS, REAR WHEEL - REPLACE

INC: R&R wheel and hub as an assembly. Clean, inspect, lubricate and
adjust bearings. Replace oil seal if necessary.
DOES NOT INC: Replace bearing cups.
RIGHT E4240 2.4
ADD:
A - To Replace Inner Bearing Cup One Wheel................................................................... .3
B - To Replace Outer Bearing Cup One Wheel................................................................... .3
LEFT E4241 2.4
ADD:
SEAL, OIL, REAR WHEEL BEARING INNER (ONE WHEEL) - REPLACE

INC: R&R wheel and hub as an assembly. Clean, inspect, lubricate and
adjust bearings. Clean brake shoes.
DOES NOT INC: Replace bearing cups.
RIGHT E4270 2.4
ADD:
C - To Replace Or Reline Brake Shoes One Wheel............................................................ .7
LEFT E4271 2.4
ADD:
C - To Replace Or Reline Brake Shoes One Wheel............................................................ .7
REAR SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
HUB ASSEMBLY, REAR WHEEL (DISC BRAKE TYPE) - REPLACE

ONE E4367 1.4
ADD:
A - To Replace Additional Hub Assembly (One)................................................................. 1.0
HUB ASSEMBLY, REAR WHEEL - REPLACE

INC: R&R wheel, axle shaft, hub bearings, cups, oil seal and hub bolts.
Inspect, lubricate and adjust bearings.
RIGHT E4370 1.8
LEFT E4371 1.8
DUMPER, AXLE - REPLACE

POLICY: A
RIGHT E4400 .3
LEFT E4401 .3
BOTH E4407 .4
BOLT, REAR LEAF SPRING CENTER - REPLACE

INC: D&C spring to axle and align spring leaves.
DOES NOT INC: Rebushing.
RIGHT E5100 1.8
LEFT E5101 1.8
BOTH E5107 3.5
SPRING ASSEMBLY, REAR LEAF - REPLACE

POLICY: A
INC: D&C spring at both hangers and axle.
RIGHT E5130 1.6
LEFT E5131 1.6
BOTH E5137 2.9
REAR SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
LEAVES, REAR SPRING - REPLACE

POLICY: A
INC: Remove, disassemble, clean, replace leaves as necessary.
RIGHT E5140 2.2
LEFT E5141 2.2
BOTH E5147 4.1
BUSHING, REAR LEAF SPRING EYE - REPLACE

POLICY: A
RIGHT E5180 .8
LEFT E5181 .8
BOTH E5185 1.7
SHACKLE AND/OR BUSHING, REAR LEAF SPRING - REPLACE

POLICY: A
RIGHT E5200 .7
LEFT E5201 .7
BOTH E5207 1.3
SHACKLE PINS, REAR SPRING - REPLACE

RIGHT E5210 .5
LEFT E5211 .5
BOTH E5217 .8
U-BOLT OR RETAINING BOLT, REAR LEAF SPRING - REPLACE

INC: Both U-Bolts or Retaining Bolts.
RIGHT E5220 .8
LEFT E5221 .8
BOTH E5227 1.3
BOLT, REAR LEAF SPRING EYE OR LINK - REPLACE

RIGHT E5240 .5
LEFT E5241 .5
BOTH E5247 .6
REAR SUSPENSION
MODEL & TIME
NUMBER
N**, QKR
HELPER DAMPER,REAR LEAF SPRING - REPLACE E5650 .3

POLICY: A
ADD:
A - To Replace Helper Damper (One)................................................................................. .1
B - To Replace Helper Damper (All).................................................................................... .2
SHOCK ABSORBER, REAR - REPLACE

POLICY: A
RIGHT E5800 .3
LEFT E5801 .3
BOTH E5807 .4
STEERING
MODEL & TIME
NUMBER
N**, QKR
EMBLEM AND/OR PAD, HORN BUTTON - REPLACE E7010 .3

INC: Transfer parts.
WHEEL, STEERING - REPLACE E7020 .3
LEVER, TURN SIGNAL - REPLACE E7050 .6
LEVER, TILT WHEEL - REPLACE E7080 .3
HORN CONTACT - REPLACE E7100 .6
CYLINDER, IGNITION LOCK - R&R OR REPLACE E7200 .6

ADD:
A - With Imobilizer System.................................................................................................. .3
COVER, LOCK HOUSING - REPLACE E7220 .3
BEARING AND/OR BUSHING, UPPER - REPLACE

STANDARD E7320 .7
TILT E7321 1.0
SHAFT AND/OR SPHERE ASSEMBLY - REPLACE E7400 1.8
BEARING AND/OR BUSHING, STEERING SHAFT LOWER - REPLACE E7620 2.0
COLUMN ASSEMBLY, STEERING - R&R E7660 1.0

POLICY: A
UNIVERSAL JOINT, STEERING SHAFT - R&R OR REPLACE

UPPER E7782 2.0
LOWER E7783 2.0
ARM, PITMAN - REPLACE E7900 .5
DAMPER, STEERING - R&R OR REPLACE E7930 .2

POLICY: A
STEERING
MODEL & TIME
NUMBER
N**, QKR
LINK, DRAG - REPLACE E7940 .6

POLICY: A
ARM, STEERING IDLER - REPLACE E7960 .6
BRACKET, IDLER ARM FRAME - REPLACE E7970 .6
TIE ROD, INNER - REPLACE

INC: Check and adjust toe-in. R&R rack and pinion gear assembly as necessary.
RIGHT E8040 .8
ADD:
A - Rack and Pinion Gear.................................................................................................... 2.1
LEFT E8041 .8
ADD:
BOTH E8047 1.2
ADD:
TIE ROD END AND/OR ADJUST SLEEVE - REPLACE

POLICY: A
INC: Check and adjust toe-in.
RIGHT E8060 1.0
LEFT E8061 1.0
BOTH E8067 1.4
TIE ROD ASSEMBLY - R&R OR REPLACE E8080 1.1
TIE ROD, IDLER ARM - REPLACE E8090 .6

POLICY: A
ARM, STEERING KNUCKLE - REPLACE

INC: Adjust toe-in. R&R wheel and hub assembly when necessary.
DOES NOT INC: Check caster or camber.
RIGHT E8100 1.1
LEFT E8101 1.1
STEERING
MODEL & TIME
NUMBER
N**, QKR
CAP, POWER STEERING PUMP RESERVOIR - REPLACE E8300 .3
PULLEY, POWER STEERING PUMP - REPLACE E8360 .4
FILTER, POWER STEERING OIL - REPLACE E8420 .4

POLICY: A
VALVE, POWER STEERING PUMP FLOW CONTROL - REPLACE E8440 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4JJ1 Engine................................................................................................................... .4
C - 4H** Engines................................................................................................................. .4
D - 4B** Engines.................................................................................................................. .4
HOSES, POWER STEERING HYDRAULIC - REPLACE

POLICY: A
INC: Check and add fluid.
PRESSURE E8622 .6
RETURN E8623 .5
PUMP ASSEMBLY, POWER STEERING - R&R E9040 .5

POLICY: A
INC: Bleed hydraulic system.
ADD:
A - To Replace Reservoir and/or Hose................................................................................ .4
B - To Recondition Pump.................................................................................................... 1.0
C - Diagnosis Time.............................................................................................................. .3
D - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .8
E - 4JJ1 Engine................................................................................................................... 1.5
F - 4H** Engines
(EXC. 4HL1 Engine & 4HK1 Engine <Euro4 Specification> Fitted 2005 Cab Model).... .6
G - 4B** Engines................................................................................................................. .6
H - 4JH1/4JB1/4JG2 Engines.............................................................................................. .5
J - 4HL1 Engine................................................................................................................... .3
STEERING
MODEL & TIME
NUMBER
N**, QKR
PUMP ASSEMBLY, POWER STEERING - REPLACE E9050 .5

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .9
C - 4JJ1 Engine................................................................................................................... 1.6
D - 4H** Engines
(EXC. 4HL1 Engine & 4HK1 Engine <Euro4 Specification> Fitted 2005 Cab Model).... .7
E - 4B** Engines.................................................................................................................. .7
F - 4JH1/4JB1/4JG2 Engines.............................................................................................. .5
G - 4HL1 Engine.................................................................................................................. .3
PUMP ASSEMBLY, POWER STEERING & HYDRAULIC POWER E9060 1.8

BRAKE BOOSTER - R&R
POLICY: A
INC: Air bleed power steering line & brake hydraulic system.
ADD:
A - Diagnosis Time.............................................................................................................. .3
RESERVOIR ASSEMBLY, POWER STEERING FLUID REMOTE - REPLACE E9100 .4

ADD:
A - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... .5
B - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .1
GEAR ASSEMBLY, MANUAL STEERING - ADJUST E9600 .3
GEAR ASSEMBLY, MANUAL STEERING - R&R E9620 1.8
GEAR ASSEMBLY, MANUAL STEERING - REPLACE E9640 1.8

ADD:
A - To Replace Drag Link.................................................................................................... .4
GEAR ASSEMBLY, POWER STEERING - ADJUST E9700 .4

STEERING
MODEL & TIME
NUMBER
N**, QKR
GEAR ASSEMBLY, POWER STEERING - R&R E9720 1.0

INC: R&R steering gear assembly, drain and refill, bleed hydraulic system.
INC: All add conditions exc bench leak test.
ADD:
A - To Replace Side Cover and/or O-Ring Seal.................................................................. .5
B - To Replace End Cover and/or O-Ring Seal................................................................... .5
C - To R&R Pitman Shaft or Bearing................................................................................... .5
D - To Recondition Adjuster Plug Assembly........................................................................ .5
E - To Recondition Valve Body Assembly........................................................................... .7
F - To Recondition Rack Piston Assembly.......................................................................... .7
G - To Replace Housing...................................................................................................... 1.1
H - To Recondition Power Steering Gear (Complete)......................................................... 1.6
I - Diagnosis Time................................................................................................................ .3
J - Rack and Pinion Gear.................................................................................................... 1.7
GEAR ASSEMBLY, POWER STEERING - REPLACE E9740 1.0

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - Rack and Pinion Gear.................................................................................................... 1.7
BELT, POWER STEERING PUMP DRIVE - REPLACE E9750 .3

POLICY: A
F AXLE AND DIFFERENTIAL A
B
C
D
E
F
H
J
K
L
N
R
S
U
AXLE AND DIFFERENTIAL F - 3
AXLE AND DIFFERENTIAL

MODEL & TIME
NUMBER
N**, QKR
BEARING, CENTER SUPPORT - REPLACE F0040 1.3

POLICY: P
INC: D&C front and intermediate universal joints. R&R center bearing support
to frame. R&R propeller shaft and hanger bearing to shaft.
UNIVERSAL JOINT, PROPELLER SHAFT - REPLACE

POLICY: P
FRONT F1002 1.2
REAR F1003 1.2
INTERMEDIATE F1004 1.2
PROPELLER SHAFT ASSEMBLY - R&R OR REPLACE

POLICY: P
ONE PIECE TYPE F1280 .5
TWO PIECE TYPE; FRONT F1281 .7
TWO PIECE TYPE; REAR F1284 .7
FRONT DRIVE (4x4) F1288 .5
SHAFT, FRONT AXLE - REPLACE

RIGHT F1520 1.7
ADD:
A - Independent Suspension............................................................................................... 4.3
LEFT F1521 1.7
ADD:
BOTH F1527 3.0
ADD:
SHAFT, REAR AXLE - REPLACE

RIGHT F1530 .7
LEFT F1531 .7
BOTH F1537 1.0
F - 4 AXLE AND DIFFERENTIAL

MODEL & TIME
NUMBER
N**, QKR
SEAL, AXLE SHAFT OIL - REPLACE

FRONT AXLE; RIGHT F1600 2.7
ADD:
FRONT AXLE; LEFT F1601 2.7
ADD:
FRONT AXLE; BOTH F1607 5.2
ADD:
A - Independent Suspension............................................................................................... .9
REAR AXLE; RIGHT F1610 .6
REAR AXLE; LEFT F1611 .6
REAR AXLE; BOTH F1617 .8
BEARING, KING PIN (4x4 MODEL) - REPLACE

RIGHT F1630 2.3
LEFT F1631 2.3
BOTH F1637 4.3
BEARING, AXLE SHAFT - REPLACE

REAR AXLE; RIGHT F1650 .7
REAR AXLE; LEFT F1651 .7
REAR AXLE; BOTH F1657 1.0
SEAL, PINION SHAFT OIL - REPLACE

FRONT DIFFERENTIAL F2022 .7
REAR DIFFERENTIAL F2023 .7
FLANGE, PINION SHAFT - REPLACE

POLICY: P
INC: Reset bearing preload. Pinion seal and add lubricant.
FRONT DIFFERENTIAL F2042 .6
REAR DIFFERENTIAL F2043 .6
AXLE AND DIFFERENTIAL F - 5

MODEL & TIME
NUMBER
N**, QKR
CARRIER ASSEMBLY, FRONT AXLE - R&R OR REPLACE F2122 4.2

POLICY: A, P
ADD:
A - To Replace Pinion Shaft and/or Side and Pinion Gears................................................ .6
B - To Replace Side Bearings............................................................................................. .5
C - To Replace Pinion Bearings.......................................................................................... .5
D - To Replace Ring Gear and Pinion................................................................................. .8
E - To Replace Case........................................................................................................... .6
F - To Replace Carrier......................................................................................................... 1.0
G - To Recondition Carrier Complete.................................................................................. 1.7
H - Independent Suspension............................................................................................... 3.1
CARRIER ASSEMBLY, REAR AXLE - R&R OR REPLACE F2123 2.8

POLICY: A, P
ADD:
A - To Replace Pinion Shaft and/or Side and Pinion Gears................................................ .6
B - To Replace Side Bearings (EXC.292/320mm Differential Size).................................... .5
C - To Replace Side Bearings; 292/320mm Differential Size.............................................. .7
D - To Replace Pinion Bearings (EXC.292/320mm Differential Size)................................. .5
E - To Replace Pinion Bearings; 292/320mm Differential Size........................................... 1.0
F - To Replace Ring Gear and Pinion (EXC.292/320mm Differential Size)......................... .8
G - To Replace Ring Gear and Pinion; 292/320mm Differential Size.................................. 1.6
H - To Replace Case........................................................................................................... .6
I - To Replace Carrier (EXC.292/320mm Differential Size)................................................. 1.0
J - To Replace Carrier; 292/320mm Differential Size.......................................................... .2
K - To Recondition Carrier Complete (EXC.292/320mm Differential Size).......................... 1.7
L - To Recondition Carrier Complete; 292/320mm Differential Size.................................... 1.6
HOUSING ASSEMBLY, REAR AXLE - REPLACE F3023 6.0

INC: R&R propeller shaft, transfer all parts, bleed brakes and make
all necessary adjustments.
HOUSING ASSEMBLY, FRONT AXLE - REPLACE F3060 7.3

ADD:
A - Leaf Spring..................................................................................................................... 1.3
F - 6 AXLE AND DIFFERENTIAL

MODEL & TIME
NUMBER
N**, QKR
DRAIN PLUG AND/OR GASKET, OIL, DIFFERENTIAL - REPLACE

FRONT F3080 .3
REAR F3081 .3
FILLER PLUG AND/OR GASKET, OIL, DIFFERENTIAL - REPLACE

FRONT F3085 .2
REAR F3086 .2
VENTILATOR, AXLE - REPLACE F3270 .4

INC: Hose assembly.
H BRAKES A
B
C
D
E
F
H
J
K
L
N
R
S
U
H - 10 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
BRAKE ASSEMBLY, FRONT - REPLACE

NOTE: Full air brake type.
RIGHT H0001 .8
LEFT H0002 .8
BOTH H0003 1.4
BRAKE ASSEMBLY, REAR - REPLACE

RIGHT H0015 1.2
LEFT H0016 1.2
BOTH H0017 2.1
INDICATOR, BRAKE PAD - REPLACE

FRONT H0038 .5
ADD:
A - To Replace Brake Pad Indicator (Both Side)................................................................. .3
REAR H0039 .7
ADD:
A - To Replace Brake Pad Indicator (Both Side)................................................................. .4
PADS, DISC BRAKE - R&R OR REPLACE

POLICY: A
FRONT BOTH H0042 .8
ADD:
A - Hydraulic Brake Type..................................................................................................... .5
REAR BOTH H0043 1.0
ADD:
A - Full Air Brake Type........................................................................................................ .1
BRACKET, SUPPORT, FRONT DISC BRAKE - REPLACE H0050 .5

ADD:
A - To Replace Support Bracket (Both Side, Hydraulic Brake Type)................................... .3
B - To Replace Support Bracket (One Side, Full Air Brake Type)....................................... .4
C - To Replace Support Bracket (Both Side, Full Air Brake Type)...................................... 1.1
BRAKES H - 11
BRAKES
MODEL & TIME
NUMBER
N**, QKR
BRACKET, SUPPORT, REAR DISC BRAKE - REPLACE H0051 .7

ADD:
A - To Replace Support Bracket (Both Side, Hydraulic Brake Type)................................... .4
B - To Replace Support Bracket (One Side, Full Air Brake Type)....................................... .4
C - To Replace Support Bracket (Both Side, Full Air Brake Type)...................................... 1.2
CALIPER ASSEMBLY - R&R

POLICY: A
INC: R&R brake pads from caliper. Clean and inspect caliper
and bleed brakes.
FRONT RIGHT H0080 .7
ADD:
A - To Recondition Caliper Assembly.................................................................................. .3
B - Full Air Brake Type........................................................................................................ .4
FRONT LEFT H0081 .7
ADD:
A - To Recondition Caliper Assembly.................................................................................. .3
FRONT BOTH H0087 1.1
ADD:
A - To Recondition Caliper Assembly (One)........................................................................ .3
B - To Recondition Caliper Assembly (All).......................................................................... .5
C - Full Air Brake Type........................................................................................................ .7
CALIPER ASSEMBLY, REAR BRAKE - R&R H0098 .7

POLICY: A
ADD:
A - To R&R Caliper Assembly (Both Side, Hydraulic Brake Type)...................................... .4
B - To Recondition Caliper Assembly (One)........................................................................ .3
C - To Recondition Caliper Assembly (All).......................................................................... .5
D - To R&R Caliper Assembly (One Side, Full Air Brake Type).......................................... .5
E - To R&R Caliper Assembly (Both Side, Full Air Brake Type).......................................... 1.4
H - 12 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
CALIPER ASSEMBLY - REPLACE

INC: R&R brake pads from caliper. Clean and inspect caliper
and bleed brakes.
ADD:
FRONT LEFT H0101 .7
ADD:
ADD:
CALIPER ASSEMBLY, REAR BRAKE - REPLACE H0118 .7

ADD:
A - To Replace Caliper Assembly (Both Side, Hydraulic Brake Type)................................ .4
B - To Replace Caliper Assembly (One Side, Full Air Brake Type)..................................... .5
C - To Replace Caliper Assembly (Both Side, Full Air Brake Type).................................... 1.4
DISC ASSEMBLY - R&R OR REPLACE

POLICY: A
INC: D&C caliper assembly and visually inspect. Check rotor lateral runout
and parallelism. Transfer seals, bearings and races. Clean and repack
wheel bearing as necessary.
FRONT RIGHT (4X2) H0120 1.3
ADD:
A - To Reface Disc (One).................................................................................................... .5
B - With Anti Lock Brake System (One).............................................................................. .4
FRONT LEFT (4X2) H0121 1.3
ADD:
A - To Reface Disc (One).................................................................................................... .5
B - With Anti Lock Brake System (One).............................................................................. .4
FRONT BOTH (4X2) H0127 2.3
ADD:
A - To Reface Disc (Both).................................................................................................... .8
B - With Anti Lock Brake System (Both).............................................................................. .6
BRAKES H - 13
BRAKES
MODEL & TIME
NUMBER
N**, QKR
DISC ASSEMBLY, REAR - R&R OR REPLACE H0138 1.0

POLICY: A
ADD:
A - To Replace Disc Assembly (One Additional)................................................................. .7
DRUM, BRAKE - R&R OR REPLACE

POLICY: A
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.
ADD:
A - To Reface Drum (One).................................................................................................. .5
FRONT LEFT H0191 .5
ADD:
FRONT BOTH H0197 .7
ADD:
A - To Reface Drum (Two)................................................................................................... .8
REAR RIGHT H0200 .7
ADD:
REAR LEFT H0201 .7
ADD:
REAR BOTH H0207 1.0
ADD:
A - To Reface Drum (Two)................................................................................................... .8
SHOES AND LININGS, DRUM BRAKE - R&R OR REPLACE

POLICY: A
INC: R&R wheel, hub, drum and brake shoes. Clean shoes and drum.
Clean and lubricate anchor pins and cam. Adjust wheel bearings
and brake shoes.
DOES NOT INC: Reline brake shoes.
FRONT RIGHT H0240 1.0
(CONTINUED)
H - 14 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
FRONT LEFT H0241 1.0
REAR RIGHT H0250 1.3
REAR LEFT H0251 1.3
REAR BOTH H0257 1.9
ADD:
A - Full Air Brake Type (Only H0257).................................................................................. .3
SPRINGS, BRAKE SHOE RETURN AND/OR HOLD DOWN - REPLACE

NOTE: Hydraulic brake type.
REAR LEFT H0291 1.2
REAR BOTH H0297 1.4
CYLINDER, BRAKE WHEEL - R&R OR REPLACE

POLICY: A
INC: Time to recondition, adjust bearings, bleed brakes.
FRONT RIGHT H0360 1.3
FRONT LEFT H0361 1.3
REAR LEFT H0371 1.7
REAR BOTH H0377 3.0
SHIELD, REAR BRAKE DUST - R&R OR REPLACE

NOTE: Hydraulic brake type.
DRUM, RIGHT H0400 1.9
DRUM, LEFT H0401 1.9
DRUM, BOTH H0407 3.6
CAMSHAFT, BRAKE - REPLACE

FRONT LEFT H0461 .9
(CONTINUED)
BRAKES H - 15
BRAKES
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
REAR LEFT H0471 1.1
REAR BOTH H0477 1.9
ADJUSTER, BRAKE SLACK - REPLACE

FRONT LEFT H0481 .5
FRONT BOTH H0487 .8
REAR LEFT H0491 1.1
REAR BOTH H0497 1.9
CYLINDER ASSEMBLY, BRAKE MASTER - R&R H0620 .8

INC: Air bleed brake system.
ADD:
A - 1995 Cab Model............................................................................................................. .8
CYLINDER ASSEMBLY, BRAKE MASTER - REPLACE H0640 .8

ADD:
A - 1995 Cab Model............................................................................................................. .8
BRAKE SYSTEM - BLEED H0700 .6
HOSE, BRAKE - REPLACE

POLICY: A
FRONT LEFT H0721 .5
FRONT BOTH H0727 .7
SWITCH, BRAKE SYSTEM FAILURE WARNING - REPLACE H0770 .2
VALVE, LOAD SENSING PROPORTIONING, BRAKE - R&R OR REPLACE H0775 2.3
VALVE, LOAD SENSING PROPORTIONING, BRAKE - ADJUST H0777 1.7

H - 16 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
VALVE, BRAKE COMBINATION - REPLACE H0780 .6
VALVE, METERING - REPLACE H0782 .6
SENSOR, VACUUM, BRAKE - REPLACE H0783 2.5

ADD:
A - To Replace Additional One............................................................................................ .1
SENSOR, PRESSURE, BRAKE FLUID - REPLACE H0784 .4
SWITCH, LOW BRAKE FLUID WARNING - REPLACE H0785 .2
PIPE, BRAKE - REPLACE

MASTER CYLINDER TO CONNECTOR H0800 .8
MASTER CYLINDER TO METERING VALVE H0825 .7
HYDRAULIC BRAKE BOOSTER H0850 1.0
CONNECTOR TO FRONT WHEEL FLEX HOSE; RIGHT H0880 .8
CONNECTOR TO FRONT WHEEL FLEX HOSE; LEFT H0881 .8
AXLE HOUSING JUNCTION TO REAR WHEEL; RIGHT H0910 .6
AXLE HOUSING JUNCTION TO REAR WHEEL; LEFT H0911 .6
VACUUM TANK - REPLACE H0960 .5
BOOSTER ASSEMBLY, VACUUM POWER BRAKE - R&R OR REPLACE

POLICY: A
MASTER VAC MODEL H1100 3.1
ADD:
A - To Recondition Booster
( 2005 Cab Model; Vacuum Booster Cannot Be Overhauled)........................................ ST
HYDRO MASTER MODEL H1110 1.1
ADD:
A - To Recondition Booster
( 2005 Cab Model; Vacuum Booster Cannot Be Overhauled)........................................ ST
BRAKES H - 17
BRAKES
MODEL & TIME
NUMBER
N**, QKR
BOOSTER ASSEMBLY, VACUUM POWER BRAKE - REPLACE H1120 3.1

POLICY: A
BOOSTER ASSEMBLY, HYDRAULIC POWER BRAKE - R&R

POLICY: A
H.B.B. MODEL H1130 4.0
BOOSTER ASSEMBLY, HYDRAULIC POWER BRAKE - REPLACE

POLICY: A
ACCUMULATOR, HYDRAULIC POWER BRAKE BOOSTER OIL - REPLACE

POLICY: A
RESERVOIR, HYDRAULIC POWER BRAKE BOOSTER OIL - REPLACE H1145 .8
VALVE, FILTER, HOSE AND/OR PIPE, VACUUM POWER BRAKE - REPLACE H1240 .3
HOSE, AIR BRAKE - REPLACE

POLICY: A
FRONT LEFT H1701 .4
FRONT BOTH H1707 .5
REAR RIGHT H1708 .2
REAR LEFT H1709 .2
REAR BOTH H1711 .3
PARKING BRAKE ONE H1718 .2
PARKING BRAKE BOTH H1719 .3
LINE, AIR BRAKE(ONE) - REPAIR OR REPLACE H1720 .5

NOTE: THIS IS A ST (STRAIGHT TIME) OPERATION WHICH REQUIRES TIME
DOCUMENTATION AS DETAILED IN THE CLAIMS PROCESSING MANUAL.
ZONE APPROVAL IS REQUIRED BEYOND .5 HOURS.
H - 18 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
LINE, AIR BRAKE (UNDER DASH) - REPAIR OR REPLACE H1740 .5

ZONE APPROVAL IS REQUIRED BEYOND .5 HOURS.
DRYER SYSTEM, AIR BRAKE - REPAIR H1750 .5

POLICY: A
ZONE APRROVAL IS REQUIRED BEYOND .5 HOURS.
DRYER SYSTEM ASSEMBLY, AIR BRAKE - R&R OR REPLACE H1753 .5

POLICY: A
ADD:
A - To Recondition Dryer System Assembly........................................................................ .8
TANK, AIR - REPLACE H1760 1.3

ADD:
A - To Replace Additional Air Tank (One)........................................................................... .5
VALVE, BRAKE QUICK RELEASE - REPLACE

FRONT H1781 .5
REAR H1782 .5
PARKING BRAKE H1785 .4
VALVE, AIR TANK DRAIN - REPLACE H1830 .2

ADD:
A - To Replace Each Additional........................................................................................... .1
VALVE, BRAKE RELAY - REPLACE

POLICY: A
FRONT H1861 .4
REAR H1862 .7
PARKING H1863 .6
VALVE, SPRING BRAKE CONTROL - REPLACE H1900 .4

BRAKES H - 19
BRAKES
MODEL & TIME
NUMBER
N**, QKR
VALVE, BRAKE SAFETY - REPLACE H2000 .2

ADD:
VALVE, DOUBLE CHECK - REPLACE H2020 .5

ADD:
VALVE, PROTECTION, MALTI CONTROL - R&R OR REPLACE H2105 .5
COMPRESSOR, AIR - R&R

4H** H2205 3.1
ADD:
A - To Recondition Compressor ......................................................................................... 1.6
COMPRESSOR, AIR - REPLACE

4H** H2225 3.1
HEAD, COMPRESSOR, AIR - R&R OR REPLACE

4H** H2240 .8
VALVE ASSEMBLY, APPLICATION - R&R OR REPLACE

POLICY: A
RHD H2320 .7
ADD:
A - To Recondition Application Valve.................................................................................. .8
LHD H2321 .7
ADD:
A - To Recondition Application Valve.................................................................................. .8
CHAMBER, AIR, BRAKE - R&R OR REPLACE

POLICY: A
ADD:
A - To Recondition Air Chamber.......................................................................................... .2
B - Full Air Disc Brake Type................................................................................................ .1
(CONTINUED)
H - 20 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
FRONT LEFT H2381 .5
ADD:
FRONT BOTH H2387 .7
ADD:
REAR RIGHT H2390 .6
ADD:
REAR LEFT H2391 .6
ADD:
REAR BOTH H2397 .9
ADD:
G - SENSOR - REPLACE H2408 .2

NOTE: Only 4x4.
ADD:
A - Diagnosis Time.............................................................................................................. .3
SPEED SENSOR, ABS - R&R

ADD:
A - Maximum Diagnosis Time Allowed................................................................................ .6
FRONT LEFT H2411 .4
ADD:
(CONTINUED)
BRAKES H - 21
BRAKES
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
REAR RIGHT H2414 .8
ADD:
REAR LEFT H2415 .8
ADD:
REAR CENTER (IN DIFF.) H2419 .4
ADD:
RING, EXCITOR, ABS - R&R

ADD:
A - For 4x4 Model................................................................................................................ .1
B - Maximum Diagnosis Time Allowed................................................................................ .6
FRONT LEFT H2451 .7
ADD:
A - For 4x4 Model................................................................................................................ .1
B - Maximum Diagnosis Time Allowed................................................................................ .6
REAR CENTER (IN DIFFERENTIAL) H2452 2.9
ADD:
REAR RIGHT H2453 .8
ADD:
REAR LEFT H2454 .8
ADD:
HYDRAULIC UNIT, ABS - R&R OR REPLACE H2480 1.3

INC: R&R battery, Time to bleed brakes.
ADD:
A - Diagnosis Time.............................................................................................................. .3
H - 22 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
MODULATOR, EBS - REPLACE

FRONT H2483 .6
ADD:
A - Diagnosis Time.............................................................................................................. .3
REAR H2484 .7
ADD:
A - Diagnosis Time.............................................................................................................. .3
MODULATOR, AIR, ABS, FRONT - R&R OR REPLACE H2485 .4

POLICY: A
ADD:
B - Diagnosis Time.............................................................................................................. .3
MODULATOR, AIR, ABS, REAR - R&R OR REPLACE H2487 .4

POLICY: A
ADD:
B - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, ABS - REPLACE H2490 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, EBS - REPLACE H2491 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL MODULE, ABS ELECTRONIC BRAKE - R&R OR REPLACE H2506 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
PEDAL AND/OR BUSHING, BRAKE - R&R OR REPLACE H2640 .5

POLICY: A
ADD:
BRAKES H - 23
BRAKES
MODEL & TIME
NUMBER
N**, QKR
PAD, BRAKE PEDAL - REPLACE H2660 .3

POLICY: A
SPRING, BRAKE PEDAL RETURN - REPLACE H2680 .3

ADD:
PARKING BRAKE - ADJUST H2800 .4
LEVER AND/OR SUPPORT, PARKING BRAKE ASSEMBLY - R&R H2860 .4

OR REPLACE
ADD:
A - 1995 Cab Model............................................................................................................. .4
CABLE, PARKING BRAKE - REPLACE

ONE PIECE TYPE H2881 1.1
ADD:
A - With Crew Cab............................................................................................................... .5
REAR SECTION (2 PIECE) H2887 1.1
ADD:
A - With Crew Cab............................................................................................................... .5
SHOE AND/OR SUPPORT PLATE, H3000 1.1

PROPELLER SHAFT PARKING BRAKE (DRUM TYPE) INTERNAL - REPLACE
POLICY: A
ADD:
A - Two Piece Type Propeller Shaft..................................................................................... .3
LEVER, PROPELLER SHAFT PARKING BRAKE SHOE - REPLACE H3010 1.0
DRUM, PROPELLER SHAFT BRAKE - REPLACE H3070 .5

POLICY: A
ADD:
A - Two Piece Type Propeller Shaft..................................................................................... .3
H - 24 BRAKES
BRAKES
MODEL & TIME
NUMBER
N**, QKR
DRUM, PARKING BRAKE (RETARDER) ASSEMBLY - R&R OR REPLACE H3300 ST

POLICY: A
VALVE, HSA - R&R OR REPLACE H3500 1.1

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, HSA - REPLACE H3600 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, HSA&ISS - REPLACE H3601 .7

ADD:
A - Diagnosis Time.............................................................................................................. .3
J ENGINE A
B
C
D
E
F
H
J
K
L
N
R
S
U
ENGINE J - 23
ENGINE
MODEL & TIME
NUMBER
N**, QKR
MANIFOLD AND/OR GASKET, EXHAUST - REPLACE

POLICY: E, P
4J** J0103 .6
ADD:
A - 4JH1 (W/O Common Rail) Engine................................................................................. 1.6
B - With Crew Cab............................................................................................................... .8
C - 4JH1 (W/Common Rail) Engine ................................................................................... .8
4B** J0104 1.6
ADD:
A - 4BD2-TC Engine............................................................................................................ .6
B - With Crew Cab............................................................................................................... 1.0
4H** J0105 1.0
ADD:
A - 4HE1-TC Engine............................................................................................................ 1.1
B - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... 1.9
C - 4HK1 Engine Fitted 2005/2008 Cab Models
(EXC. <Euro4 Specification> Fitted 2005 Cab Model)................................................... 1.4
D - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)..................................... .7
E - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)............................................... .3
F - With Crew Cab............................................................................................................... 1.0
4JJ1 J0113 2.6
ADD:
A - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... .5
B - With Crew Cab............................................................................................................... 1.0
RZ4E J0115 2.3
4HL1 J0118 1.8
MANIFOLD AND/OR GASKET, INTAKE - REPLACE

POLICY: P
4J** J0203 1.0
ADD:
B - With Crew Cab............................................................................................................... .5
C - 4JB1/4JG2 Engines....................................................................................................... .2
(CONTINUED)
J - 24 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4B** J0204 1.2
ADD:
A - 4BD1 Engine.................................................................................................................. .5
B - With Crew Cab............................................................................................................... 3.2
4H** J0205 1.2
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... 1.6
B - 4HK1 Engine Fitted 2005/2008 Cab Models
C - With Crew Cab.............................................................................................................. 3.2
D - 4HV1 Engine.................................................................................................................. .2
4JJ1 J0213 1.7
ADD:
B - With A/C......................................................................................................................... .4
C - With Crew Cab.............................................................................................................. 3.2
D - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .4
RZ4E J0216 1.8
4HL1 J0217 2.0
CASE, INLET EGR - REPLACE J0230 1.7

ADD:
A - With Crew Cab............................................................................................................... 3.2
PUMP AND/OR GASKET, VACUUM - R&R OR REPLACE J0240 .7

ADD:
A - 4HK1 Engine (Generator Tandem Type)....................................................................... .3
B - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... .7
C - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model
(EXC. Generator Tandem Type)..................................................................................... 1.8
D - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... .6
E - 4HK1 Engine Fitted 2005/2008 Cab Models (EXC. <Euro4 Specification>
Fitted 2005 Cab Model) (EXC. Generator Tandem Type).............................................. 1.4
F - 4JJ1 Engine Fitted 2005/2008 Cab Models
(EXC. <Euro4 Specification> Fitted 2005 Cab Model)................................................... .4
(CONTINUED)
ENGINE J - 25
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
G - To Recondition Vacuum Pump (4JJ1 Engine)............................................................... .4
H - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .1
RZ4E J0241 .3
FLEXIBLE PIPE, VACUUM PUMP - REPLACE

DIESEL J0245 .3
ADD:
GASKET, CAM END - REPLACE

4H** J0291 .4
ADD:
C - 4HV1 Engine.................................................................................................................. .2
D - With Crew Cab.............................................................................................................. 1.9
4JJ1 J0293 .8
ADD:
B - With Crew Cab............................................................................................................... 1.9
4HL1 J0294 .7
COVER AND/OR GASKET, ROCKER - REPLACE

4J** J0303 .3
ADD:
A - 4JH1 (W/O Common Rail) Engine................................................................................. .6
B - With Crew Cab............................................................................................................... .1
C - 4JB1/4JG2 Engines....................................................................................................... .2
4B** J0304 .4
ADD:
A - With Crew Cab............................................................................................................... 1.9
4H** J0305 .4
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .8
(CONTINUED)
J - 26 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
C - With Crew Cab.............................................................................................................. 1.9
D - 4HV1 Engine.................................................................................................................. .1
4JJ1 J0313 .7
ADD:
B - With Crew Cab............................................................................................................... 1.9
C - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .5
RZ4E J0315 1.4
4HL1 J0318 .4
COVER AND/OR GASKET, PUSH ROD SIDE - REPLACE

ONE 4B** J0324 .5
ADD:
A - To Replace All Covers................................................................................................... .3
B - With Crew Cab............................................................................................................... 1.9
ROCKER ARM - REPLACE

INC: R&R rocker cover and install new gasket.
4J** J0353 .5
ADD:
A - With Crew Cab............................................................................................................... .2
B - 4JH1 (W/O Common Rail) Engine................................................................................. .6
C - 4JB1/4JG2 Engines....................................................................................................... .2
4B** J0354 .8
ADD:
A - With Crew Cab............................................................................................................... 1.9
4H** J0355 1.0
ADD:
C - With Crew Cab.............................................................................................................. 1.9
D - 4HV1 Engine.................................................................................................................. .1
(CONTINUED)
ENGINE J - 27
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4JJ1 J0363 2.3
ADD:
B - With Crew Cab............................................................................................................... 1.9
C - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ 1.6
RZ4E J0365 2.2
4HL1 J0368 1.2
VALVE LASH - ADJUST

4J** J0423 .4
ADD:
B - With Crew Cab............................................................................................................... .2
C - 4JB1/4JG2 Engines....................................................................................................... .2
4B** J0424 .8
ADD:
A - With Crew Cab............................................................................................................... 1.9
4H** J0425 .8
ADD:
C - With Crew Cab.............................................................................................................. 1.9
D - 4HV1 Engine.................................................................................................................. .2
4HL1 J0429 .9
4JJ1 J0433 1.1
ADD:
B - With Crew Cab............................................................................................................... 1.9
C - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .5
GASKET, CYLINDER HEAD - REPLACE

INC: R&R rocker cover, loosen rocker arms and remove push rods.
D&C exhaust pipe and make all necessary adjustments.
4HL1 J0493 5.6
(CONTINUED)
J - 28 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
RZ4E J0496 6.7
4J** J0503 3.0
ADD:
A - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... 5.5
B - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
C - 4JB1-T/4JH1 (W/O Common Rail) Engines.................................................................. 1.5
D - With EGR Cooler (4JH1 Engine) .................................................................................. .5
E - With A/C. (4JB1/4JG2/4JH1 Engines)........................................................................... .7
F - With A/C. (4JJ1 Engine)................................................................................................. .5
G - With Crew Cab (4JJ1 Engine)....................................................................................... 3.4
H - 4JB1-NA/4JG2 Engines................................................................................................. .5
J - 4JJ1 (W/O Cam End Gasket) Engine............................................................................. 3.5
K - With Crew Cab (4JB1/4JH1 Engines)............................................................................ 1.5
4B** J0504 4.2
ADD:
A - With Crew Cab............................................................................................................... 3.4
4H** J0505 3.6
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 2.6
C - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... 4.4
D - 4HK1 Engine Fitted 2005/2008 Cab Models
E - With A/C. (4H** Engines <EXC. 4HK1 Engine Fitted 2005/2008 Cab Models>)........... .7
F - With A/C. (4HK1 Engine <Euro4 Specification> Fitted 2005 Cab Model)...................... .4
G - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)
H - With Crew Cab.............................................................................................................. 3.4
J - To Replace Nozzle Sleeves (All).................................................................................... 1.4
ENGINE J - 29
ENGINE
MODEL & TIME
NUMBER
N**, QKR
HEAD, CYLINDER - REPLACE

POLICY: P
INC: R&R rocker cover, loosen rocker arms and remove push rods.
D&C exhaust pipe and make all necessary adjustments.
4HL1 J0510 9.5
4J** J0513 5.3
ADD:
B - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Model
D - With EGR Cooler (4JH1 Engine)................................................................................... .5
E - With A/C. (4JB1/4JG2/4JH1 Engines)........................................................................... .7
H - 4JH1 (W/Common Rail) Engine.................................................................................... .4
J - 4JJ1 (W/O Cam End Gasket) Engine............................................................................. 6.0
K - With Crew Cab (4JB1/4JH1 Engines)............................................................................ 1.4
4B** J0514 7.4
ADD:
A - With Crew Cab............................................................................................................... 2.8
4H** J0515 5.4
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
D - 4HK1 Engine Fitted 2005/2008 Cab Models
E - With A/C. (4H** Engines <EXC. 4HK1 Engine Fitted 2005/2008 Cab Models>)........... .7
F - With A/C. (4HK1 Engine <Euro4 Specification> Fitted 2005 Cab Model)...................... .4
G - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)
H - With Crew Cab.............................................................................................................. 2.8
RZ4E J0516 9.9
J - 30 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
VALVE - RECONDITION OR REPLACE

INC: R&R rocker cover, rocker arms, push rods, cylinder head, recondition
valve seat and replace valve seal and make all necessary adjustments.
ONE CYLINDER; 4J** J0523 3.5
ADD:
A - To Recondition Valves One Additional Cylinder (INC: Replace valves as necessary).. .5
B - To Recondition All Valves (INC: Replace valves as necessary).................................... 1.3
D - With EGR Cooler........................................................................................................... .5
E - With A/C......................................................................................................................... .7
F - With Crew Cab............................................................................................................... 2.8
G - 4JB1-NA/4JG2 Engines................................................................................................. .3
ONE CYLINDER; 4B** J0524 4.6
ADD:
A - To Recondition Valves One Additional Cylinder (INC: Replace valves as necessary).. .5
B - To Recondition All Valves (INC: Replace valves as necessary).................................... 1.3
C - With Crew Cab.............................................................................................................. 2.6
ONE CYLINDER; 4H** J0525 4.7
ADD:
A - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 2.3
D - To Recondition Valves One Additional Cylinder (EXC. 4HK1 Engine)
(INC: Replace valves as necessary) ............................................................................. .5
E - To Recondition Valves One Additional Cylinder (4HK1 Engine)
(INC: Replace valves as necessary) ............................................................................. 1.0
F - To Recondition All Valves (EXC. 4HK1 Engine)
G - To Recondition All Valves (4HK1 Engine)
H - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)..................................... .7
J - With A/C. (4HK1 Engine <Euro4 Specification> Fitted 2005 Cab Model)...................... .4
K - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)
L - With Crew Cab............................................................................................................... 2.6
(CONTINUED)
ENGINE J - 31
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
ONE CYLINDER; RZ4E J0532 7.4
ADD:
A - To Recondition All Valves.............................................................................................. 2.2
ONE CYLINDER; 4JJ1 J0533 7.7
ADD:
B - To Recondition Valves One Additional Cylinder (INC: Replace valves as necessary).. 1.1
C - To Recondition All Valves (INC: Replace valves as necessary).................................... 3.2
D - With A/C........................................................................................................................ .5
E - With Crew Cab............................................................................................................... 2.6
F - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
ONE CYLINDER; 4HL1 J0536 6.3
ADD:
A - To Recondition Valves One Additional Cylinder............................................................ 1.0
B - To Recondition All Valves.............................................................................................. 2.6
SPRING, CAP AND/OR SEAL, VALVE - REPLACE

ADD:
A - To Replace Springs, Caps and/or Seals One Additional Cylinder................................. .4
B - To Replace Springs, Caps and/or Seals Two Additional Cylinder................................. .6
C - To Replace All Springs, Caps and/or Seals................................................................... .8
D - With Crew Cab (4JH1 <W/Common Rail> Engine) ...................................................... 2.2
E - 4JH1 (W/Common Rail) Engine .................................................................................... 2.2
F - With Crew Cab (4JB1/4JH1 <W/O Common Rail> Engines)......................................... .2
ADD:
C - To Replace All Springs, Caps and/or Seals................................................................... .8
D - With Crew Cab.............................................................................................................. 1.9
ADD:
A - 4HK1 Engine Fitted 1995 Cab Model............................................................................ .4
(CONTINUED)
J - 32 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - To Replace Springs, Caps and/or Seals One Additional Cylinder................................. .4
E - To Replace Springs, Caps and/or Seals Two Additional Cylinder
(EXC. 4HK1 Engine)....................................................................................................... .6
F - To Replace Springs, Caps and/or Seals Two Additional Cylinder (4HK1 Engine)......... 1.3
G - To Replace All Springs, Caps and/or Seals (EXC. 4HK1 Engine)................................. .8
H - With Crew Cab.............................................................................................................. 1.9
J - To Replace Springs, Caps and/or Seals One Additional Cylinder (4HK1 Engine)......... .7
K - To Replace All Springs, Caps and/or Seals (4HK1 Engine).......................................... 1.9
ADD:
B - To Replace Springs, Caps and/or Seals One Additional Cylinder................................. .7
C - To Replace Springs, Caps and/or Seals Two Additional Cylinder................................. 1.3
D - To Replace All Springs, Caps and/or Seals................................................................... 1.9
E - With Crew Cab............................................................................................................... 1.9
F - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
G - With A/C........................................................................................................................ .5
ADD:
C - To Replace All Springs, Caps and/or Seals................................................................... 1.1
ADD:
B - To Replace Springs, Caps and/or Seals Two Additional Cylinder................................. 1.3
C - To Replace All Springs, Caps and/or Seals................................................................... 1.9
ADJUSTER, VALVE LASH - REPLACE

RZ4E J0561 2.2
ENGINE J - 33
ENGINE
MODEL & TIME
NUMBER
N**, QKR
PUSH ROD - REPLACE

ONE CYLINDER; 4J** J0583 .5
ADD:
A - To Replace All Push Rods............................................................................................. .2
B - With Crew Cab............................................................................................................... .2
C - 4JB1/4JG2 Engines....................................................................................................... .2
D - 4JH1 (W/O Common Rail) Engine................................................................................. .6
ONE CYLINDER; 4B** J0584 .8
ADD:
A - To Replace All Push Rods............................................................................................. .2
B - With Crew Cab............................................................................................................... 1.9
LIFTER, VALVE - REPLACE

INC: R&R engine assembly.
ADD:
A - With A/C......................................................................................................................... .5
B - To Replace All Lifters..................................................................................................... .2
C - With Crew Cab.............................................................................................................. 1.0
D - With Noise Cover........................................................................................................... .6
E - 4JH1 (W/Common Rail) Engine..................................................................................... .5
ADD:
A - With A/C......................................................................................................................... .6
B - To Replace All Lifters..................................................................................................... .2
C - With Crew Cab.............................................................................................................. 3.7
E - Automatic Transmission................................................................................................. .8
BELT, DRIVE - ADJUST

NOTE: Without serpentine type.
ONE; 4J** J0653 .3
ADD:
A - To Adjust All Belts.......................................................................................................... .2
B - With Crew Cab............................................................................................................... .1
(CONTINUED)
J - 34 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
ONE; 4B** J0654 .3
ADD:
B - With Crew Cab............................................................................................................... .1
ONE; 4H** J0655 .3
ADD:
B - With Crew Cab............................................................................................................... .1
BELT, DRIVE - REPLACE

POLICY: A
A/C J0660 .4
ADD:
A - With Crew Cab............................................................................................................... .3
FAN GENERATOR J0663 .4
ADD:
C - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .1
SERPENTINE J0667 .3
TENSIONER, SERPENTINE BELT - R&R OR REPLACE J0680 .3
TENSIONER, DRIVE BELT - R&R OR REPLACE J0681 .3

ADD:
A - To Replace Bearing....................................................................................................... .1
PULLEY, CRANKSHAFT - REPLACE

4J** J0703 .7
ADD:
A - With Crew Cab............................................................................................................... .5
B - With Noise Cover........................................................................................................... .6
4B** J0704 .7
ADD:
A - With Crew Cab............................................................................................................... 1.0
(CONTINUED)
ENGINE J - 35
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4H** J0705 1.2
ADD:
A - With Crew Cab............................................................................................................... 1.0
RZ4E J0712 1.1
4JJ1 J0713 1.6
ADD:
B - With Crew Cab............................................................................................................... 1.0
C - Six Crank Pulley Bolt Type............................................................................................ .3
4HL1 J0716 .8
SEAL, CRANKCASE FRONT COVER - REPLACE

4HL1 J0735 1.0
RZ4E J0738 1.2
4H** J0745 1.3
ADD:
A - With A/C......................................................................................................................... .1
B - With Crew Cab............................................................................................................... 1.0
SEAL, TIMING COVER OIL - REPLACE (GEAR TYPE)

INC: R&R harmonic balancer.
4J** J0753 .8
ADD:
A - With Crew Cab............................................................................................................... .8
4B** J0754 1.0
ADD:
A - With Crew Cab............................................................................................................... 1.2
4JJ1 J0755 2.5
ADD:
B - With Crew Cab............................................................................................................... 1.0
J - 36 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
COVER AND/OR GASKET, CRANKCASE FRONT - REPLACE

INC: R&R engine assembly. (RZ4E Engine)
4HL1 J0758 4.6
RZ4E J0759 14.9
ADD:
A - With Smoother............................................................................................................... .7
4H** J0760 3.1
ADD:
A - With Crew Cab............................................................................................................... 1.2
C - 4H** Engines (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)............................... 1.1
D - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .6
COVER AND/OR GASKET, TIMING - REPLACE

4J** J0783 1.1
ADD:
A - With Crew Cab............................................................................................................... 1.1
C - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines............................................................ .7
4B** J0784 1.9
ADD:
A - With Crew Cab............................................................................................................... 1.2
4JJ1 J0785 3.2
ADD:
B - With Crew Cab............................................................................................................... 1.2
HOUSING AND/OR GASKET, TIMING PULLEY - REPLACE

INC: R&R engine assembly. (4JJ1 Engine)
4JJ1 J0790 11.7
ADD:
B - With Crew Cab............................................................................................................... 3.7
(CONTINUED)
ENGINE J - 37
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
C - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
D - With Smoother............................................................................................................... .2
E - With A/C......................................................................................................................... .5
F - For 4x4 Model................................................................................................................ 1.0
4J** J0793 2.4
ADD:
A - With Crew Cab............................................................................................................... 1.4
4B** J0794 5.5
ADD:
A - With Crew Cab............................................................................................................... 1.2
GEAR, IDLER TIMING - REPLACE

INC: R&R engine assembly. (4H**/RZ4E Engines)
4JJ1 J0822 3.3
ADD:
B - To Replace Idle Gear "B"............................................................................................... .2
C - With Crew Cab.............................................................................................................. 1.2
D - Six Crank Pulley Bolt Type............................................................................................ .4
4J** J0823 1.4
ADD:
A - To Replace Idle Gear "B"............................................................................................... .2
B - With Crew Cab............................................................................................................... 1.8
C - With Noise Cover........................................................................................................... .6
D - 4JB1/4JH1 (W/O Common Rail) Engine....................................................................... .4
4B** J0824 1.9
ADD:
A - To Replace Idle Gear "B"............................................................................................... .2
B - With Crew Cab............................................................................................................... 2.2
(CONTINUED)
J - 38 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4H** J0825 11.9
ADD:
A - 4H** Engines (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)................................ .6
C - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model).................................. 1.3
D - To Replace Idle Gear "B"............................................................................................... .2
E - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)...................................... .8
F - With Crew Cab............................................................................................................... 2.2
G - With Noise Cover.......................................................................................................... .6
H - For 4x4 Manual Transmission Model............................................................................. 1.0
J - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
K - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)............................................... .2
L - Automatic Transmission (1992 To 1997 Model)............................................................. 1.2
M - Automatic Transmission (EXC. 1992 To 1997 Model).................................................. .4
N - For 4x4 Smoother Model............................................................................................... .8
RZ4E J0826 12.4
ADD:
A - To Replace Idle Gear (One Additional).......................................................................... .1
B - With Smoother............................................................................................................... .7
4HL1 J0827 10.1
ADD:
A - To Replace Idle Gear (One Additional).......................................................................... .1
GEAR, CRANKSHAFT TIMING - REPLACE

RZ4E J0829 16.9
ADD:
A - With Smoother............................................................................................................... .7
4HL1 J0830 14.5
4J** J0833 1.5
ADD:
B - 4JJ1 Engine Fitted 2005/2008 Cab Models
C - With Crew Cab (4JJ1 Engine)....................................................................................... 1.2
(CONTINUED)
ENGINE J - 39
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
E - For 4x4 Model................................................................................................................ 1.0
F - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines............................................................ .5
G - Six Crank Pulley Bolt Type (4JJ1 Engine)..................................................................... .4
H - With Crew Cab (4JB1/4JH1 Engines)............................................................................ 1.8
4B** J0834 2.0
ADD:
A - With Crew Cab............................................................................................................... 2.2
4H** J0835 16.3
ADD:
A - 4H** Engines
(EXC. 4HE1-TC Engine and 4HK1 Engine Fitted 2005/2008 Cab Models).................... .3
C - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model).................................. 1.3
D - With Crew Cab.............................................................................................................. 3.7
E - With Noise Cover........................................................................................................... .6
F - For 4x4 Manual Transmission Model............................................................................. 1.0
G - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
H - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)............................................... .2
J - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)...................................... .8
K - Automatic Transmission (1992 To 1997 Model)............................................................ 1.2
L - Automatic Transmission (EXC. 1992 To 1997 Model)................................................... .4
M - 4HE1-TC Engine........................................................................................................... 1.0
GEAR, CAMSHAFT TIMING - REPLACE

NOTE: EXC. 4JJ1 Engine.
4HL1 J0840 1.9
4H** J0841 1.1
ADD:
(CONTINUED)
J - 40 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - With Crew Cab.............................................................................................................. 1.9
E - 4HV1 Engine.................................................................................................................. .4
4J** J0843 1.5
ADD:
A - With Crew Cab............................................................................................................... 1.8
4B** J0844 2.2
ADD:
A - With Crew Cab............................................................................................................... 1.9
CAMSHAFT - REPLACE
INC: R&R radiator, harmonic balancer, cover and seal. Replace
camshaft gear if necessary. Adjust valves.
INC: R&R engine assembly. (EXC.4JJ1/4H** Engines)
4HL1 J0850 1.9
4J** J0853 1.2
ADD:
A - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines............................................................ 4.9
B - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... .2
C - To Replace All Valve Lifter............................................................................................ .2
D - To Replace One Additional (4JJ1 <W/Cam End Gasket> Engine)................................ .5
E - With A/C. (Engine Remove Work Only)......................................................................... .6
F - With Crew Cab (4JJ1 Engine)........................................................................................ 1.9
H - 4JH1 (W/Common Rail) Engine ................................................................................... 5.9
J - 4JJ1 (W/O Cam End Gasket) Engine............................................................................. .6
K - To Replace One Additional (4JJ1 <W/O Cam End Gasket> Engine)............................ .1
L - With Crew Cab (4JB1/4JH1 Engines)............................................................................ 1.0
4B** J0854 4.8
ADD:
A - To Replace All Valve Lifter............................................................................................. 1.2
B - With A/C......................................................................................................................... .6
C - With Crew Cab.............................................................................................................. 3.7
(CONTINUED)
ENGINE J - 41
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
E - Automatic Transmission................................................................................................. .8
4H** J0855 1.1
ADD:
D - With Crew Cab.............................................................................................................. 1.9
E - 4HV1 Engine.................................................................................................................. .4
TENSIONER ASSEMBLY, AND/OR GASKET TIMING CHAIN - REPLACE

4JJ1 J0865 1.5
ADD:
B - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .2
CHAIN, TIMING - REPLACE

4JJ1 J0866 2.4
ADD:
A - With A/C......................................................................................................................... .4
B - To Replace Sprocket (Supply Pump Side).................................................................... .6
C - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... 1.0
D - With Crew Cab.............................................................................................................. 1.2
E - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
LEVER, TIMING CHAIN - REPLACE

4JJ1 J0867 2.5
ADD:
A - With A/C......................................................................................................................... .4
B - To Replace Chain Guide................................................................................................ .3
C - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... 2.1
D - With Crew Cab.............................................................................................................. 1.2
(CONTINUED)
J - 42 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
CARRIER, CAMSHAFT - R&R

RZ4E J0872 2.0
ADD:
A - To Replace Camshaft Carrier........................................................................................ .5
B - To Replace Intake Camshaft......................................................................................... .3
C - To Replace Exhaust Camshaft...................................................................................... .2
TENSIONER ASSEMBLY, AND/OR GASKET TIMING CHAIN - REPLACE

RZ4E J0880 .2
CHAIN, TIMING - R&R OR REPLACE

INC: R&R engine assembly. (RZ4E Engine)
RZ4E J0885 12.3
ADD:
A - To Replace Timing Chain Guide.................................................................................... .1
B - With Smoother............................................................................................................... .7
LEVER, TIMING CHAIN - R&R OR REPLACE

RZ4E J0899 1.7
CAP, OIL FILLER - REPLACE J0900 .3
TUBE, DIPSTICK - REPLACE J0930 .2

ADD:
A - Non Tilt Cab................................................................................................................... .6
B - 4JH1 (W/O Common Rail) Engine................................................................................. .2
C - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... .2
D - 4JH1 (W/Common Rail) Engine ................................................................................... .3
E - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .3
F - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .4
G - RZ4E Engine................................................................................................................. .1
ENGINE J - 43
ENGINE
MODEL & TIME
NUMBER
N**, QKR
DRAIN PLUG AND/OR GASKET, OIL, ENGINE - REPLACE J0931 .4
BEARINGS, CAMSHAFT - REPLACE J0945 1.0

ADD:
A - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines............................................................ 5.4
B - 4HK1 Engine Fitted 1995 Cab Model............................................................................ .3
C - With Crew Cab (4H** Engines)...................................................................................... 1.9
D - With Noise Cover (Engine Remove Work Only)............................................................ .6
E - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... 1.2
F - 4HK1 Engine Fitted 2005/2008 Cab Models
G - 4HV1 Engine................................................................................................................. .4
H - 4JH1 (W/Common Rail) Engine ................................................................................... 6.4
J - With Crew Cab (4JB1/4JH1 Engines)............................................................................ 1.0
K - With A/C. (Engine Remove Work Only)......................................................................... .6
L - With Crew Cab (4B** Engines)....................................................................................... 3.7
M - Automatic Transmission (4B** Engines)....................................................................... .8
N - 4HL1 Engine.................................................................................................................. .9
FILTER, OIL - REPLACE

POLICY: A
RZ4E J0948 .3
4J** J0953 .4
ADD:
A - With Noise Cover........................................................................................................... .6
4B** J0954 .4
ADD:
4H** J0955 .5
ADD:
ADAPTER, OIL FILTER - REPLACE J0961 .5

ADD:
A - With Crew Cab............................................................................................................... .5
(CONTINUED)
J - 44 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - RZ4E Engine................................................................................................................. .7
E - 4HL1 Engine.................................................................................................................. .4
OIL PIPE, COOLER TO FILTER - REPLACE

4BE1 J0962 .4
COVER, OIL PAN - REPLACE

4J** J0985 1.4
ADD:
PAN AND/OR GASKET, OIL - REPLACE

4HL1 J0986 .9
RZ4E J0989 .8
4J** J0992 .8
ADD:
A - 4JB1/4JG2 Engines ...................................................................................................... .8
B - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... .3
C - With Oil Pan Cover........................................................................................................ 1.2
E - For 4x4 Model................................................................................................................ .2
F - 4JJ1 Engine Fitted 2005/2008 Cab Models
G - 4JH1 (W/O Common Rail) Engine................................................................................ .3
4B** J0993 2.0
ADD:
A - With Oil Pan Cover........................................................................................................ 1.2
4H** J0997 .9
ADD:
A - 4H** Engines (EXC. 4HK1 Engine)................................................................................ .2
C - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .2
(CONTINUED)
ENGINE J - 45
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
E - For 4x4 Model................................................................................................................ .2
CRANKCASE OR MAIN PAN AND/OR GASKET, OIL - REPLACE

POLICY: P
INC: R&R engine assembly or front axle case assembly,
clean oil pump screen.
4JJ1 J1001 13.1
ADD:
B - With A/C......................................................................................................................... .5
C - For 4x4 Model................................................................................................................ 1.0
D - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
E - With Smoother............................................................................................................... .2
F - With Crew Cab............................................................................................................... 3.7
RZ4E J1006 13.7
ADD:
A - With Smoother............................................................................................................... .7
GEAR, OIL PUMP DRIVE - R&R OR REPLACE

4J** J1013 1.0
ADD:
A - To Replace Pump Seal.................................................................................................. .2
4B** J1014 2.3
ADD:
A - To Replace Pump Seal.................................................................................................. .2
PUMP, ENGINE OIL - REPLACE

NOTE: 4H**/RZ4E engines, include R&R engine assembly, R&R cylinder head assembly,
oil pan and flywheel housing.
4HL1 J1018 10.1
(CONTINUED)
J - 46 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
RZ4E J1019 14.4
ADD:
A - With Smoother............................................................................................................... .7
4JJ1 J1022 3.1
ADD:
B - With Crew Cab............................................................................................................... 1.2
C - For 4x4 Model................................................................................................................ 1.0
D - Six Crank Pulley Bolt Type............................................................................................ .4
4J** J1023 .9
ADD:
4B** J1024 2.3
ADD:
4H** J1026 11.9
ADD:
A - 4HE1-TC Engine............................................................................................................ 1.0
B - 4H** Engines
D - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model).................................. 1.3
E - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)...................................... .8
F - With A/C. (4HK1 Engine) Fitted 2005/2008 Cab Models............................................... .2
G - With Crew Cab.............................................................................................................. 2.2
H - With Noise Cover........................................................................................................... .6
J - For 4x4 Manual Transmission Model.............................................................................. 1.0
K - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
ENGINE J - 47
ENGINE
MODEL & TIME
NUMBER
N**, QKR
STRAINER, OIL - REPLACE

INC: R&R engine assembly. (4JJ1 Engine)
4J** J1034 .9
ADD:
D - For 4x4 Model................................................................................................................ 1.0
E - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ 12.3
H - With Smoother............................................................................................................... .2
4H** J1035 .9
ADD:
A - 4H** Engines (EXC. 4HK1 Engine)................................................................................ .4
D - For 4x4 Model................................................................................................................ .2
E - 4HK1 Engine Fitted 1995 Cab Model............................................................................ .7
RZ4E J1038 1.1
4HL1 J1039 .9
VALVE, RELIEF, OIL FILTER - REPLACE

4J** J1060 .4
ADD:
VALVE, CHECK, OIL - REPLACE

RZ4E J1070 .7
TANK ASSEMBLY, OIL CATCH - R&R OR REPLACE J1092 .3

J - 48 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
SEALS, CRANKSHAFT REAR MAIN - REPLACE

INC: R&R transmission.
4JJ1 J1119 2.8
ADD:
B - For 4x4 Model................................................................................................................ 1.0
C - With Smoother............................................................................................................... .2
4J** J1123 4.4
ADD:
4B** J1124 4.4
ADD:
A - Automatic Transmission................................................................................................. .8
4H** J1125 2.8
ADD:
A - EXC. 4HL1 Engine and 4HK1 Engine Fitted 2005/2008 Cab Models............................ 1.6
C - For 4x4 Manual Transmission Model............................................................................. 1.0
F - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
G - Automatic Transmission (1992 To 1997 Model)............................................................ 1.7
H - Automatic Transmission (1998 To 2006 Model)............................................................ 1.0
J - Automatic Transmission (EXC. 1992 To 2006 Model).................................................... .4
K - For 4x4 Smoother Model................................................................................................ .8
RZ4E J1131 2.8
ADD:
A - With Smoother............................................................................................................... .7
BEARING, CRANKSHAFT MAIN - REPLACE

POLICY: P
INC; R&R engine assembly, oil pan and flywheel housing,
plastic type gauge bearing.
4HL1 J1145 14.5
(CONTINUED)
ENGINE J - 49
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
RZ4E J1149 16.8
ADD:
A - With Smoother............................................................................................................... .7
ONE BEARING; 4JJ1 J1152 14.4
ADD:
B - To Replace Main Bearings (One Additional).................................................................. .3
C - To Replace Main Bearings (Two Additional).................................................................. .5
D - To Replace All Main Bearings....................................................................................... 1.0
E - To Replace Connecting Rod Bearings (One Additional)................................................ .2
F - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
G - To Replace All Connecting Rod Bearings..................................................................... .6
H - With A/C........................................................................................................................ .5
J - With Crew Cab............................................................................................................... 3.7
K - For 4x4 Model................................................................................................................ 1.0
L - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
M - With Smoother.............................................................................................................. .2
ONE BEARING; 4J** J1153 8.0
ADD:
A - To Replace Main Bearings (One Additional).................................................................. .3
B - To Replace Main Bearings (Two Additional).................................................................. .5
C - To Replace All Main Bearings....................................................................................... 1.0
D - To Replace Connecting Rod Bearings (One Additional)............................................... .2
E - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
F - To Replace All Connecting Rod Bearings...................................................................... .6
G - With A/C. (Engine Remove Work Only)........................................................................ .8
H - With Crew Cab.............................................................................................................. 1.2
J - With Noise Cover........................................................................................................... .6
K - 4JH1 (W/Common Rail) Engine .................................................................................... 2.7
ONE BEARING; 4B** J1154 8.0
ADD:
A - To Replace Main Bearings (One Additional).................................................................. .3
B - To Replace Main Bearings (Two Additional).................................................................. .5
C - To Replace All Main Bearings....................................................................................... 1.0
(CONTINUED)
J - 50 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - To Replace Connecting Rod Bearings (One Additional)............................................... .2
E - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
F - To Replace All Connecting Rod Bearings...................................................................... .6
G - Automatic Transmission................................................................................................ .8
H - With A/C........................................................................................................................ .8
J - With Crew Cab............................................................................................................... 3.7
K - With Noise Cover........................................................................................................... .6
4H** J1155 16.3
ADD:
A - 4HE1-TC Engine............................................................................................................ 1.0
C - To Replace Connecting Rod Bearings (One Additional)............................................... .2
D - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
E - To Replace All Connecting Rod Bearings...................................................................... .6
F - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model).................................. 1.3
G - With A/C. (Engine Remove Work Only)
(EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)....................................................... .8
J - With Crew Cab............................................................................................................... 3.7
L - For 4x4 Manual Transmission Model............................................................................. 1.0
M - 4H** Engines
N - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
P - Automatic Transmission (1992 To 1997 Model)............................................................ 1.2
Q - Automatic Transmission (EXC. 1992 To 1997 Model)................................................... .4
R - For 4x4 Smoother Model............................................................................................... .8
ENGINE J - 51
ENGINE
MODEL & TIME
NUMBER
N**, QKR
BEARING, CONNECTING ROD - REPLACE

POLICY: P
INC: R&R oil pan, oil pump, plastic type gauge bearings ,
clean and inspect oil pump and pan.
R&R engine assembly. (4JJ1 Engine)
ONE BEARING; 4J** J1183 1.0
ADD:
C - To Replace Connecting Rod Bearings (One Additional)............................................... .3
D - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
E - To Replace All Connecting Rod Bearings...................................................................... .6
J - For 4x4 Model................................................................................................................. 1.0
K - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ 12.2
L - With Smoother............................................................................................................... .2
ONE BEARING; 4B** J1184 2.3
ADD:
A - To Replace Connecting Rod Bearings (One Additional)................................................ .3
B - To Replace Connecting Rod Bearings (Two Additional)................................................ .4
C - To Replace All Connecting Rod Bearings..................................................................... .6
ONE BEARING; 4H** J1185 2.3
ADD:
E - For 4x4 Model................................................................................................................ .2
F - 4HK1 Engine Fitted 1995 Cab Model............................................................................. .3
ONE BEARING; RZ4E J1191 14.6
ADD:
(CONTINUED)
J - 52 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - With Smoother............................................................................................................... .7
ONE BEARING; 4HL1 J1196 2.3
ADD:
CRANKSHAFT - REPLACE
POLICY: P
NOTE: EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 cab models.
INC: R&R engine assembly. R&R cylinder head assembly, oil pan and flywheel
housing, plastic type gauge bearings.
4J** J1203 8.0
ADD:
A - To Replace Rod and/or Pin Only (One)......................................................................... .4
B - To Replace Rod and/or Pin Only (Two)......................................................................... .7
C - To Replace Rod and/or Pin Only (All)............................................................................ 1.1
D - To Replace Cylinder Head............................................................................................. 2.5
E - To Recondition or Replace All Valve............................................................................. 1.7
F - To Replace Piston, Rod and/or Rings (One).................................................................. .4
G - To Replace Piston, Rod and/or Rings (Two)................................................................. .7
H - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
J - To Replace Cylinder Liner (One).................................................................................... .6
K - To Replace Cylinder Liner (Two)................................................................................... 1.2
L - To Replace Cylinder Liner (All)...................................................................................... 1.9
M - With A/C........................................................................................................................ .8
N - With Crew Cab.............................................................................................................. 1.2
P - With Noise Cover........................................................................................................... .6
Q - 4JH1 (W/Common Rail) Engine ................................................................................... 3.1
4B** J1204 8.0
ADD:
A - To Replace Rod and/or Pin Only (One)......................................................................... .4
B - To Replace Rod and/or Pin Only (Two)......................................................................... .7
(CONTINUED)
ENGINE J - 53
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
C - To Replace Rod and/or Pin Only (All)............................................................................ 1.1
D - To Replace Cylinder Head............................................................................................. 2.5
E - To Recondition or Replace All Valve............................................................................. 1.7
F - To Replace Piston, Rod and/or Rings (One).................................................................. .4
G - To Replace Piston, Rod and/or Rings (Two)................................................................. .7
H - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
J - To Replace Cylinder Liner (One).................................................................................... .6
K - To Replace Cylinder Liner (Two)................................................................................... 1.2
L - To Replace Cylinder Liner (All)...................................................................................... 1.9
M - Automatic Transmission................................................................................................ .8
N - With A/C........................................................................................................................ .8
P - With Crew Cab............................................................................................................... 3.7
Q - With Noise Cover.......................................................................................................... .6
4H** J1205 16.6
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - To Replace Rod and/or Pin Only (One)......................................................................... .4
C - To Replace Rod and/or Pin Only (Two)......................................................................... .7
D - To Replace Rod and/or Pin Only (All)............................................................................ 1.1
E - To Replace Cylinder Head............................................................................................. 2.5
F - To Recondition or Replace All Valve.............................................................................. 1.7
G - To Replace Piston, Rod and/or Rings (One)................................................................. .4
H - To Replace Piston, Rod and/or Rings (Two)................................................................. .7
J - To Replace Piston, Rod and/or Rings (All)..................................................................... 1.1
K - To Replace Cylinder Liner (One)................................................................................... .3
L - To Replace Cylinder Liner (Two).................................................................................... .5
M - To Replace Cylinder Liner (All)...................................................................................... .8
N - With Smoother............................................................................................................... 1.3
P - With A/C......................................................................................................................... .8
Q - With Crew Cab.............................................................................................................. 3.7
R - With Noise Cover........................................................................................................... .6
S - For 4x4 Model................................................................................................................ 1.0
T - Automatic Transmission (1992 To 1997 Model)............................................................. 1.2
U - Automatic Transmission (EXC. 1992 To 1997 Model)................................................... .4
(CONTINUED)
J - 54 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
RZ4E J1212 17.0
ADD:
A - With Smoother............................................................................................................... .7
4HL1 J1217 14.5
CRANKSHAFT - R&R OR REPLACE

POLICY: P
NOTE: 4JJ1/4HK1 engines fitted 2005/2008 cab models only.
4JJ1 J1250 14.5
ADD:
B - To Replace Cylinder Head............................................................................................. 3.7
C - To Recondition or Replace All Valves........................................................................... 3.9
D - To Replace Piston, Rod and/or Rings (One)................................................................. .3
E - To Replace Piston, Rod and/or Rings (Two).................................................................. .6
F - To Replace Piston, Rod and/or Rings (All).................................................................... .9
G - With A/C........................................................................................................................ .5
H - With Crew Cab.............................................................................................................. 3.7
J - For 4x4 Model................................................................................................................. 1.0
K - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
L - With Smoother............................................................................................................... .2
4HK1 J1251 16.3
ADD:
D - To Replace Piston, Rod and/or Rings (One)................................................................. .4
E - To Replace Piston, Rod and/or Rings (Two).................................................................. .7
F - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
G - With A/C........................................................................................................................ .2
H - With Crew Cab.............................................................................................................. 3.7
K - For 4x2 Smoother Model................................................................................................ .2
(CONTINUED)
ENGINE J - 55
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
L - For 4x4 Smoother Model................................................................................................ .8
PISTON, ROD AND/OR RINGS - REPLACE

POLICY: P
INC: R&R oil pan and cylinder head, R&R piston and rod assembly.
R&R engine assembly. (4JJ1 Engine)
ADD:
A - To Replace Cylinder Head (INC. Recondition or Replace All Valves)........................... 2.5
B - To Recondition or Replace All Valves............................................................................ 1.7
C - To Replace Piston, Rod and/or Rings (One Additional)................................................ .4
D - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .7
E - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
F - To Replace Cylinder Liner (One)................................................................................... .6
G - To Replace Cylinder Liner (Two)................................................................................... 1.2
H - To Replace Cylinder Liner (All)...................................................................................... 1.9
J - 4JB1-T/4JH1 (W/O Common Rail) Engines................................................................... 3.9
K - With EGR Cooler (4JH1 Engine)................................................................................... .5
L - With A/C......................................................................................................................... .7
M - With Crew Cab.............................................................................................................. 1.3
N - With Noise Cover........................................................................................................... .6
P - 4JB1-NA/4JG2 Engines................................................................................................. 2.9
ADD:
C - To Replace Piston, Rod and/or Rings (One Additional)................................................ .4
D - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .7
E - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
F - To Replace Cylinder Liner (One)................................................................................... .6
G - To Replace Cylinder Liner (Two)................................................................................... 1.2
H - To Replace Cylinder Liner (All)...................................................................................... 1.9
J - With A/C......................................................................................................................... .7
K - With Crew Cab............................................................................................................... 2.6
L - With Noise Cover........................................................................................................... .6
(CONTINUED)
J - 56 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
D - To Replace Cylinder Head (INC. Recondition or Replace All Valves)
(EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)....................................................... 2.5
E - To Replace Cylinder Head (4HK1 Engine Fitted 2005/2008 Cab Models).................... 4.9
F - To Recondition or Replace All Valves
(EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)....................................................... 1.7
G - To Recondition or Replace All Valves (4HK1 Engine Fitted 2005/2008 Cab Models)... 2.9
H - To Replace Piston, Rod and/or Rings (One Additional)................................................ .4
J - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .7
K - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
L - To Replace Cylinder Liner (One).................................................................................... .3
M - To Replace Cylinder Liner (Two)................................................................................... .5
N - To Replace Cylinder Liner (All)...................................................................................... .8
P - With A/C......................................................................................................................... .2
Q - With Crew Cab (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)............................ 2.6
R - With Noise Cover........................................................................................................... .6
S - For 4x4 Model................................................................................................................ .2
T - With Crew Cab (4HK1 Engine <Euro4 Specification> Fitted 2005 Cab Model)............. 3.7
U - With Crew Cab (4HK1 Engine Fitted 2005/2008 Cab Models)
V - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 2.2
ADD:
A - To Replace Piston, Rod and/or Rings (One)................................................................. .4
B - To Replace Piston, Rod and/or Rings (Two).................................................................. .7
C - To Replace Piston, Rod and/or Rings (All).................................................................... 1.0
D - With Smoother............................................................................................................... .7
ADD:
A - To Recondition or Replace All Valves............................................................................ 3.9
(CONTINUED)
ENGINE J - 57
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - To Replace Piston, Rod and/or Rings (One Additional)................................................. .3
C - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .6
D - To Replace Piston, Rod and/or Rings (All).................................................................... .9
E - To Replace Cylinder Head............................................................................................. 3.7
F - With A/C......................................................................................................................... .5
G - With Crew Cab.............................................................................................................. 3.7
H - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... 3.4
J - For 4x4 Model................................................................................................................. 1.0
K - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
L - With Smoother............................................................................................................... .2
ADD:
A - To Replace Piston, Rod and/or Rings (One Additional)................................................. .4
B - To Replace Piston, Rod and/or Rings (Two Additional)................................................. .7
C - To Replace Piston, Rod and/or Rings (All).................................................................... 1.1
D - To Replace Cylinder Liner (One)................................................................................... .3
E - To Replace Cylinder Liner (Two)................................................................................... .5
F - To Replace Cylinder Liner (All)...................................................................................... .8
FLYWHEEL (SMOOTHER) - REPLACE

POLICY: P
4JJ1 J1398 2.8
ADD:
4HK1 J1399 2.8
ADD:
D - For 4x4 Model ............................................................................................................... .6
RZ4E J1400 3.4
J - 58 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
FLYWHEEL (AUTOMATIC TRANSMISSION) - REPLACE J1401 3.0

POLICY: P
ADD:
B - 1992 To 1997 Models.................................................................................................... 1.3
C - 1998 To 2006 Models.................................................................................................... .6
FLYWHEEL (MANUAL TRANSMISSION) - REPLACE

POLICY: P
INC: R&R transmission.
RZ4E J1419 2.8
4J** J1423 2.6
ADD:
A - To Replace Clutch Pilot Bearing.................................................................................... .3
B - To Replace Ring Gear................................................................................................... .6
D - For 4x4 Model................................................................................................................ 1.0
E - 4JB1/4JG2/4JH1 Engines.............................................................................................. 1.6
F - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model............................................ .5
4B** J1424 4.2
ADD:
4H** J1425 2.6
ADD:
D - For 4x4 Model................................................................................................................ 1.0
E - EXC. 4HL1 Engine and 4HK1 Engine Fitted 2005/2008 Cab Models............................ 1.6
F - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .5
ENGINE J - 59
ENGINE
MODEL & TIME
NUMBER
N**, QKR
FLYWHEEL HOUSING - REPLACE J1430 11.9

ADD:
A - EXC. 4HK1 Engine Fitted 2005/2008 Cab Models........................................................ .6
C - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)..................................... .6
D - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)............................................... .2
E - Automatic Transmission (1992 To 1997 Model)............................................................ 1.2
F - Automatic Transmission (EXC. 1992 To 1997 Model)................................................... .4
G - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model)................................. 1.3
H - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
J - With Crew Cab............................................................................................................... 2.2
M - For 4x4 Smoother Model............................................................................................... .8
4JJ1 J1431 2.8
ADD:
A - 4JJ1 Engine Fitted 2005 Cab Model.............................................................................. .6
B - For 4x4 Model................................................................................................................ 1.0
C - With Smoother .............................................................................................................. .2
RZ4E J1433 11.2
ADD:
A - With Smoother............................................................................................................... .7
4HL1 J1434 10.1
FLYWHEEL POWER TAKE OFF ASSEMBLY (PTO) - R&R OR REPLACE J1439 1.1
ADD:
A - To Recondition PTO...................................................................................................... .8
MOUNT, ENGINE - REPLACE

FRONT RIGHT J1500 .5
ADD:
C - For 4x4 Model (4JJ1 Engine)......................................................................................... .3
(CONTINUED)
J - 60 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .8
E - RZ4E Engine.................................................................................................................. .1
F - 4HL1 Engine.................................................................................................................. .3
FRONT LEFT J1501 .5
ADD:
E - RZ4E Engine.................................................................................................................. .3
F - 4HL1 Engine.................................................................................................................. .1
FRONT BOTH J1507 .6
ADD:
E - RZ4E Engine.................................................................................................................. .4
F - 4HL1 Engine.................................................................................................................. .3
REAR J1510 .5
ADD:
PLUG, EXPANSION - REPLACE J1600 .5

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

INC: R&R flywheel.
4J** J1643 2.4
ADD:
(CONTINUED)
ENGINE J - 61
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4B** J1644 4.1
ADD:
4H** J1645 5.5
ADD:
BLOCK, ENGINE FITTED - R&R OR REPLACE

POLICY: P
4JJ1 J1802 16.4
ADD:
D - To Boring....................................................................................................................... ST
E - With A/C......................................................................................................................... .5
F - With Crew Cab............................................................................................................... 3.7
G - For 4x4 Model................................................................................................................ 1.0
H - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
J - With Smoother................................................................................................................ .2
4J** J1803 11.6
ADD:
C - To Boring....................................................................................................................... ST
D - 4JB1-T/4JH1 (W/O Common Rail) Engines.................................................................. 6.6
E - With EGR Cooler........................................................................................................... .5
F - With A/C......................................................................................................................... .8
G - With Crew Cab.............................................................................................................. 1.2
J - 4JB1-NA/4JG2 Engines.................................................................................................. 5.6
(CONTINUED)
J - 62 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4B** J1804 12.8
ADD:
C - To Boring....................................................................................................................... ST
D - Automatic Transmission................................................................................................ .8
E - With A/C......................................................................................................................... .8
F - With Crew Cab............................................................................................................... 3.7
4H** J1805 16.9
ADD:
A - 4HE1-TC Engine............................................................................................................ .7
B - 4H** Engines
D - To Replace Cylinder Head (INC. Recondition or Replace All Valves)........................... 2.5
E - To Recondition or Replace All Valves............................................................................ 1.7
F - To Boring........................................................................................................................ ST
G - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)..................................... .8
J - With Crew Cab............................................................................................................... 3.7
M - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model)................................. 1.3
N - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
P - Automatic Transmission (1992 To 1997 Model)............................................................ 1.2
Q - Automatic Transmission (EXC. 1992 To 1997 Model)................................................... .4
R - For 4x4 Smoother Model............................................................................................... .8
RZ4E J1811 17.8
ADD:
A - With Smoother............................................................................................................... .7
4HL1 J1814 15.1
ENGINE J - 63
ENGINE
MODEL & TIME
NUMBER
N**, QKR
ENGINE PARTIAL/BASIC - REPLACE

POLICY: A, P
4JJ1 J1822 13.3
ADD:
B - To Replace Cylinder Head (INC. Recondition or Replace All Valves)........................... 3.7
D - With A/C........................................................................................................................ .5
E - With Crew Cab............................................................................................................... 3.7
F - For 4x4 Model................................................................................................................ 1.0
G - 4JJ1 (W/Cam End Gasket) Engine Fitted 2005/2008 Cab Models
H - With Smoother............................................................................................................... .2
4J** J1823 10.4
ADD:
D - With EGR Cooler........................................................................................................... .5
E - With A/C......................................................................................................................... .8
F - With Crew Cab............................................................................................................... 1.3
H - 4JB1-NA/4JG2 Engines................................................................................................. 1.2
4B** J1824 11.6
ADD:
C - Automatic Transmission................................................................................................ .8
D - With A/C........................................................................................................................ .8
E - With Crew Cab............................................................................................................... 3.7
F - With Noise Cover........................................................................................................... .6
4H** J1825 12.9
ADD:
A - 4HE1-TC Engine............................................................................................................ 3.2
(CONTINUED)
J - 64 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - 4H** Engines
(EXC. 4HE1-TC Engine and 4HK1 Engine Fitted 2005/2008 Cab Models).................... 2.5
D - To Recondition or Replace All Valves........................................................................... 1.7
E - To Replace Cylinder Head (INC. Recondition or Replace All Valves)........................... 2.5
F - For 4x2 Smoother Model (4HK1 Engine Fitted 1995 Cab Model).................................. 1.3
G - With A/C. (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)..................................... .8
J - With Crew Cab............................................................................................................... 3.7
M - To Recondition or Replace All Valves (4HK1 Engine)................................................... 3.4
N - To Replace Cylinder Head (INC. Recondition or Replace All Valves) (4HK1 Engine).. 4.2
P - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
Q - Automatic Transmission (1992 To 1997 Model)............................................................ 1.2
R - Automatic Transmission (EXC. 1992 To 1997 Model)................................................... .4
S - For 4x4 Smoother Model................................................................................................ .8
RZ4E J1831 16.0
ADD:
A - With Smoother............................................................................................................... .7
4HL1 J1832 11.1
ENGINE ASSEMBLY - REPLACE

POLICY: A, P
4JJ1 J1882 5.4
ADD:
A - 4JJ1 Engine Fitted 2005 Cab Model.............................................................................. 1.1
B - With A/C......................................................................................................................... .5
C - With Crew Cab.............................................................................................................. 3.7
D - For 4x4 Model................................................................................................................ 1.0
E - With Smoother............................................................................................................... .2
4J** J1883 5.0
ADD:
A - With A/C......................................................................................................................... .6
B - With Crew Cab............................................................................................................... 2.0
(CONTINUED)
ENGINE J - 65
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4B** J1884 4.3
ADD:
A - Automatic Transmission................................................................................................. .8
B - With A/C......................................................................................................................... .6
C - With Crew Cab.............................................................................................................. 3.7
4H** J1885 4.3
ADD:
A - 4H** Engines (EXC. 4HK1 Engine)................................................................................ 1.5
E - With A/C. (4HK1 Engine Fitted 1995 Cab Model).......................................................... .4
F - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)............................................... .2
G - With Crew Cab.............................................................................................................. 3.7
K - For 4x2 Smoother Model (4HK1 Engine Fitted 2005/2008 Cab Models)....................... .2
RZ4E J1892 4.1
4HL1 J1894 3.6
CAP, RADIATOR FILLER - REPLACE J3020 .3

INC: Diagnosis to pressure test cap.
COCK OF PLUG, RADIATOR DRAIN - REPLACE J3040 .4

INC: Drain and refill.
RADIATOR ASSEMBLY - R&R J3080 1.2

POLICY: A
ADD:
A - 4JH1 Engine (EXC. 4JH1-TC Engine)........................................................................... .3
(CONTINUED)
J - 66 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... 1.1
C - 4JJ1 Engine................................................................................................................... .6
RADIATOR ASSEMBLY - REPLACE J3100 1.2

POLICY: A
ADD:
A - 4JH1 Engine (EXC. 4JH1-TC Engine)........................................................................... .3
C - 4JJ1 Engine................................................................................................................... .6
COOLER, ENGINE OIL - REPLACE

RZ4E J3122 1.2
4J** J3123 .8
ADD:
C - To Repair Core.............................................................................................................. 1.2
D - To Replace Core............................................................................................................ 1.2
E - With Crew Cab (4JJ1 Engine)....................................................................................... 1.9
F - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines............................................................ .6
G - With Crew Cab (4JB1/4JH1 Engines)........................................................................... .5
4B** J3124 4.6
ADD:
A - To Repair Core.............................................................................................................. 1.2
B - To Replace Core............................................................................................................ 1.2
C - With Crew Cab.............................................................................................................. 1.9
4H** J3127 2.9
ADD:
A - 4HK1 Engine (Euro4 Specification) Fitted 2005 Cab Model.......................................... .6
B - To Repair Core.............................................................................................................. 1.2
(CONTINUED)
ENGINE J - 67
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
C - To Replace Core............................................................................................................ 1.2
D - With Crew Cab.............................................................................................................. 1.9
4HL1 J3131 2.6
ADD:
A - To Repair Core.............................................................................................................. 1.2
B - To Replace Core............................................................................................................ 1.2
TUBE, OVERFLOW - REPLACE J3180 .3

ADD:
A - With Crew Cab............................................................................................................... .1
SHROUD, RADIATOR FAN - REPLACE

ONE PIECE J3247 .6
ADD:
A - 4JJ1 Engine................................................................................................................... .4
C - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... 1.1
RESERVOIR, RADIATOR COOLANT - REPLACE J3260 .2

ADD:
A - With Crew Cab............................................................................................................... .1
CLAMP, RADIATOR HOSE - REPLACE

ONE J3340 .3
ADD:
A - To Replace Clamp (One Additional).............................................................................. .2
B - To Replace Clamp (Two Additional).............................................................................. .3
C - To Replace Clamp (Three Additional)........................................................................... .4
D - To Replace Clamp (Four Additional)............................................................................. .5
HOSE, ENGINE COOLANT - REPLACE

INC: Drain and refill radiator as necessary.
UPPER J3362 .4
ADD:
(CONTINUED)
J - 68 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
LOWER J3363 .5
BOTH J3367 .6
ADD:
A - With Crew Cab (4B**/4JJ1/4H** Engines) (Only J3367)................................................ .7
BELL MOUTH, FAN GUIDE - R&R OR REPLACE J3370 .5

ADD:
A - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... 1.7
B - 4JJ1 Engine................................................................................................................... .3
COOLING FAN - REPLACE J3380 .4

INC: R&R fan clutch assembly if any.
ADD:
B - 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models....................................................... .2
D - 4H** Engines (EXC. 4HL1 Engine and 4HK1 Engines Fitted 2005/2008 Cab Models). .7
E - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .3
CLUTCH ASSEMBLY, COOLING FAN - REPLACE J3390 .4

ADD:
B - 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models....................................................... .2
D - 4H** Engines (EXC. 4HL1 Engine and 4HK1 Engines Fitted 2005/2008 Cab Models). .7
PULLEY, COOLANT PUMP - REPLACE J3420 .4

INC: Adjust belt tension.
ADD:
B - 4HK1 Engine Fitted 2005/2008 Cab Models.................................................................. .4
C - 4JJ1 Engine................................................................................................................... .2
D - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines............................................................ .8
(CONTINUED)
ENGINE J - 69
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
E - 4H** Engines (EXC. 4HL1 Engine and 4HK1 Engines Fitted 2005/2008 Cab Models). .8
F - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .3
PIPE, WATER SUCTION - REPLACE J3470 .7
PUMP AND/OR GASKET, COOLANT - REPLACE

POLICY: P
INC: Drain and refill radiator as necessary.
4J** J3483 .7
ADD:
A - 4JB1/4JG2/4JH1 (W/O Common Rail) Engines ........................................................... 1.1
B - 4JJ1 Engine Fitted 2005/2008 Cab Models................................................................... .4
C - With A/C........................................................................................................................ .3
D - With Crew Cab (4JJ1 Engine)....................................................................................... 1.0
4B** J3484 1.2
ADD:
A - With A/C......................................................................................................................... .3
B - With Crew Cab............................................................................................................... 1.0
4H** J3485 .6
ADD:
A - EXC. 4HL1 Engine and 4HK1 Engine Fitted 2005/2008 Cab Models............................ .7
C - With A/C........................................................................................................................ .3
D - With Crew Cab.............................................................................................................. 1.0
RZ4E J3492 .8
THERMOSTAT, OUTLET AND/OR GASKET - REPLACE J3500 .4

INC: Drain and refill radiator as necessary and test thermostat.
ADD:
A - 4JJ1 Engine................................................................................................................... .2
C - 4JH1 (W/Common Rail) Engine.................................................................................... .1
D - RZ4E Engine................................................................................................................. .1
E - 4HL1 Engine.................................................................................................................. .5
J - 70 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
HOUSING AND/OR GASKET, THERMOSTAT - REPLACE J3520 .7

ADD:
A - 4JH1 (W/Common Rail) Engine..................................................................................... .1
B - With Crew Cab............................................................................................................... .4
COOLING SYSTEM - FLUSH J3540 1.0

INC: Drain cooling system, R&R thermostat, flush with clear water
and test coolant.
PULLEY AND/OR FAN, GENERATOR - REPLACE J4020 .5

ADD:
A - With Crew Cab............................................................................................................... .1
BEARING, GENERATOR - REPLACE

INC: R&R generator, separate end frame, and R&R rotor.
FRONT J4042 .9
ADD:
B - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. .2
C - With A/C. (4HE1-TC Engine)......................................................................................... .6
D - With A/C. (4JH1-T Engine)............................................................................................ .5
E - With A/C. (4HK1 Engine 1995 Cab Model).................................................................... .3
REAR J4043 .8
ADD:
BOTH J4047 1.0
ADD:
(CONTINUED)
ENGINE J - 71
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
DIODE, CHARGING SYSTEM (JUMPER) - REPLACE J4050 1.5

INC: R&R and disassemble generator as necessary.
ADD:
A - With A/C. (4HE1-TC Engine)......................................................................................... .6
C - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. .2
REGULATOR, VOLTAGE - TEST AND REPLACE J4060 1.7

INC: R&R and disassemble generator as necessary.
ADD:
C - With A/C. (4JH1-T Engine)............................................................................................ .5
D - With A/C. (4HK1 Engine 1995 Cab Model).................................................................... .3
GENERATOR ASSEMBLY - DISASSEMBLE, INSPECT, TEST AND REASSEMBLE

POLICY: A
INC: R&R generator assembly.
DIESEL J4080 .5
ADD:
A - To Replace Rotor, Drive End Frame, Pulley, Fan and/or Front Bearing........................ .5
B - To Replace Stator.......................................................................................................... .1
C - To Replace Diode Trio................................................................................................... .8
D - To Recondition Complete.............................................................................................. .8
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 - With A/C. (4HE1-TC Engine)......................................................................................... .6
(CONTINUED)
J - 72 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
F - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... .4
G - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. .2
H - With A/C. (4JH1-T Engine)............................................................................................ .5
J - With A/C. (4HK1 Engine 1995 Cab Model).................................................................... .3
K - With A/C. (4HK1 Engine Fitted 2005/2008 Cab Models)............................................... .2
GENERATOR ASSEMBLY - REPLACE

POLICY: A
INC: Transfer pulley and adjust belt tension.
DIESEL J4100 .5
ADD:
B - With A/C. (4JH1-T Engine)............................................................................................ .5
C - With A/C. (4HK1 Engine Fitted 1995 Cab Model).......................................................... .3
D - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... .4
E - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. .2
BRACE, GENERATOR ADJUSTING - REPLACE J4120 .4
BRACKET, GENERATOR MOUNTING - REPLACE

DIESEL J4160 1.1
ADD:
A - With A/C. (EXC. 4HE1-TC Engine)................................................................................ .3
B - With A/C. (4HE1-TC Engine)......................................................................................... .6
C - With Crew Cab.............................................................................................................. .4
D - 4JJ1 Engine (Euro4 Specification) Fitted 2005 Cab Model........................................... .7
E - 4JJ1 Engine Fitted 2005/2008 Cab Models
RZ4E J4162 .7
4HL1 J4163 .7
SENSOR, CAMSHAFT ANGLE - REPLACE J4350 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
(CONTINUED)
ENGINE J - 73
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - 4HK1 Engines Fitted 1995 Cab Model........................................................................... .4
C - With Crew Cab (4HK1 Engine)...................................................................................... .2
D - 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models....................................................... .1
E - RZ4E Engine.................................................................................................................. .1
SOLENOID, STARTER MOTOR - REPLACE J4580 1.1
DRIVE ASSEMBLY, STARTER MOTOR - REPLACE J4600 .8

INC: R&R starter motor.
MOTOR ASSEMBLY, STARTER - R&R J4620 .7

ADD:
A - To Replace Starter Drive Assembly............................................................................... .4
B - To Recondition Starter Motor
(INC. Replace Starter Drive Assembly and Recondition Armature)............................... 1.4
C - To Replace Field Coils................................................................................................... .5
D - To Recondition Armature............................................................................................... .5
MOTOR ASSEMBLY, STARTER - REPLACE J4640 .7
SOLENOID, OR ACTUATOR FAST IDLE (DIESEL) - REPLACE J4750 .4

INC: Adjustment of fast idle speed.
GLOW PLUG - REPLACE

POLICY: A
ONE J4790 .3
ADD:
A - To Replace Glow Plug (One or Two)............................................................................. .2
B - To Replace Glow Plugs (All).......................................................................................... .2
C - 4HK1 Engine.................................................................................................................. .4
D - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... .4
E - R&R EGR Cooler and/or EGR Valve............................................................................. 1.1
F - Diagnosis Time.............................................................................................................. .3
G - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .5
H - RZ4E Engine................................................................................................................. .1
J - 74 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
CONTROLLER, QOS - REPLACE J4791 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL MODULE, GLOW PLUG - REPLACE J4792 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
DROPPING RESISTOR - REPLACE J4793 .3
AFTER GLOW TIMER - REPLACE J4794 .3
SWITCH, QOS THERMO - REPLACE J4796 .4
AIR CLEANER ASSEMBLY - REPLACE

POLICY: E
RZ4E J4998 .5
4J** J5003 .5
ADD:
A - 4JB1/4JG2/4JH1 Engines.............................................................................................. .2
B - With Crew Cab (4JJ1 Engine)....................................................................................... .2
4B** J5004 .4
ADD:
A - With Crew Cab............................................................................................................... .2
4H** J5005 .5
ADD:
A - With Crew Cab............................................................................................................... .2
ELEMENT, AIR CLEANER - REPLACE J5010 .3

POLICY: A
DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE J5020 .3

POLICY: E
ADD:
A - 4JJ1 Engine................................................................................................................... .3
ENGINE J - 75
ENGINE
MODEL & TIME
NUMBER
N**, QKR
DUCT AND/OR HOSE, TURBO. TO INLET MANIFOLD - REPLACE J5023 .4

ADD:
A - With Crew Cab............................................................................................................... .1
SOLENOID, SWIRL CONTROL, INTAKE MANIFOLD - REPLACE J5260 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
VALVE ASSEMBLY, INTAKE THROTTLE - R&R OR REPLACE J5275 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
D - RZ4E Engine................................................................................................................. .1
CABLE, ACCELERATOR CONTROL - REPLACE

4J** J5333 .6
ADD:
A - With Crew Cab............................................................................................................... .6
4B** J5334 .7
ADD:
A - With Crew Cab............................................................................................................... .6
4H** J5335 .7
ADD:
A - With Crew Cab............................................................................................................... .6
MOTOR AND/OR CABLE, ENGINE STOP - REPLACE

DIESEL J5340 1.0
ADD:
A - With Crew Cab............................................................................................................... .6
SOLENOID, ENGINE STOP - REPLACE

POLICY: E
DIESEL J5345 .3
ADD:
A - With Crew Cab............................................................................................................... .6
J - 76 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
PEDAL, ACCELERATOR - REPLACE J5350 .4
ENGINE EXHAUST BRAKE SYSTEM COMPONENTS - REPLACE

POLICY: A
POWER CHAMBER J5391 .5
VALVE ASSEMBLY J5393 .8
MAGNETIC VALVE J5394 .2
ADD:
A - Diagnosis Time (Only J5394)......................................................................................... .3
SWITCH ASSEMBLY, COMBINATION J5395 .3
SWITCH, ACCELERATOR EXHAUST BRAKE J5396 .3
SWITCH, CLUTCH EXHAUST BRAKE J5397 .3
FILTER, FUEL ELEMENT - REPLACE J5420 .3

POLICY: A
ADD:
A - 4JJ1 Engine................................................................................................................... .2
B - With Crew Cab (4HK1 Engine)...................................................................................... .2
VALVE, OVERFLOW, INJECTION PUMP - REPLACE J5424 .3
PUMP AND/OR GASKET, FUEL - REPLACE

MECHANICAL J5430 .3
ADD:
A - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. .4
LIMITER, FUEL PRESSURE (DIESEL) - REPLACE J5565 .3

ADD:
A - 4JJ1 Engine................................................................................................................... .6
B - 4HK1 Engine.................................................................................................................. .4
RAIL ASSEMBLY, COMMON, FUEL INJECTION (DIESEL) - R&R OR REPLACE J5665 .7

ADD:
A - With Crew Cab (4JJ1/4H** Engines)............................................................................. 1.7
C - 4JJ1 (W/Cam End Gasket) Engine................................................................................ .5
(CONTINUED)
ENGINE J - 77
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - 4HK1 Engines Fitted 2005/2008 Cab Models................................................................ .2
E - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ 1.1
F - With Crew Cab (4JH1 Engine)....................................................................................... .4
G - Diagnosis Time.............................................................................................................. .3
4HL1 J5666 1.0
ADD:
A - Diagnosis Time.............................................................................................................. .3
INTERCOOLER COMPONENTS - REPLACE

INTERCOOLER ASSEMBLY J5685 .6
ADD:
B - 4JJ1 Engine................................................................................................................... .3
C - With Crew Cab (4JB1/4JH1 Engine)............................................................................. .1
TURBOCHARGER TO INTERCOOLER INLET PIPE J5690 .3
ADD:
B - With Crew Cab (4JB1/4JH1 Engine).............................................................................. .3
INTER COOLER TO INTAKE MANIFOLD PIPE J5691 .3
ADD:
ONE RUBBER HOSE J5692 .3
ADD:
TWO RUBBER HOSE J5693 .5
ADD:
TURBOCHARGER ASSEMBLY - REPLACE

POLICY: A
NOTE: EXC. 4HL1 Engine.
RZ4E J5859 2.5
ADD:
A - Diagnosis Time.............................................................................................................. .3
(CONTINUED)
J - 78 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
4H** J5861 1.9
ADD:
A - 4HK1 Engines Fitted 2005/2008 Cab Models................................................................ .5
B - With Crew Cab............................................................................................................... .8
4JJ1 J5862 2.2
ADD:
A - With Crew Cab............................................................................................................... .8
4J** J5863 1.5
ADD:
A - 4JB1 Engine................................................................................................................... 1.4
B - With Crew Cab............................................................................................................... .7
C - 4JH1 (W/O Common Rail) Engine................................................................................. .2
4B** J5864 1.9
ADD:
A - With Crew Cab............................................................................................................... .8
PIPE, OIL PRESSURE (TURBO) - REPLACE J5866 .6

ADD:
A - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 1.1
C - 4HK1 Engine Fitted 2005/2008 Cab Models................................................................. .3
PIPE, OIL RETURN (TURBO) - REPLACE J5867 .6

ADD:
A - 4JJ1 Engine................................................................................................................... 1.1
PIPE, OIL PRESSURE & RETURN (TURBOCHARGER) - REPLACE J5875 1.5
HOSE, WATER RETURN (TURBO) - REPLACE J5885 .5

ADD:
A - 4JJ1 Engine................................................................................................................... .3
(CONTINUED)
ENGINE J - 79
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
D - RZ4E Engine................................................................................................................. 1.0
HOSE, WATER FEED (TURBO) - REPLACE J5886 .4

ADD:
A - 4JJ1 Engine................................................................................................................... 1.3
VALVE,MAGNETIC, VGS - REPLACE J5890 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... .2
C - 4JJ1 (W/Cam End Gasket) Engine................................................................................ .3
SOLENOID, TURBOCHARGER CONTROL - REPLACE J5891 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR,VACUUM, VGS - REPLACE J5895 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
INJECTOR ASSEMBLY, EXHAUST - R&R J5900 .3

POLICY: A
ADD:
A - To Replace Exhaust Injector.......................................................................................... .1
B - To Replace Tip Seal...................................................................................................... .1
C - To Clean Exhaust Injector (INC. Replace Tip Seal)....................................................... .1
INJECTOR, FUEL (DIESEL) - R&R OR REPLACE

POLICY: A
ONE; 4HL1 J5919 .8
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - To Replace Additional Injector (One or Two)................................................................. .4
(CONTINUED)
J - 80 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
C - To Replace All Injectors................................................................................................. .6
ONE; RZ4E J5922 .4
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - To Replace Additional Injector (One or Two)................................................................. .4
C - To Replace All Injectors................................................................................................. .7
ONE J5926 .7
ADD:
A - To Replace Additional Injector (One or Two, EXC. 4HK1 Engine)................................. .2
B - To Replace Additional Injector (One or Two, 4HK1 Engine).......................................... .4
C - To Replace All Injectors (EXC. 4HK1 Engine)............................................................... .3
D - To Replace All Injectors (4HK1 Engine)........................................................................ .8
E - To Adjust Injection Pressure (1 - 2)............................................................................... .3
F - To Adjust Injection Pressure (3 - 4)................................................................................ .5
G - To Lap Nozzle............................................................................................................... ST
H - 4BD2-TC Engine............................................................................................................ .4
I - 4JH1 (W/O Common Rail) Engine.................................................................................. .4
J - 4HK1 Engine Fitted 1995 Cab Model............................................................................. .8
K - Program ECU................................................................................................................. .3
L - Diagnosis Time............................................................................................................... .3
M - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... 1.8
N - 4JJ1 (W/Cam End Gasket) Engine................................................................................ .2
O - 4HK1 Engine Fitted 2005/2008 Cab Models................................................................. 1.4
P - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .5
Q - With Crew Cab (4JB1/4JH1 Engines)........................................................................... .3
LINE, FUEL INJECTION HIGH PRESSURE DIESEL - R&R OR REPLACE

ONE; 4HL1 J5932 .4
ADD:
A - To Replace Additional Line (One).................................................................................. .1
B - To Replace Additional Line (Two).................................................................................. .2
C - To Replace All Lines...................................................................................................... .3
ONE; RZ4E J5933 .2
ADD:
A - To Replace Additional Line (One).................................................................................. .1
(CONTINUED)
ENGINE J - 81
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - To Replace Additional Line (Two).................................................................................. .1
C - To Replace All Lines...................................................................................................... .1
ONE J5935 .6
ADD:
A - To Replace Additional Line (One, EXC. 4HK1 Engine)................................................. .2
B - To Replace Additional Line (One, 4HK1 Engine)........................................................... .3
C - To Replace Additional Line (Two).................................................................................. .3
D - To Replace All Lines...................................................................................................... .4
E - 4JH1 (W/O Common Rail) Engine................................................................................. .6
F - 4HK1 Engine.................................................................................................................. .3
G - With Crew Cab (4B**/4JJ1/4H** Engines)..................................................................... 1.7
H - 4JJ1 (W/Cam End Gasket) Engine................................................................................ .2
J - 4JJ1 (W/O Cam End Gasket) Engine............................................................................. .3
K - With Crew Cab (4JB1/4JH1 Engines)............................................................................ .4
LINE, FUEL RETURN - REPLACE J5937 .3

ADD:
A - 4JJ1 Engine................................................................................................................... .4
B - 4HK1 Engine.................................................................................................................. .9
E - 4HL1 Engine.................................................................................................................. .1
PUMP, FUEL INJECTION DIESEL - R&R OR REPLACE

4HL1 J5950 1.2
ADD:
A - Diagnosis Time.............................................................................................................. .3
4JJ1 J5952 3.4
ADD:
B - Diagnosis Time.............................................................................................................. .3
C - With Crew Cab.............................................................................................................. 1.7
D - To Replace Gasket........................................................................................................ .1
(CONTINUED)
J - 82 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
GEAR TYPE; 4J** J5953 .8
ADD:
B - 4JG2 Engine.................................................................................................................. 4.0
C - To Replace Gasket........................................................................................................ .1
D - Diagnosis Time.............................................................................................................. .3
E - 4JB1 Engine................................................................................................................... 1.6
GEAR TYPE; 4B** J5954 3.8
ADD:
A - With Crew Cab............................................................................................................... 1.7
B - To Replace Gasket........................................................................................................ .1
GEAR TYPE; 4H** J5955 1.2
ADD:
A - 4H*1 Engines (EXC. 4HK1 Engine)............................................................................... .9
D - Diagnosis Time.............................................................................................................. .3
E - With Crew Cab............................................................................................................... 1.7
F - To Replace Gasket........................................................................................................ .1
RZ4E J5957 2.0
ADD:
A - Diagnosis Time.............................................................................................................. .3
GEAR AND/OR ADVANCE TIMING MECHANISM, FUEL INJECTION J5962 2.0

PUMP - REPLACE
ADD:
A - 4H*1 Engines................................................................................................................. .3
B - With Crew Cab............................................................................................................... 1.7
TIMING, FUEL INJECTION PUMP DIESEL - ADJUST J5965 .6

POLICY: E
ENGINE J - 83
ENGINE
MODEL & TIME
NUMBER
N**, QKR
FRP (FUEL RAIL PRESSURE) / SCV (SUCTION CONTROL VALVE) - J5995 .2

REPLACE (ON VEHICLE)
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab (4JJ1/4H** Engines)............................................................................. 1.2
C - 4JJ1 Engine................................................................................................................... .4
E - 4HL1 Engine.................................................................................................................. .1
VALVE, PCV - REPLACE J6000 .3

POLICY: E
ADD:
PIPE, EGR - R&R OR REPLACE J6269 .2

POLICY: P
ADD:
A - With Crew Cab............................................................................................................... .6
B - EXC. 4JJ1(W/O Cam End Gasket) / RZ4E Engine........................................................ .3
C - RZ4E Engine................................................................................................................. 1.5
VALVE AND/OR GASKET, EGR - REPLACE J6270 .3

POLICY: E, P
ADD:
A - 4HK1 Engine.................................................................................................................. .3
B - With Crew Cab............................................................................................................... 1.2
C - Diagnosis Time.............................................................................................................. .3
D - EXC. 4JJ1(W/O Cam End Gasket) / RZ4E Engine....................................................... .1
E - RZ4E Engine.................................................................................................................. .8
MOTOR, EGR VALVE - REPLACE J6271 .2

POLICY: E, P
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .1
J - 84 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
COOLER, EGR VALVE - REPLACE J6275 .5

POLICY: P
ADD:
B - With Crew Cab............................................................................................................... .6
C - To Replace Additional (One)......................................................................................... .1
D - 4JJ1 (W/Cam End Gasket) Engine................................................................................ 1.0
E - 4HK1 Engine Fitted 2005/2008 Cab Models.................................................................. .6
F - 4JJ1 (W/O Cam End Gasket) Engine............................................................................ .5
G - RZ4E Engine................................................................................................................. .6
BYPASS PIPE AND/OR GASKET, EGR - REPLACE J6280 .2

POLICY: P
BYPASS VALVE AND/OR GASKET, EGR - REPLACE J6285 .6

POLICY: P
ADD:
A - RZ4E Engine.................................................................................................................. .5
SOLENOID, BYPASS CONTROL, EGR - REPLACE J6286 .2

POLICY: P
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - RZ4E Engine.................................................................................................................. .3
HOSES, EGR/EFE VACUUM - REPLACE J6320 .4
SWITCH, EGR/EFE THERMAL VACUUM - REPLACE J6340 .4

POLICY: E
CHAMBER ASSEMBLY, DIAPHRAGM - REPLACE J6353 .4
SENSOR, CRANKSHAFT ANGLE - REPLACE J6355 .4

ADD:
B - Diagnosis Time.............................................................................................................. .3
ENGINE J - 85
ENGINE
MODEL & TIME
NUMBER
N**, QKR
SERVICE PROGRAMMING SYSTEM - REPROGRAM J6358 .5
CONTROLLER, EDU (ENGINE DRIVE UNIT) - REPLACE J6359 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROLLER, ECM (ENGINE CONTROL MODULE) - R&R OR REPLACE J6360 .4

POLICY: E
ADD:
A - To Program.................................................................................................................... .4
B - Diagnosis Time.............................................................................................................. .3
CONTROL MODULE, VGS, TURBOCHARGER - REPLACE J6365 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, FUEL TEMPERATURE - REPLACE J6368 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab (4JJ1/4H** Engines)............................................................................. 1.2
D - RZ4E Engine................................................................................................................. 1.6
E - 4HL1 Engine.................................................................................................................. .8
SENSOR, COOLANT TEMPERATURE - REPLACE J6369 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, MAP (MANIFOLD ABSOLUTE PRESSURE) - REPLACE J6370 .3

POLICY: E
ADD:
A - Diagnosis Time.............................................................................................................. .3
J - 86 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
SENSOR, IAT/MAT (INTAKE AIR TEMPERATURE / MANIFOLD AIR TEMPERATURE) - J6371 .4

REPLACE
ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, O-2 (EXHAUST OXYGEN) - REPLACE J6372 .2

POLICY: E
ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, THROTTLE POSITION - REPLACE J6374 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
C - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. .1
SENSOR, EGR VACUUM - REPLACE J6377 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, AIR FLOW - REPLACE J6378 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
SWITCH - REPLACE
ACCELERATOR J6381 .3
ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, BOOST PRESSURE - REPLACE J6383 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - With Crew Cab............................................................................................................... .1
C - RZ4E Engine................................................................................................................. .7
ENGINE J - 87
ENGINE
MODEL & TIME
NUMBER
N**, QKR
SENSOR, BARO - REPLACE J6384 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
UNIT, THERMOMETER - REPLACE J6386 .4
SENSOR, IAT (INTAKE AIR TEMPERATURE), INTERCOOLER - REPALCE J6389 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - To Replace One Additional............................................................................................ .1
CONTROLLER, EGR - REPLACE J6396 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, ENGINE SPEED - REPLACE J6540 .6

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, EGR TEMPERATURE (IN) - REPLACE J6543 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, EGR TEMPERATURE (OUT) - REPLACE J6544 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, FUEL PRESSURE, COMMON RAIL (DIESEL) - REPLACE J6547 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 4HK1 Engine.................................................................................................................. .1
C - 4JJ1 Engine................................................................................................................... .2
CONVERTER, DC-DC, CNG (MULTIPOINT INJECTION) - REPLACE J7005 .6

J - 88 ENGINE
ENGINE
MODEL & TIME
NUMBER
N**, QKR
COIL, IGNITION, CNG (MULTIPOINT INJECTION) - REPLACE J7010 .2

NOTE: To replace (one or all).
ADD:
A - Diagnosis Time.............................................................................................................. .3
PLUGS, SPARK, CNG (MULTIPOINT INJECTION) - REPLACE

POLICY: A
ALL J7020 .4
SENSOR, GAS PRESSURE / TEMPERATURE, CNG (MULTIPOINT INJECTION) - REPLACE J7211 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, MANIFOLD AIR PRESSURE, CNG (MULTIPOINT INJECTION) - REPLACE J7212 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, INTAKE AIR TEMPERATURE, CNG (MULTIPOINT INJECTION) - REPLACE J7213 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, KNOCK, CNG (MULTIPOINT INJECTION) - REPLACE J7214 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
INJECTOR, GAS, CNG (MULTIPOINT INJECTION) - R&R OR REPLACE

POLICY: A
ONE J7500 .3
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - To Additional Injector (One)........................................................................................... .2
C - To Additional Injectors (Two)......................................................................................... .3
D - To Additional Injectors (All)............................................................................................ .4
E - To Clean Filters (All)...................................................................................................... .4
F - To Replace Filters (All)................................................................................................... .4
K TRANSAXLE AND TRANSMISSION A
B
C
D
E
F
H
J
K
L
N
R
S
U
K - 8 TRANSAXLE AND TRANSMISSION
CLUTCH & CONTROLS

MODEL & TIME
NUMBER
N**, QKR
CLUTCH SYSTEM, HYDRAULIC - BLEED K0040 .3
PEDAL, SHAFT AND/OR BUSHING, CLUTCH - REPLACE K0060 .7

POLICY: A
INC: Adjust linkage.
PUSH ROD AND/OR SEAL, CLUTCH PEDAL - REPLACE K0080 .7

INC: Adjust linkage.
SPRING, CLUTCH PEDAL RETURN - REPLACE K0100 .3
DUST COVER, CLUTCH SHIFT FORK - REPLACE K0579 .3
CYLINDER, CLUTCH MASTER - R&R OR REPLACE K0600 .5

INC: Bleed system.
ADD:
A - To Recondition Clutch Master Cylinder.......................................................................... .3
B - 1995 Cab Model............................................................................................................. .3
CYLINDER, CLUTCH DAMPER - R&R OR REPLACE K0610 .4

INC: Bleed system.
CYLINDER, SLAVE - R&R OR REPLACE K0620 .5

POLICY: A
INC: Bleed system.
ADD:
A - To Recondition Slave Cylinder....................................................................................... .3
BOOSTER ASSEMBLY CLUTCH - R&R OR REPLACE K0630 1.2

POLICY: A
ADD:
A - To Recondition Booster................................................................................................. ST
TRANSAXLE AND TRANSMISSION K - 9
CLUTCH & CONTROLS

MODEL & TIME
NUMBER
N**, QKR
LINE, CLUTCH HYDRAULIC (MASTER CYLINDER TO SLAVE CYLINDER) - REPLACE

PIPE K0646 .7
ADD:
SENSOR, CLUTCH STROKE (HSA) - REPLACE K0650 .7

ADD:
A - Diagnosis Time.............................................................................................................. .3
BEARING, CLUTCH RELEASE - REPLACE

INC: R&R transmission, adjust clutch free travel and/or linkage for all series.
(4x2) K0700 2.1
ADD:
A - To Replace Clutch Disc and/or Pressure Plate.............................................................. .5
C - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. 1.6
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model............................... .4
(4x4) K0701 3.0
ADD:
A - To Replace Clutch Disc and/or Pressure Plate.............................................................. .5
C - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. 1.6
TMM K0714 2.2
MVC K0716 1.9
DISC AND/OR PRESSURE PLATE, CLUTCH - REPLACE

POLICY: A
INC: R&R transmission, adjust clutch free travel and/or linkage for all series.
(4x2) K0800 2.3
ADD:
A - To Replace Clutch Fork Shaft and/or Bushings............................................................. .3
B - To Replace Clutch Pilot Bearing.................................................................................... .3
C - To Replace Flywheel..................................................................................................... .3
D - To Replace Clutch Release Bearing.............................................................................. .3
(CONTINUED)
CLUTCH & CONTROLS

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
F - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. 1.6
G - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model............................... .5
(4x4) K0801 3.2
ADD:
A - To Replace Clutch Fork Shaft and/or Bushings............................................................. .3
B - To Replace Clutch Pilot Bearing.................................................................................... .3
C - To Replace Flywheel..................................................................................................... .4
D - To Replace Clutch Release Bearing.............................................................................. .3
F - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. 1.6
G - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model............................... .6
TMM K0816 2.4
MVC K0818 2.3
ADD:
COUPLING, FLUID - REPLACE K0900 2.6

ADD:
C - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model............................... .5
D - For 4x4 Model ............................................................................................................... .6
KNOB, TRANSMISSION SHIFT CONTROL LEVER - REPLACE K1000 .2
LINKAGE OR CABLE, SHIFT - ADJUST K1020 .3

MANUAL TRANSMISSION CONTROLS

MODEL & TIME
NUMBER
N**, QKR
LEVER, GEARSHIFT CONTROL - REPLACE K1060 .4
LEVER, GEARSHIFT CONTROL (SMOOTHER) - REPLACE K1065 .4
SEAL AND/OR BOOT, FLOOR MOUNTED GEARSHIFT - REPLACE

TRANSMISSION GEARSHIFT K1080 .5
SHIFT CABLE, GEARSHIFT CONTROL - REPLACE K1190 .6

POLICY: A
ADD:
CABLE, PARKING LOCK - ADJUST K1194 .3
CABLE, PARKING LOCK - REPLACE K1195 .9

INC: Adjust cable.
LEVER, PTO CONTROL - REPLACE K2020 .3
POWER TAKE OFF (PTO) - REPLACE K2030 .8

POLICY: A
ADD:
A - To Recondition PTO...................................................................................................... 1.2
CABLE, PTO CONTROL - REPLACE K2035 .6

ADD:
A - 2008 Cab Model............................................................................................................. .2
SENSOR, VEHICLE SPEED - REPLACE K2050 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, INPUT SHAFT SPEED - REPLACE K2051 .3

ADD:
(CONTINUED)
MANUAL TRANSMISSION CONTROLS

MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
B - Diagnosis Time.............................................................................................................. .3
SENSOR, ATF TEMPERATURE - REPLACE K2054 3.6

ADD:
B - Diagnosis Time.............................................................................................................. .3
C - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 2.7
E - For 4x4 Model ............................................................................................................... .6
SENSOR, TURBINE SPEED - REPLACE K2056 .3

ADD:
B - Diagnosis Time.............................................................................................................. .3
SENSOR, SHIFT STROKE - REPLACE K2057 2.5

ADD:
B - Diagnosis Time.............................................................................................................. .3
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model............................... 1.0
E - For 4x4 Model ............................................................................................................... .6
SENSOR, SELECT STROKE - REPLACE K2058 2.5

ADD:
B - Diagnosis Time.............................................................................................................. .3
D - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model............................... 1.0
E - For 4x4 Model ............................................................................................................... .6
GEAR AND/OR SEAL SPEEDOMETER DRIVEN - REPLACE K2060 .4

MANUAL TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
6 SPEED TRANSMISSION OF 6TH GEAR SET - REPLACE K2145 4.8

NOTE: Only MZZ transmission.
INC: R&R Transmission case. To replace 6th gear, clutch hub, shift rod and shift arm.
GEAR AND/OR SHIFT ROD,6TH,TRANSMISSION - REPLACE K2150 1.3
SEAL, TRANSMISSION EXTENSION REAR OIL - REPLACE K2160 .8

INC: D&C front universal joint and hanger bearing support to frame.
Drain and refill transmission. R&R hand brake and yoke flange.
DOES NOT INC: R&R transmission assembly or recondition universal joint.
ADD:
A - R&R Transmission Extension Rear Cover..................................................................... 1.4
COVER, TRANSMISSION EXTENSION REAR - R&R K2180 1.3

NOTE: Only TMM transmission.
ADD:
A - To Replace Transmission Extension Rear Cover.......................................................... .2
B - To Replace Shift Control Lever and/or Oil Seal............................................................. .1
C - To Replace Select Control Lever and/or Oil Seal.......................................................... .1
COVER AND/OR GASKET, TRANSMISSION SHIFT - R&R OR REPLACE K2240 .6

INC: R&R shift linkage and shift cover
and gasket. Clean, inspect and retorque.
DOES NOT INC: Recondition remote control assembly.
ADD:
SHIFT CONTROL BOX ASSEMBLY, SMOOTHER - R&R OR REPLACE K2246 3.3

ADD:
A - To Recondition Shift Control Box................................................................................... 1.4
E - For 4x4 Model ............................................................................................................... .6
BREATHER, MANUAL TRANSMISSON - REPLACE K2265 .2

MANUAL TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
BREATHER, SMOOTHER - REPLACE K2266 .2
COOLER, OIL, TRANSMISSION - REPLACE K2300 .6
INHIBITOR SWITCH, SMOOTHER - REPLACE K2481 .5
SOLENOID, SELECT (SMOOTHER) - REPLACE K2490 2.2

ADD:
SOLENOID, SHIFT (SMOOTHER) - REPLACE K2491 2.2

ADD:
A - To Replace Both............................................................................................................ .3
C - 4HK1 Engine Fitted 1995 Cab Model............................................................................ .7
TRANSMISSION ASSEMBLY - REMOVE AND REINSTALL

POLICY: A, P
NOTE: EXC. smoother.
INC: Adjust clutch free travel and/or linkage for all series.
INC: R&R transfer assembly for 4x4 models.
MVC K2694 1.9
ADD:
A - To Recondition Transmission Assembly........................................................................ 2.9
B - To Replace Front Cover Oil Seal................................................................................... .2
C - To Replace Clutch Shift Fork......................................................................................... .1
TMM K2699 2.2
ADD:
A - To Recondition Transmission Assembly........................................................................ 4.2
B - To Replace Front Cover Oil Seal................................................................................... .4
C - To Replace Clutch Shift Fork......................................................................................... .1
(CONTINUED)
MANUAL TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
(4x2) K2700 2.1
ADD:
A - To Recondition Shifter Cover......................................................................................... .4
B - To Replace Main Drive Gear Bearing Retainer and/or Gasket or Seal.......................... .4
C - To Replace Main Drive Gear Bearing............................................................................ 2.0
INC: The above add condition.
D - To Recondition Main Shaft............................................................................................ 2.6
E - To Replace Case Extension And Seal........................................................................... .5
F - To Replace Speedometer Drive Gear............................................................................ .6
G - To Replace Case........................................................................................................... 1.2
H - To Recondition Counter Shaft....................................................................................... 1.0
I - With Noise Cover............................................................................................................ .6
J - EXC. 4HL1 Engine and 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.................. 1.6
K - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model................................ .4
L - To Replace Clutch Shift Fork......................................................................................... .1
M - To Replace Front Cover Oil Seal (MYY/MZZ Transmissions)....................................... 2.1
(4x4) K2701 3.0
ADD:
A - To Recondition Shifter Cover......................................................................................... .4
B - To Replace Main Drive Gear Bearing Retainer and/or Gasket or Seal.......................... .4
C - To Replace Main Drive Gear Bearing............................................................................ 2.0
INC: The above add condition.
D - To Recondition Main Shaft............................................................................................ 2.6
E - To Replace Case Extension And Seal........................................................................... .5
F - To Replace Speedometer Drive Gear............................................................................ .6
G - To Replace Case........................................................................................................... 1.2
H - To Recondition Counter Shaft....................................................................................... 1.0
I - With Noise Cover............................................................................................................ .6
J - 4H** Engines (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)................................ 1.6
K - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model................................ .6
L - To Replace Clutch Shift Fork......................................................................................... .1
M - To Replace Front Cover Oil Seal (MYY/MZZ Transmissions)....................................... 2.1
MANUAL TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
TRANSMISSION ASSEMBLY (SMOOTHER) - REMOVE AND REINSTALL

POLICY: A, P
MYY, MZZ K2705 2.5
ADD:
B - Diagnosis Time.............................................................................................................. .3
C - To Recondition Transmission Assembly
(4HK1 Engine Fitted 1995 Cab Model)........................................................................... 7.9
D - To Recondition Transmission Assembly
(4JJ1/4HK1 Engines <Euro4 Specification> Fitted 2005 Cab Model)............................ 8.9
E - To Recondition Transmission Assembly
(4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models)
F - To Replace Clutch Assembly......................................................................................... .7
G - To Replace Oil Pump Assembly.................................................................................... .7
H - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 2.7
J - 4JJ1/4HK1 Engines (Euro4 Specification) Fitted 2005 Cab Model................................ .5
K - To Recondition Transmission Assembly (With Parking Range).................................... 6.4
L - To Replace Front Cover Oil Seals.................................................................................. 2.9
M - To Recondition Transmission Assembly (RZ4E Engine)............................................... 4.9
N - For 4x4 Model ............................................................................................................... .6
TRANSMISSION ASSEMBLY - REPLACE

POLICY: A, P
(4x2) K2720 2.6
ADD:
B - EXC. 4JJ1/4HK1 Engines Fitted 2005/2008 Cab Models.............................................. 1.6
(4x4) K2721 3.5
ADD:
B - 4H** Engines (EXC. 4HK1 Engine Fitted 2005/2008 Cab Models)................................ 1.6
MVC K2737 2.4
MANUAL TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
TRANSMISSION ASSEMBLY (SMOOTHER) - REPLACE

POLICY: A, P
MYY, MZZ K2751 3.0
ADD:
A - Diagnosis Time.............................................................................................................. .3
D - 4HK1 Engine Fitted 1995 Cab Model............................................................................ 2.7
E - For 4x4 Model ............................................................................................................... .6
OIL PAN AND/OR GASKET, SMOOTHER - R&R OR REPLACE K2805 .8

ADD:
DRAIN PLUG AND/OR GASKET, OIL, MANUAL TRANSMISSION - REPLACE

ONE OR ALL K2810 .4
DRAIN PLUG AND/OR GASKET, OIL, SMOOTHER - REPLACE K2811 .4
FILLER PLUG AND/OR GASKET, OIL, MANUAL TRANSMISSION - REPLACE K2815 .2
CONTROL UNIT, SMOOTHER - REPLACE K2960 .6

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - 2005 Cab Model............................................................................................................. .1
AUXILIARY TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
LEVER, TRANSFER CASE GEARSHIFT - REPLACE K4133 1.0
VALVE, SWITCH, VACUUM - REPLACE K4135 .3

ADD:
A - To Replace One Additional............................................................................................ .1
ACTUATOR, TRANSFER 2W/4W SHIFT - REPLACE K4140 .4
ACTUATOR, TRANSFER SELECT - REPLACE K4141 .4
SEAL, TRANSFER CASE OIL - REPLACE

FRONT K4162 .7
REAR K4163 .8
FRONT INPUT K4164 2.4
TRANSFER CASE ASSEMBLY - RECONDITION K4399 2.9

POLICY: A
DRAIN PLUG AND/OR GASKET, OIL, TRANSFER - REPLACE K4600 .3
FILLER PLUG AND/OR GASKET, OIL, TRANSFER - REPLACE K4601 .2
BREATHER, TRANSFER - REPLACE K4605 .2

AUTOMATIC TRANSMISSION CONTROLS

MODEL & TIME
NUMBER
N**, QKR
INDICATOR PLATE AND/OR ASSEMBLY SHIFT RANGE INDICATOR - REPLACE K5100 .3
SHIFT KNOB - R&R OR REPLACE K5110 .3
CABLE AND/OR SHIFT LEVER, CONTROL - REPLACE K5169 .7
SHIFT LEVER, CONTROL LINKAGE - REPLACE K5170 .8

ADD:
A - 2005 Cab Model............................................................................................................. .2
LINKAGE, SHIFT - ADJUST K5171 .7
CABLE, CONTROL - ADJUST K5175 .3
CABLE, CONTROL - REPLACE K5180 .7

AUTOMATIC TRANSMISSION
MODEL & TIME
NUMBER
N**, QKR
OIL COOLER PIPES, TRANSMISSION - REPAIR OR REPLACE

INLET K5262 1.0
ADD:
OUTLET K5263 .6
ADD:
BOTH K5267 1.3
ADD:
CURVED LOOP PIPE - A/T. K5268 1.9
ADD:
FILTER HOUSING, OIL FILTER - REPLACE K5281 .7
OIL COOLER HOSES, TRANSMISSION - REPAIR OR REPLACE

RADIATOR SIDE : UPPER K5285 .4
RADIATOR SIDE : LOWER K5286 .4
RADIATOR SIDE : BOTH K5287 .8
A/T. SIDE : BOTH K5288 .7
ADD:
A/T. SIDE : RIGHT K5289 .4
ADD:
A/T. SIDE : LEFT K5290 .4
ADD:
BREATHER, AUTOMATIC TRANSMISSON - REPLACE K6120 .2
LEVEL GAUGE (DIPSTICK), TRANSMISSION ATF - REPLACE K6130 .3

ADD:
A - With Crew Cab............................................................................................................... .2
MODEL & TIME
NUMBER
N**, QKR
FILLER TUBE AND/OR GASKET, TRANSMISSION - REPLACE K6140 .4

ADD:
INHIBITOR SWITCH, TRANSMISSION - ADJUST K6274 .2
INHIBITOR SWITCH, TRANSMISSION - REPLACE K6275 .5

INC: D&C shift arm, cable - transmission side
ADD:
COVER AND/OR GASKET, POWER TAKE OFF (PTO) - REPLACE K6280 .6

ADD:
BOLTS, CONVERTER TO FLYWHEEL - REPLACE K6300 1.0

ADD:
DRIVEN GEAR AND/OR GASKET, SPEEDOMETER - REPLACE K6320 .3
SENSOR, VEHICLE SPEED - REPLACE K6330 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, SPEED, A/T. REVOLUTION - REPLACE K6331 .6

ADD:
B - Diagnosis Time.............................................................................................................. .3
SWITCH ASSEMBLY, FLUID PRESSURE - REPLACE K6351 1.3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - TCM freeze frame collection.......................................................................................... .2
C - To Replace ALL Switches.............................................................................................. .1
MODEL & TIME
NUMBER
N**, QKR
OIL SEAL, EXTENSION HOUSING FLANGE YOKE - REPLACE K6360 .8

INC: Drain and refill ATF.
ADD:
A - 1995 Cab Model............................................................................................................. .6
COMPANION FLANGE - REPLACE K6365 .6

ADD:
A - 1995 Cab Model............................................................................................................. .7
SEALED PLUG - REPLACE K6367 .3

ADD:
SEALED BOLT - INSTALL K6368 .3

ADD:
OIL PRESSURE TEST K6400 .6

ADD:
DRAIN PLUG AND/OR GASKET, FLUID, AUTOMATIC TRANSMISSION - R&R OR REPLACE

ONE OR ALL K6490 .4
OIL PAN AND/OR GASKET, TRANSMISSION - R&R OR REPLACE

TRANSMISSION K6500 1.3
ADD:
A - To Replace Oil filter....................................................................................................... .2
B - To Replace Solenoids (One or All, EXC. Pressure Control Solenoid)........................... .3
SWITCHES AND/OR SENSORS - REPLACE K6515 1.2

NEUTRAL, THERMO, OVER-DRIVE, TRANSFER-POSITION SWITCHES
THERMO A/T. SENSOR, THERMO T/F. SENSOR
ADD:
MODEL & TIME
NUMBER
N**, QKR
TRANSMISSION CONTROL MODULE - R&R OR REPLACE K6517 .3

ADD:
A - 1995 Cab Model............................................................................................................. .2
B - Diagnosis Time.............................................................................................................. .3
C - To Reprogram................................................................................................................ .3
DROPPING RESISTOR - REPLACE K6518 .3
VALVE BODY, TRANSMISSION - R&R OR REPLACE

INC: K6500 R&R transmission oil pan.
MAIN CASE K6560 1.8
ADD:
A - To Replace Spool Valves or Springs (One or All).......................................................... .6
B - To Replace Accumulator Pistons (One or All)............................................................... .5
C - To Replace Separator Plate or Gaskets........................................................................ .3
D - To Clean and Recondition Valve Body (Main Case)...................................................... .7
E - To Replace Oil Filter...................................................................................................... .2
F - With Noise Cover........................................................................................................... .6
SHIFT SOLENOID - REPLACE K6630 .9

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - TCM freeze frame collection.......................................................................................... .2
C - To Replace ALL Shift Solenoids.................................................................................... .1
PARKING PAWL SHAFT, ROD OR SPRING - REPLACE K6640 1.7

INC: Drain and refill, R&R propeller shaft, center bearing,
speedometer drive gear and cable.
ADD:
ATF THERMO SENSOR - REPLACE K6645 .3

ADD:
MODEL & TIME
NUMBER
N**, QKR
MOUNT, TRANSMISSION - REPLACE

RIGHT K6720 .5
LEFT K6721 .5
BOTH K6727 .8
AUTOMATIC TRANSMISSION ASSEMBLY - REPLACE K7000 3.4

POLICY: A, P
ADD:
A - To Replace Torque Converter........................................................................................ .2
B - To Replace Front Oil Seal.............................................................................................. .3
C - To Flush Cooling Line.................................................................................................... .7
E - 1992 To 1997 Models.................................................................................................... 1.3
F - 1998 To 2006 Models.................................................................................................... .7
TORQUE CONVERTER ASSEMBLY - REPLACE K7020 3.4

INC: R&R automatic transmission assembly.
ADD:
A - 1992 To 1997 Models.................................................................................................... 1.4
C - 1998 To 2006 Models.................................................................................................... .7
CONVERTER HOUSING, TRANSMISSION - REPLACE K7040 3.6

INC: R&R torque converter.
ADD:
A - 1992 To 1997 Models.................................................................................................... 1.4
C - 1998 To 2006 Models.................................................................................................... .7
SEAL, TRANSMISSION OIL PUMP - REPLACE K7100 3.5

ADD:
A - 1992 To 1997 Models.................................................................................................... 1.4
C - 1998 To 2006 Models.................................................................................................... .7
MODEL & TIME
NUMBER
N**, QKR
OIL PUMP AND/OR GASKET, TRANSMISSION - REPLACE K7120 3.8

ADD:
A - To Replace Front Oil Pump Seal................................................................................... .3
B - To Recondition Oil Pump............................................................................................... .4
C - 1992 To 1997 Models.................................................................................................... 1.4
E - 1998 To 2006 Models.................................................................................................... .8
AUTOMATIC TRANSMISSION ASSEMBLY - RECONDITION K7900 14.9

POLICY: P
INC: R&R automatic transmission assembly.
ADD:
B - EXC. 1995 Cab Model................................................................................................... 1.5
L FUEL AND EXHAUST A
B
C
D
E
F
H
J
K
L
N
R
S
U
L - 6 FUEL AND EXHAUST
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
PIPES, FUEL - REPLACE

NOTE: This is a ST (straight time) operation which requires time
RETURN OR FEED LINES, TANK TO ENGINE COMPARTMENT L0120 .5
HOSES, FUEL TANK AREA - REPLACE L0240 .3

POLICY: A
BRACKET, FUEL SEDIMENTER - REPLACE L0700 .4

ADD:
A - With Crew Cab............................................................................................................... .5
PUMP, FUEL - REPLACE L0701 .2
CAP, FUEL FILTER - REPLACE L0702 .2
FILTER ELEMENT, SEDIMENTER, FUEL (DIESEL) - REPLACE L0731 .3

ADD:
A - To Replace Fuel Filter Element (One Additional).......................................................... .1
SEDIMENTER ASSEMBLY, FUEL - REPLACE L0740 .4

POLICY: A
ADD:
A - To Replace Fuel Sedimenter Assembly (One Additional).............................................. .1
SENSOR ASSEMBLY, SEDIMENTER - REPLACE L0748 .3

ADD:
A - 4JJ1 Engine................................................................................................................... .2
CAP, FUEL TANK - REPLACE L1020 .3
GAUGE UNIT ASSEMBLY, FUEL TANK - REPLACE L1228 .4

FUEL AND EXHAUST L - 7
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
TANK, FUEL - REPLACE L1280 .7

INC: Drain and refill tank.
CORE, FUEL COOLER - REPLACE L1290 .3
HANGER AND/OR CLAMP, EXHAUST SYSTEM - REPLACE L2020 .3

POLICY: A
ADD:
A - To Replace Additional Hanger and/or Clamp................................................................ .2
B - To Replace Two Additional Hanger and/or Clamp......................................................... .3
SEAL, EXHAUST PIPE - REPLACE L2040 .6

POLICY: E
ADD:
A - With Skid Plate.............................................................................................................. .3
PIPE, FRONT EXHAUST - REPLACE L2160 .6

POLICY: E
ADD:
A - EXC. 4JJ1/4HK1 Engines (Euro4 Specification Fitted 2005/2008 Cab Models)
& RZ4E Engine & 4HL1 Engine...................................................................................... .4
CONVERTER, EXHAUST CATALYTIC - REPLACE L2300 .4

POLICY: A, E
INC: Check system for leaks.
ADD:
A - Diagnosis Time.............................................................................................................. .3
PIPE, INTERMEDIATE EXHAUST - REPLACE L2420 .6

POLICY: A
MUFFLER - REPLACE L2584 .4

POLICY: A
INC: Check system for leaks.
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
PIPE, DIFFERENTIAL PRESSURE, EXHAUST SILENCER - R&R OR REPLACE L2585 .4

NOTE: One or All.
SENSOR, DIFFERENTIAL PRESSURE, EXHAUST SILENCER - REPLACE L2586 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
SILENCER, EXHAUST - REPLACE L2587 .7

POLICY: A
DIESEL PARTICULATE DEFUSER ASSEMBLY - R&R OR REPLACE L2600 1.1

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - RZ4E Engine.................................................................................................................. .3
DIESEL PARTICULATE DEFUSER - RECONDITION AND/OR CLEAN L2610 1.5

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - Euro4,5 Specification..................................................................................................... .5
DIESEL PARTICULATE DEFUSER - SLOW REGENERATION L2611 .5

POLICY: A
NOTE: This operation code is to be used with other operation code. Do not use by itself.
INC: Replace engine oil.
DIESEL PARTICULATE DEFUSER FILTER - R&R L2612 1.2

ADD:
A - Euro4,5 Specification..................................................................................................... .4
DIESEL PARTICULATE DEFUSER REAR COVER - REPLACE L2615 1.0

POLICY: A
ADD:
A - Euro4,5 Specification..................................................................................................... .6
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
DIESEL PARTICULATE DEFUSER CATALYTIC CONVERTER - REPLACE L2620 1.1

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - Euro4,5 Specification..................................................................................................... .6
MAGNETIC VALVE, EXHAUST THROTTLE, L2625 .4

DIESEL PARTICULATE DEFUSER - REPLACE
INC: Check system.
VALVE, EXHAUST THROTTLE, DIESEL PARTICULATE DEFUSER - REPLACE L2626 .6

POLICY: A
POWER CHAMBER, EXHAUST THROTTLE VALVE, L2627 .2

DIESEL PARTICULATE DEFUSER - REPLACE
POLICY: A
PIPE, DIFFERENTIAL PRESSURE,DIESEL PARTICULATE DEFUSER - L2630 .4

REPLACE (ONE OR ALL)
ADD:
A - RZ4E Engine.................................................................................................................. .2
SENSOR, PM - REPLACE L2670 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, TEMPERATURE,DIESEL PARTICULATE DEFUSER - L2680 .4

REPLACE (ONE OR ALL)
ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, DIFFERENTIAL PRESSURE, DIESEL PARTICULATE DEFUSER - REPLACE L2685 .4

ADD:
A - Diagnosis Time.............................................................................................................. .3
CATALYST, SCR - REPLACE L2700 1.3

POLICY: A
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
TANK, UREA FLUID - REPLACE L2705 .5
CONTROL VALVE, HEATER COOLANT, UREA FLUID TANK - REPLACE L2706 .4
PUMP, UREA FLUID - REPLACE L2707 .5

POLICY: A
DOSING MODULE ASSEMBLY - REPLACE L2708 .4

POLICY: A
ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, UREA - REPLACE L2720 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, TEMPERATURE, EXHAUST, SCR - REPLACE L2721 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, NOX, EXHAUST - REPLACE (IN) L2722 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, NOX, EXHAUST - REPLACE (OUT) L2723 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SENSOR, LAMBDA, EXHAUST - REPLACE L2724 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
B - To Replace Lambda Sensor (Front Exhaust Pipe Side)................................................ .4
PIPE, TAIL - REPLACE L2800 .3

POLICY: A
INC: Align and check system.
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
EXHAUST SYSTEM (COMPLETE) - REPLACE L2904 1.1

INC: Replace hangers, brackets or clamps as necessary.
COVER, GAS CONTAINER, CNG (MULTIPOINT INJECTION) - REPLACE

POLICY: A
RIGHT L3000 .6
ADD:
A - To Replace Each Additional Container Cover............................................................... .2
LEFT L3001 .6
ADD:
A - To Replace Each Additional Container Cover............................................................... .2
STRAP, GAS CONTAINER RETAINING, CNG (MULTIPOINT INJECTION) - REPLACE

RIGHT; ONE OR ALL L3010 .9
LEFT; ONE OR ALL L3011 .9
CONTAINER, GAS, CNG (MULTIPOINT INJECTION) - REPLACE

RIGHT L3110 2.3
LEFT L3120 2.3
FILLING UNIT, CNG (MULTIPOINT INJECTION) - REPLACE L3205 .5
COUPLER, GAS CHARGE, CNG (MULTIPOINT INJECTION) - REPLACE L3206 .5
INDICATOR, FUEL PRESSURE, CNG (MULTIPOINT INJECTION) - REPLACE L3207 .3
VALVE, CHECK, CNG (MULTIPOINT INJECTION) - R&R OR REPLACE L3210 .4
VALVE, SERVICE, CNG (MULTIPOINT INJECTION) - REPLACE L3215 .4
REGULATOR, GAS PRESSURE, CNG (MULTIPOINT INJECTION) - R&R OR REPLACE L3505 .8
VALVE, MAGNETIC, CNG (MULTIPOINT INJECTION) - REPLACE L3705 .8

ADD:
A - Diagnosis Time.............................................................................................................. .3
FUEL AND EXHAUST

MODEL & TIME
NUMBER
N**, QKR
VALVE, MAGNETIC, HIGH PRESSURE GAS, CNG (MULTIPOINT INJECTION) - REPLACE L3706 .5
ADD:
A - Diagnosis Time.............................................................................................................. .3
CARTRIDGE FILTER, GAS, CNG (MULTIPOINT INJECTION) - REPLACE L3980 .3

POLICY: A
FILTER ASSEMBLY, HIGH PRESSURE GAS, CNG (MULTIPOINT INJECTION) - REPLACE L3981 .5
FILTER, HIGH PRESSURE GAS, CNG (MULTIPOINT INJECTION) - REPLACE L3982 .3

POLICY: A
N ELECTRICAL A
B
C
D
E
F
H
J
K
L
N
R
S
U
ELECTRICAL N - 11
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
BATTERY - REPLACE
POLICY: A
ONE N0110 .3
ADD:
A - Diagnosis Time.............................................................................................................. .2
BOTH N0117 .3
ADD:
A - Diagnosis Time.............................................................................................................. .2
CABLES, BATTERY - REPLACE

POSITIVE N0120 .4
NEGATIVE N0126 .4
BATTERY TO BATTERY N0129 .2
RETAINER AND/OR BOLTS, BATTERY - REPLACE N0150 .3
TRAY OR SUPPORT, BATTERY - REPLACE N0160 .4
BATTERY EQUALIZER - REPLACE N0170 .6
HORN ASSEMBLY - REPLACE

HIGH NOTE N0200 .3
LOW NOTE N0201 .3
HEADLAMP ASSEMBLY - REPLACE

INC: Aim headlamps.
ONE N0250 .4
BOTH N0252 .5
HEADLAMP HOUSING - REPLACE

INC: Aim headlamps.
ONE N0260 .5
BOTH N0261 .8
HEADLAMP - AIM
ONE N0265 .4
(CONTINUED)
N - 12 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
BOTH N0266 .4
ACTUATOR, HEADLIGHT LEVELING - REPLACE

RIGHT N0281 .5
LEFT N0282 .5
RESISTER, DRL (DAY TIME RUNNING LAMP) - REPLACE

RIGHT N0285 .3
LEFT N0286 .3
BOTH N0287 .3
SEALED BEAM AND/OR RETAINING RING, HEADLAMP - REPLACE

POLICY: A
INC: Aim headlamps.
RIGHT N0300 .4
ADD:
A - To Replace Headlamp Bulb (One Side)......................................................................... .2
LEFT N0301 .4
ADD:
A - To Replace Headlamp Bulb (One Side)......................................................................... .2
BULBS, LAMP - REPLACE

POLICY: A
NOTE: Per one lamp housing.
: Names of lamp; housings; bulbs.
BACK UP; RIGHT; ONE N0415 .3
BACK UP; LEFT; ONE N0416 .3
BACK UP; BOTH; TWO N0417 .4
HEAD; RIGHT; ONE OR ALL N0442 .3
HEAD; LEFT; ONE OR ALL N0443 .3
HEAD; BOTH; TWO OR ALL N0444 .4
COURTECY; ONE; ONE N0480 .3
COURTECY; TWO; TWO N0481 .4
DOME; ONE; ONE N0507 .3
DOME; TWO; TWO N0508 .3
(CONTINUED)
ELECTRICAL N - 13
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
FLUORESCENT; ONE: ONE N0509 .2
INSTRUMENT PANEL CLUSTER; ONE; ONE OR ALL N0627 .4
ADD:
A - 1995 Cab Model; (N0627 Only)..................................................................................... .2
INSTRUMENT PANEL WARNING; ONE; ONE OR ALL N0647 .4
ADD:
A - 1995 Cab Model; (N0647 Only)..................................................................................... .2
LICENSE; ONE; ONE N0657 .3
LICENSE; TWO; TWO N0658 .3
PARK AND TURN SIGNAL; RIGHT; ONE OR ALL N0685 .4
PARK AND TURN SIGNAL; LEFT; ONE OR ALL N0686 .4
PARK AND TURN SIGNAL; BOTH; TWO OR ALL N0687 .5
SIDE TURN SIGNAL; RIGHT; ONE N0692 .2
SIDE TURN SIGNAL; LEFT; ONE N0693 .2
SIDE TURN SIGNAL; BOTH; TWO N0694 .3
POSITION INDICATOR; ONE; ONE N0725 .3
SIDE MARKER, FRONT; RIGHT; ONE N0736 .3
SIDE MARKER, FRONT; LEFT; ONE N0737 .3
SIDE MARKER, REAR; RIGHT; ONE N0746 .4
SIDE MARKER, REAR; LEFT; ONE N0747 .4
STOP, TAIL AND TURN SIGNAL; RIGHT; ONE OR ALL N0765 .3
STOP, TAIL AND TURN SIGNAL; LEFT; ONE OR ALL N0766 .3
STOP, TAIL AND TURN SIGNAL; BOTH; TWO OR ALL N0767 .4
FOG; RIGHT; ONE N0852 .2
FOG; LEFT; ONE N0853 .2
FOG; BOTH; TWO N0854 .3
DRL; RIGHT; ONE N0860 .2
DRL; LEFT; ONE N0861 .2
DRL; BOTH; TWO N0862 .2
REAR FOG LIGHT; RIGHT N0883 .2
N - 14 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
LENS AND/OR GASKET, LAMP - REPLACE

POLICY: A
NOTE: Per one lamp housing.
: Names of lamp; housings; lenses.
COURTECY; ONE; ONE N1139 .3
COURTECY; TWO; TWO N1140 .3
LUGGAGE COMPARTMENT; ONE; ONE N1145 .3
DOME; ONE; ONE N1156 .3
DOME; TWO; TWO N1157 .3
FLUORESCENT; ONE: ONE N1158 .2
LICENSE; ONE; ONE N1176 .3
LICENSE; TWO; TWO N1177 .3
PARK AND TURN SIGNAL; RIGHT; ONE N1215 .4
PARK AND TURN SIGNAL; LEFT; ONE N1216 .4
PARK AND TURN SIGNAL; BOTH; TWO N1217 .5
STOP, TAIL AND TURN SIGNAL; RIGHT; ONE N1224 .4
STOP, TAIL AND TURN SIGNAL; LEFT; ONE N1225 .4
STOP, TAIL AND TURN SIGNAL; BOTH; TWO N1226 .5
MAP; RIGHT; ONE N1314 .3
MAP; LEFT; ONE N1315 .3
MAP; BOTH; TWO N1316 .3
LAMP ASSEMBLY - REPLACE

POLICY: A
DOME; ONE OR ALL N1456 .3
DOME (FLUORESCENT LAMP) N1457 .2
FOG AND DRL; RIGHT N1463 .2
FOG AND DRL; LEFT N1464 .2
FOG; RIGHT N1466 .3
FOG; LEFT N1467 .3
LICENSE; ONE OR BOTH N1477 .3
PARK AND TURN SIGNAL; RIGHT N1520 .5
PARK AND TURN SIGNAL; LEFT N1521 .5
REAR COMBINATION; RIGHT N1524 .5
(CONTINUED)
ELECTRICAL N - 15
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
REAR COMBINATION; LEFT N1525 .5
SIDE TURN SIGNAL; RIGHT N1564 .2
SIDE TURN SIGNAL; LEFT N1565 .2
BOX ASSEMBLY, FUSE - REPLACE N1710 .8
FUSE, FUSIBLE LINK - REPLACE N1720 .3

POLICY: A
INC: One or more.
FLASHER UNIT - REPLACE N1750 .3
SWITCH - REPLACE
NOTE: Switch or sending unit.
INC: Replace fuse where necessary.
COMBINATION N2000 .6
ADD:
A - With Air Bag................................................................................................................... 1.2
BACK-UP LIGHT N2030 .4
ADD:
B - For 4x4 Model................................................................................................................ .2
TRANSFER INDICATOR N2032 .3
TRANSFER SELECT; HIGH N2034 .3
TRANSFER SELECT; LOW N2035 .3
POWER WINDOW; FRONT RIGHT N2144 .3
POWER WINDOW; FRONT LEFT N2145 .3
POWER WINDOW; FRONT CENTER N2146 .3
ENGINE OIL PRESSURE N2220 .4
ENGINE OIL LEVEL N2222 1.2
ENGINE COOLANT TEMPERATURE N2230 .4
DPD (DIESEL PARTICULATE DEFUSER) N2237 .3
4WD (FOUR WHEEL DRIVE) N2240 .3
CRUISE CONTROL MAIN N2241 .3
FOG LAMP N2244 .4
(CONTINUED)
N - 16 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
HAZARD WARNING N2247 .3
HEADLIGHT LEVELING N2315 .3
IGNITION N2320 .2
LOW AIR PRESSURE N2340 .3
ADD:
A - To Replace Each Additional (N2340 Only).................................................................... .1
NEUTRAL; M/T N2360 .4
ADD:
NEUTRAL; SMOOTHER N2361 2.6
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - For 4x4 Model................................................................................................................ .6
PARKING BRAKE LIGHT N2380 .4
STOP LIGHT N2440 .4
EMERGENCY MAIN (SMOOTHER) N2451 .6
ADD:
A - Diagnosis Time (N2451 Only)........................................................................................ .3
EMERGENCY SHIFT (SMOOTHER) N2454 .6
ADD:
A - Diagnosis Time.............................................................................................................. .3
ECONO MODE CHANGEOVER (SMOOTHER) N2455 .6
ADD:
A - Diagnosis Time.............................................................................................................. .3
ADJUST (SMOOTHER) N2456 .3
ADD:
A - Diagnosis Time.............................................................................................................. .3
IDLE CONTROL N2648 .3
HSA OFF N2710 .3
ADD:
B - EXC. 2008 Cab Model (N2710 Only)............................................................................. .2
HSA ADJUST N2711 .4
ADD:
A - Diagnosis Time.............................................................................................................. .3
(CONTINUED)
ELECTRICAL N - 17
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
HSA CLUTCH FLUID PRESSURE N2712 .6
ADD:
A - Diagnosis Time.............................................................................................................. .3
HSA RESET N2713 .4
ADD:
A - Diagnosis Time.............................................................................................................. .3
WARM UP N2714 .3
LDWS (LANE DEPARTURE WARNING SYSTEM) N2715 .3
INTERIOR LIGHT N2716 .3
REMOTE CONTROL MIRROR N2718 .3
MIRROR HEATER N2719 .3
ASR OFF N2722 .3
POWER TAKE OFF (PTO) N2730 .3
AEBS OFF N2740 .3
4x4 INDICATOR LIGHT N2778 .2
ESC OFF N2780 .2
TRANSFER GEAR CONTROL N2782 .3
HILL HOLD ASSIST OFF N2783 .3
HILL HOLD ASSIST ADJUST N2784 .4
HILL HOLD ASSIST RESET N2785 .4
RELAY - REPLACE
ENGINE MAIN (ECM) N2800 .3
IGNITION N2801 .3
ACCESSORY N2803 .3
STARTER N2810 .3
STARTER CUT N2814 .3
HEAD LIGHT N2820 .3
TAIL LIGHT N2830 .3
DIMMER N2850 .3
DAYTIME RUNNING LAMP N2851 .3
REAR FOG N2857 .3
CORNERING LAMP N2859 .3
MARKER LAMP N2860 .3
(CONTINUED)
N - 18 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
CHARGE N2870 .3
HORN N2880 .3
FOG LAMP N2888 .3
EXHAUST BRAKE N2889 .3
PM SENSOR N2894 .3
WIPER N2900 .3
POWER TAKE OFF (PTO) N2902 .3
POWER TAKE OFF (PTO) SOLENOID N2903 .3
POWER TAKE OFF (PTO) CUT N2904 .3
A/C COMPRESSOR N2910 .3
A/C CONDENSOR N2912 .3
WIPER INTERMITTENT N2919 .3
GLOW PLUG N2922 .3
TRANSFER HIGH/LOW SHIFT N2950 .3
TRANSFER 2WD/4WD N2951 .3
FUEL HEATER N2965 .3
SMOOTHER GEAR SHIFT N2972 .3
POWER WINDOW N2980 .3
POWER WINDOW REAR N2981 .3
CNG GAS CUT N2998 .3
SENSOR - REPLACE
ESC (ELECTRONIC STABILITY CONTROL) N3001 .2
ADD:
A - Diagnosis Time.............................................................................................................. .3
B - Chassis Side.................................................................................................................. .2
SAS (STEERING ANGLE SENSOR) N3002 .5
ADD:
A - Diagnosis Time.............................................................................................................. .3
MOTOR - REPLACE
POWER WINDOW; FRONT RIGHT N3310 .7
ADD:
A - 1995/2005 Cab Models.................................................................................................. .4
(CONTINUED)
ELECTRICAL N - 19
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
POWER WINDOW; FRONT LEFT N3311 .7
ADD:
A - 1995/2005 Cab Models.................................................................................................. .4
MOTOR, WIPER - R&R

WINDSHIELD N3510 .4
ADD:
A - 2005 Cab Model............................................................................................................. .2
MOTOR, WIPER - REPLACE

WINDSHIELD N3520 .3
ADD:
A - 2005 Cab Model............................................................................................................. .3
B - 1995 Cab Model............................................................................................................. .1
BLADE, WIPER - REPLACE

POLICY: A
WINDSHIELD N3615 .3
ARM, WIPER - REPLACE

INC: One or both.
WINDSHIELD N3620 .3
LINK, WINDSHIELD WIPER OPERATING - REPLACE

BOTH N3637 .2
ADD:
A - 2005 Cab Model............................................................................................................. 5.1
B - 1995 Cab Model............................................................................................................. 1.1
HOSES, NOZZLES, WASHER AND/OR WIPER STOPS - REPLACE

INC: One or all.
WINDSHIELD N3700 .3
N - 20 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
CONTAINER AND COVER, WASHER - REPLACE

WINDSHIELD N3750 .3
ADD:
A - 1995/2005 Cab Models.................................................................................................. .3
PUMP ASSEMBLY, WASHER - R&R OR REPLACE

INC: One or both.
WINDSHIELD N3860 .3
ADD:
A - 1995 Cab Model............................................................................................................. .5
LIGHTER ASSEMBLY, CIGARETTE - REPLACE N4010 .3
LENS AND/OR BEZEL, INSTRUMENT CLUSTER - REPLACE N4120 .3

ADD:
A - 1995/2005 Cab Models.................................................................................................. .2
CLOCK ASSEMBLY - R&R N4200 .3
CLOCK ASSEMBLY - REPLACE N4210 .3
SPEEDOMETER - REPLACE N4310 .5

POLICY: A
ADD:
A - 1995 Cab Model............................................................................................................. .3
CABLE, SPEEDOMETER - R&R OR REPLACE

ALL SERIES N4399 1.0
METER BOARD ASSEMBLY - REPLACE N4410 .3

POLICY: A
NOTE; 2008 Cab model only.
ADD:
A - Diagnosis Time.............................................................................................................. .3
ELECTRICAL N - 21
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
TACHOMETER - R&R N4500 .5

ADD:
A - 1995 Cab Model............................................................................................................. .3
TACHOMETER - REPLACE N4510 .5

ADD:
A - 1995 Cab Model............................................................................................................. .3
GAUGE - REPLACE
INC: R&R instrument cluster necessary.
ENGINE COOLANT TEMPERATURE N4640 .5
ADD:
A - 1995 Cab Model............................................................................................................. .3
FUEL N4680 .5
ADD:
A - 1995 Cab Model............................................................................................................. .3
BUZZER, BACK - REPLACE N5100 .3
CIRCUIT, PRINTED - R&R OR REPLACE

INSTRUMENT CLUSTER N5140 .5
COIL ASSEMBLY, SRS (AIR BAG) - REPLACE N5810 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
G-SENSOR, SRS (AIR BAG) - REPLACE N5811 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
SRS - AIR BAG - REPLACE

POLICY: A
DRIVER N5820 .3
ADD:
A - Diagnosis Time.............................................................................................................. .3
(CONTINUED)
N - 22 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
PASSENGER N5821 .1
ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, CENTRAL DOOR LOCK - REPLACE N5831 .3
CONTROL UNIT, VEHICLE SPEED SENSOR - REPLACE N5845 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, SRS (AIR BAG) - REPLACE N5860 .5

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, CAN CONVERTER (FCG) - REPLACE N5861 .2

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, VIEW ASSIST TECHNOLOGY (VAT) - REPLACE N5862 1.0

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONTROL UNIT, CAN CONVERTER (LDWS/AEBS) - REPLACE N5868 .3

ADD:
A - Diagnosis Time.............................................................................................................. .3
CONVERTER, DC-DC, (LDWS/AEBS) - REPLACE N5892 .3
DATA RECORDING MODULE (DRM) - DOWNLOAD N5950 .4
BODY CONTROL MODULE (BCM) - DOWNLOAD N5951 .2
INFORMATION MODULE (MIMAMORI) - DOWNLOAD N5952 .3

ELECTRICAL N - 23
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
DATA RECORDING MODULE (DRM) - REPLACE N5953 .6

POLICY: A
BODY CONTROL MODULE (BCM) - REPLACE N5954 .7

POLICY: A
WIRING AND/OR CONNECTOR - REPAIR

INC: Connect and use diagnostic equipment to locate problem,
R&R any necessary components and replace fuse if necessary.
AIR CONDITIONING N6030 .5
AUTOMATIC TRANSMISSION N6031 .5
CAB MAIN N6070 .5
CHASSIS; FRONT N6112 .5
CHASSIS; REAR N6113 .5
DOME; LIGHT N6180 .5
DOOR WINDOW; RIGHT FRONT N6254 .5
DOOR WINDOW; LEFT FRONT N6255 .5
ENGINE N6270 .5
HEADLIGHT N6290 .5
HEATER N6310 .5
INSTRUMENT PANEL N6360 .5
HARNESS, WIRING - REPLACE

Authorization request is required beyond 1.5 hours.
INSTRUMENT PANEL N7060 3.9
ADD:
A - 1995/2005 Cab Models.................................................................................................. 2.2
(CONTINUED)
N - 24 ELECTRICAL
ELECTRICAL
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
ENGINE N7063 .6
ADD:
A - EXC. RZ4E/4HL1 Engine............................................................................................... 1.7
B - RZ4E Engine.................................................................................................................. .6
DOOR; RIGHT FRONT N7066 .8
DOOR; LEFT FRONT N7067 .8
A/T. INTERNAL N7075 .8
ADD:
B - TCM freeze frame collection (N7075 Only).................................................................... .2
C - To Replace Wiring Harness 10 Pin Type (N7075 Only)................................................ .1
CHASSIS; FRONT N7112 1.5
CHASSIS; REAR N7113 .5
R ACCESSORIES A
B
C
D
E
F
H
J
K
L
N
R
S
U
ACCESSORIES R - 3
ACCESSORIES
MODEL & TIME
NUMBER
N**, QKR
STANDING WAVE RATIO SWR - ADJUST R0120 .5
ANTENNA COMPONENTS - REPLACE R0220 .2

ADD:
A - 1995 Cab Model............................................................................................................. .2
RADIO RECEIVER - R&R R0750 .4
CASSETTE DECK - R&R R0751 .4
RADIO RECEIVER - REPLACE R0760 .4
CASSETTE DECK - REPLACE R0761 .4
CAMERA, LANE RECOGNITION - REPLACE R0772 .5
CAMERA, STEREO (LDWS/AEBS) - REPLACE R0773 1.2
GRILLE, RADIO SPEAKER - R&R OR REPLACE

FRONT RIGHT R0910 .4
FRONT LEFT R0911 .4
SPEAKER, RADIO - REPLACE

FRONT RIGHT R0940 .4
ADD:
A - 1995 Cab Model............................................................................................................. .2
FRONT LEFT R0941 .4
ADD:
A - 1995 Cab Model............................................................................................................. .2
GLASS; MIRROR, OUTSIDE REAR VIEW - REPLACE

MANUAL; RIGHT R3260 .4
MANUAL; LEFT R3261 .4
MIRROR COMPONENTS, OUTSIDE REAR VIEW - REPLACE

MANUAL; RIGHT R3390 .4
(CONTINUED)
R - 4 ACCESSORIES
ACCESSORIES
MODEL & TIME
NUMBER
N**, QKR
(CONT'D)
MANUAL; LEFT R3391 .4
CONTROLLER, IMMOBILIZER - REPLACE R9047 .6

ADD:
A - Diagnosis Time.............................................................................................................. .3
KEYLESS ENTRY SYSTEM - REPLACE

CONTROL UNIT R9050 .5
KEY; REMOTE CONTROLLER R9054 .1
BATTERY; KEY, REMOTE CONTROLLER R9056 .2
CONTROL UNIT, MIMAMORI - REPLACE R9180 .6

ADD:
A - Diagnosis Time.............................................................................................................. .3
DIGITAL OR ANALOG TACHOGRAPH - R&R OR REPLACE R9200 .3

S NON WARRANTY (PANEL REPLACEMENT) A
B
C
D
E
F
H
J
K
L
N
R
S
U
S - 2 NON WARRANTY (PANEL REPLACEMENTS)
PANEL REPLACEMENTS
MODEL & TIME
NUMBER
N**, QKR
PANEL ASSEMBLY, FRONT - REPLACE S0500 18.7

INC: R&R bumper, outside mirror, front windshield glass,
instrument panel, steering shaft, evaporator and heater unit.
NON WARRANTY (PANEL REPLACEMENTS) S - 3
CORROSION PERFORATION REPAIRS

MODEL & TIME
NUMBER
N**, QKR
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.
PANEL, GRILLE HEADER AND/OR FRONT END - CORROSION S5030 1.5

PERFORATION REPAIR
RADIATOR SUPPORT AND/OR TIE BAR - CORROSION PERFORATION REPAIR S5050 1.5
PANEL MOTOR COMPARTMENT SIDE AND WHEELHOUSE INCLUDING S5110 1.5

STRUT TOWER - CORROSION PERFORATION REPAIR
PILLAR, WINDSHIELD - CORROSION PERFORATION REPAIR S5150 1.5
PANEL, ROOF - CORROSION RERFORATION REPAIR S5170 1.5
PANEL, FLOOR - CORROSION PERFORATION REPAIR S5230 1.5
DOOR - CORROSION PERFORATION REPAIR S5250 1.5
PANEL, CAB REAR - CORROSION PERFORATION REPAIR S5310 1.5

U OTHERS A
B
C
D
E
F
H
J
K
L
N
R
S
U
U - 2 OTHERS
OTHERS
MODEL & TIME
NUMBER
N**, QKR
NOTE: If vehicle becomes inoperative due to a failure and needs to be towed,

ISUZU covers the towing cost to the nearest ISUZU Dealer by the third party
upon an ISUZU's approval on the towing service.
Reimbursement of the towing cost requires an ISUZU's approval through an
Authorization Request (AR) submission beforehand. The invoice of the towing
cost must be submitted together with the AR submission. The invoice needs
to include the information of VIN, towing date and towing cost at least.
TOWING
POLICY: A
TOWING; 1-50km U0001 .0
TOWING; 51-100km U0002 .0
TOWING; More than 100km U0003 .0
Labor Time Guide Difference List for N**, QKR ( L4G-LE-99K6 vs L4G-LE-99L1 )
MODEL & TIME

OPERATION DESCRIPTION OPERATION The Contents of Change
NUMBER
N**, QKR
2020 model year has been added to the text data.
SWITCH, COMPRESSOR CUT-OFF - REPLACE

DUAL PRESSURE D1116 .3
ADD:
A - Discharge/Charge A/C. System.................................................................................. .6
B - To Leak Check A/C. System...................................................................................... .4 Added new additional item.
SWITCH, THERMOSTATIC CONTROL - REPLACE D1140 .7

ADD:
B - 1995 Cab Model......................................................................................................... .5
C - To Leak Check A/C. System...................................................................................... .4 Added new additional item.
CASE, EVAPORATOR - R&R OR REPLACE D2510 1.3

ADD:
A - 1995 Cab Model......................................................................................................... .5
B - Discharge/Charge A/C. System.................................................................................. .6
CORE, HEATER - R&R

ADD:
A - 1995 Cab Model......................................................................................................... 1.2
WITH A/C. D2802 1.8
ADD:
A - Discharge/Charge A/C. System (EXC. 2005 Cab Model)............................................ .6
B - 1995 Cab Model......................................................................................................... 1.2
CORE, HEATER - REPLACE

ADD:
A - 1995 Cab Model......................................................................................................... 1.2
WITH A/C. D2822 1.8
ADD:
A - Discharge/Charge A/C. System (EXC. 2005 Cab Model)............................................ .6
B - 1995 Cab Model......................................................................................................... 1.2
A/C. SYSTEM - LEAK TEST DISCHARGED SYSTEM D3000 .4 Delete operation number.
NOTE: This labor operation to be used when necessary to partially
charge 1 lb. max. the A/C. system to locate a leak. Other Labor Hours
not allowed with this labor operation. This operation may only be
claimed in conjunction with a failed part operation.
SEALS, REFRIGERANT O-RING - REPLACE

COMPRESSOR MANIFOLD D3040 .4
ADD:
CONDENSER D3041 .3
ADD:
(CONTINUED)
1/3
MODEL & TIME

NUMBER
N**, QKR
(CONT'D)
CONDENSER OUTLET PIPE D3042 .3
ADD:
EXPANSION VALVE D3043 1.0
ADD:
B - 1995 Cab Model......................................................................................................... .6
C - 2008 Cab Model........................................................................................................ .6
D - To Leak Check A/C. System...................................................................................... .4 Added new additional item.
EVAPORATOR D3044 .4
ADD:
FILTER DRYER D3048 .3
ADD:
HOSES AND/OR LINES, REFRIGERANT - REPLACE

INC: Assemble service hose as necessary.
CONDENSER INLET D3081 .4
ADD:
COMPRESSOR DISCHARGE D3082 .4
ADD:
EVAPORATOR OUTLET D3084 .4
ADD:
COMPRESSOR SUCTION AND DISCHARGE HOSE ASSEMBLY D3088 .4
ADD:
COMPRESSOR SUCTION D3089 .4
ADD:
FILTER DRYER TO CONDENSER D3096 .4
ADD:
FILTER DRYER OUTLET D3097 .4
ADD:
ANY ONE PIPE EXPANSION VALVE INLET D3099 1.0
ADD:
B - 1995 Cab Model......................................................................................................... .6
C - 2008 Cab Model........................................................................................................ .6
(CONTINUED)
2/3
MODEL & TIME

NUMBER
N**, QKR
(CONT'D)
CONDENSER - REPLACE D3140 .6

ADD:
VALVE, EXPANSION - REPLACE D3220 1.0

ADD:
B - 1995 Cab Model......................................................................................................... .4
C - 2008 Cab Model........................................................................................................ .6
DRYER, IN-LINE FILTER - REPLACE D3250 .4

ADD:
CORE, EVAPORATOR - REPLACE D3320 .8

ADD:
B - 1995 Cab Model......................................................................................................... .4
C - 2008 Cab Model........................................................................................................ .9
CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR - REPLACE D4240 .8

INC. R&R compressor assembly.
ADD:
B - EXC. 4HK1 Engine (Euro4 Specification) Fitted 2005/2008 Cab Models.................... .6
C - 4JJ1 Engine............................................................................................................... .2
COMPRESSOR ASSEMBLY - REPLACE D4440 .4

ADD:
B - EXC. 4HK1 Engine (Euro4 Specification) Fitted 2005/2008 Cab Models.................... .6
C - 4JJ1 Engine............................................................................................................... .2
3/3

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LIGHT DUTY VEHICLE

ISUZU MOTORS LIMITED

Publication No. L4G-LE-99L1

This Labor Time Guide is designed for more POLICY CODES

MAJOR OPERATIONS REPLACE (as a single action word)

VEHICLES MODEL YEAR

Refer to below illustrations for vehicles model.

2008 Cab Model (N series)

The Engine Code designation from the Vehicle

Abbreviations Description Abbreviations Description

A/C Air Conditioning EXC Except

IS REQUESTED BECAUSE: SERVICE MGR. SIGNATURE:

A New Labor Operation description is recommended DISTRIBUTOR USE ONLY

STEP DESCRIPTION OF BASIC STEPS TIME

VIN # Engine Family Trans #

Rear Axle # Body Type Special Equip.

PANEL, FRONT END

FRAME, FRONT DOOR WINDOW

PANEL, CAB SIDE

PANEL, CAB BACK

SUPPORT, STEP, DOOR OPENING

BUMPER AND FRONT END

BUMPER ASSEMBLY, FRONT - REPLACE B0048 .5

PROTECTOR, UNDER, FRONT - REPLACE B0220 .6

BUMPER ASSEMBLY, FRONT - ALIGN B0260 .3

BAR, REAR BUMPER FACE - REPLACE B0800 .4

BUMPER ASSEMBLY, REAR - ALIGN B0860 .4

GRILLE ASSEMBLY - REPLACE

INSULATION, ENGINE HOOD - REPLACE B1510 .4

PANEL ASSEMBLY, (LID) FRONT CENTER - REPLACE B1770 .2

GUARD, MUD - REPLACE B1830 .3

BUMPER AND FRONT END

FLAP, MUD GUARD - REPLACE B1831 .2

PLATE, FLAP - REPLACE B1832 .2

COVER, NOISE - R&R OR REPLACE

STEP, CAB ASSIST - REPLACE

DOORS AND REAR COMPARTMENT

DOOR ASSEMBLY, FRONT - ALIGN

DOOR ASSEMBLY, FRONT - R&R

HINGE, FRONT DOOR (BOLT ON) - REPLACE

CHECK ASSEMBLY, FRONT DOOR - REPLACE

HANDLE, FRONT DOOR OUTSIDE - REPLACE

CYLINDER, FRONT DOOR LOCK - R&R OR REPLACE

STRIKER, FRONT DOOR LOCK - REPLACE

DOORS AND REAR COMPARTMENT

LOCK, FRONT DOOR - R&R OR REPLACE

HANDLE, FRONT DOOR INSIDE OPENING - R&R OR REPLACE

CONTROL, FRONT DOOR LOCK REMOTE - REPLACE

KNOB, FRONT DOOR INSIDE LOCKING - REPLACE

ROD, FRONT DOOR INSIDE LOCKING - R&R OR REPLACE

CABLE, FRONT DOOR INSIDE LOCKING - REPLACE

DOORS AND REAR COMPARTMENT

DOOR ASSEMBLY, REAR - ALIGN

DOOR ASSEMBLY, REAR - R&R

HINGE, REAR DOOR - REPLACE

HANDLE, REAR DOOR OUTSIDE - REPLACE

STRIKER, REAR DOOR LOCK - REPLACE

LOCK, REAR DOOR - R&R OR REPLACE