BULLETIN

FLAT RATES

SAGA

Model YR 2011
English Edition RDCE-08M040-05
Destination: ALL
July 2011 Printed in Malaysia

Copyright ©

Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
Printed in Malaysia 19 July 2011 Eng
 BULLETIN -
Group Index /I

00 GENERAL ..................................................................................... 00/1 - 00/4

11 ENGINE ........................................................................................ 11/1 - 11/4
13 FUEL ............................................................................................ 13/1 - 13/3
15 INTAKE AND EXHAUST ................................................................. 15/1 - 15/3
21 CLUTCH ....................................................................................... 21/1 - 21/3
22 MANUAL TRANSMISSION ............................................................. 22/1 - 22/7
23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) .......................... 23/1 - 23/7
32 POWER PLANT MOUNT ................................................................ 32/1 - 32/3
35 BRAKES ....................................................................................... 35/1 - 35/3
37 STEERING ..................................................................................... 37/1 - 37/3
42 BODY .......................................................................................... 42/1 - 42/3
55 HEATER, AIR CONDITIONER AND VENTILATION ............................. 55/1 - 55/3

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

Printed in Malaysia 19 July 2011 Eng

- BULLETIN
/ II Group Index

NOTE

Printed in Malaysia 19 July 2011 Eng

 GENERAL 00
Content /1

00 GENERAL
OUTLINE OF CHANGES ............................................................... 00/2
DESCRIPTION ......................................................................... 00/2
TABLE OF CHANGE ITEMS & REFERENCE MANUALS ......................... 00/2
OUTLINE OF CHANGE ITEMS DETAIL ............................................ 00/4

Printed in Malaysia 19 July 2011 Eng

00 GENERAL
/2 OUTLINE OF CHANGES

OUTLINE OF CHANGES FRM000FWORD11001

DESCRIPTION
This bulletin is additional supplement to WORKSHOP MANUAL FLAT RATE Pub. No.: RDFE-08M040 ,
RDFE-08M040–01,RDFE-08M040-02, RDFE-08M040–03, RDFE-08M040–04, RDFE-08M040–05.which
contains only changes/updates and modification/additional information due to the introduction at
Saga FL Phase 1 model.
TABLE OF CHANGE ITEMS & REFERENCE MANUALS
LEGEND:
: The symbol indicates item in which no change has been made and not in this supplement
manual. The respective item should be referred to the respective manual (supplement
or basic).
: The symbol indicates the item in which a change and/or addition has been made and
the item is presented in this supplement manual.
: The symbol indicates the information is not included in the respective manual (basic or
supplement)
RDFE- RDFE- RDFE- RDFE- RDFE- RDFE-
MAIN CLASSIFICA-
08M040 08M040–01 08M040–02 08M040–03 08M040–04 08M040–05
TITLE TION
(BASIC) (BULLETIN) (BULLETIN) (BULLETIN) (BULLETIN) (BULLETIN)
GRP 00-
—
GENERAL
GRP 11-
—
ENGINE
GRP 12–
LUBRICA- —
TION
GRP 13-
FUEL —
<MPI>
GRP 14–
—
COOLING
GRP 15–
INTAKE
AND EX- —
HAUST
MANIFOLD
GRP 16–
ENGINE
—
ELECTRIC-
AL
GRP 17–
EMISSION —
CONTROL
GRP 21–
—
CLUTCH

Printed in Malaysia 19 July 2011 Eng

 GENERAL 00
OUTLINE OF CHANGES /3

RDFE- RDFE- RDFE- RDFE- RDFE- RDFE-

MAIN CLASSIFICA-
08M040 08M040–01 08M040–02 08M040–03 08M040–04 08M040–05
TITLE TION
(BASIC) (BULLETIN) (BULLETIN) (BULLETIN) (BULLETIN) (BULLETIN)
GRP 22–
MANUAL
—
TRANSMIS-
SION
GRP 23–
AUTOMAT-
IC TRANS-
MIS-
SION/CON-
—
TINU-
OUSLY
VARIABLE
TRANSMIS-
SION (CVT)
GRP 26–
FRONT —
AXLE
GRP 27–
—
REAR AXLE
GRP 31–
WHEEL & —
TYRE
GRP 32–
POWER
—
PLANT
MOUNT
GRP 33-
FRONT
—
SUSPEN-
SION
GRP 34–
REAR SUS- —
PENSION
GRP 35–
SERVICE —
BRAKES
GRP 36–
PARKING —
BRAKES
GRP 37-
—
STEERING
GRP 42–
—
BODY
GRP 42A–
BODY
PAINT

Printed in Malaysia 19 July 2011 Eng

00 GENERAL
/4 OUTLINE OF CHANGES

RDFE- RDFE- RDFE- RDFE- RDFE- RDFE-

MAIN CLASSIFICA-
08M040 08M040–01 08M040–02 08M040–03 08M040–04 08M040–05
TITLE TION
(BASIC) (BULLETIN) (BULLETIN) (BULLETIN) (BULLETIN) (BULLETIN)
GRP 51–
—
EXTERIOR
GRP 52- IN-
—
TERIOR
GRP 54–
CHASSIS
—
ELECTRIC-
AL
GRP 55–
HEATER,
VENTILA-
TION & —
AIR-CONDI-
TIONING
SYSTEM
GRP 100–
WORK
—
CODE
TABLE
GRP 102–
FAILURE —
CODE
OUTLINE OF CHANGE ITEMS DETAIL
Change Items Description Of Changes
GROUP 000 - GENERAL Change item.
GROUP 011 - ENGINE Flat rate time of Flywheel and timing belt.
GROUP 021 - CLUTCH Flat rate time of Clutch.
GROUP 013 - FUEL Flat rate time of Ecu and Tcu
GROUP 022 - MANUAL TRANSMISSION New flat rate time of T/mission.
GROUP 023 - CONTINUOUSLY VARIABLE
New flat rate time of T/mission.
TRANSMISSION (CVT)
GROUP 032 - POWER PLANT MOUNT New flat rate,mounting and illustration
GROUP 035 - SERVICE BRAKE New flat rate time Anti-skid (ABS) control unit.
GROUP 037 - STEERING New flat rate time Electronic stability control (ESC).
GROUP 042 - BODY New flat rate time Rear splash shield,Air guide.
GROUP 055 - HEATER,VENTILATION & AIR-
New flat rate Cooler themistor .
CONDITIONING SYSTEM

Printed in Malaysia 19 July 2011 Eng

 ENGINE 11
Content /1

11 ENGINE
GRAPHICAL ILLUSTRATIONS ........................................................ 11/2

ENGINE .................................................................................. 11/4

Printed in Malaysia 19 July 2011 Eng

11 ENGINE
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM011GRAPH11001

DOIMF011R11001

Printed in Malaysia 19 July 2011 Eng

 ENGINE 11
GRAPHICAL ILLUSTRATIONS /3

DOIMF011R11002

Printed in Malaysia 19 July 2011 Eng

11 ENGINE
/4 ENGINE

ENGINE FRM0110112411003

OPERATION
SAGA
CODE DESCRIPTION
1124 ENGINE FLYWHEEL GENERAL
112410 10 FLYWHEEL ... REPLACEMENT 4.9
Incl
Transmission assy-R&I
Subframe assy (With CVT R&I)
Additional time allowance

P1 ... Continuously Varible Transmission <CVT> 1.2

112411 10 FLYWHEEL RING GEAR ... REPLACEMENT 4.9
Incl
Transmission assy-R&I
Subframe assy (With CVT R&I)
Additional time allowance

P1 ... Continuously Varible Transmission <CVT> 1.2

112422 10 DAMPER ASSY VT2 ... REPLACEMENT 3.8
Incl
Transmission assy-R&I
1134 ENGINE TIMING BELT GENERAL FRM0110113411005

113410 10 TIMING BELT (A) ... REPLACEMENT 1.7

Incl
Timing belt cover-R&I
Engine-adjustment
Braket moulting - For <IAFM+>
Additional operation.

A1 ... Timing belt tensioner … replacement 0.1

1135 ENGINE BELT TENSIONER FRM0110113511003

113510 10 TIMING BELT TENSIONER ASSY ... REPLACEMENT 1.7

Incl
Timing belt cover-R&I
Engine-adjustment

Printed in Malaysia 19 July 2011 Eng

 FUEL 13
Content /1

13 FUEL
GRAPHICAL ILLUSTRATIONS ........................................................ 13/2

FUEL ..................................................................................... 13/3

Printed in Malaysia 19 July 2011 Eng

13 FUEL
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM013GRAPH11003

DOIMF013R11001

Printed in Malaysia 19 July 2011 Eng

 FUEL 13
FUEL /3

FUEL FRM0130138311005

OPERATION
SAGA
CODE DESCRIPTION
1383 SENSOR AND GAUGE UNIT GENERAL
138351 10 OXYGEN SENSOR (BEFORE FCC) ... REPLACEMENT 0.3
Additional time allowance

M4 ... With radiator shroud 0.2

Additional operation.

A9 ... Inspection by PADT- II 0.2

1385 CONTROL UNIT GENERAL FRM0130138511003

138501 10 MPI CONTROL UNIT ... REPLACEMENT 0.4

Additional time allowance.

M3 ... With <IAFM +> Engine – 0.1

Additional operation.

A9 ... Inspection by PADT- II 0.2

Printed in Malaysia 19 July 2011 Eng

13 FUEL
/4 FUEL

NOTE

Printed in Malaysia 19 July 2011 Eng

 INTAKE AND EXHAUST 15
Content /1

15 INTAKE AND EXHAUST

GRAPHICAL ILLUSTRATIONS ........................................................ 15/2

INTAKE AND EXHAUST .............................................................. 15/3

Printed in Malaysia 19 July 2011 Eng

15 INTAKE AND EXHAUST
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM015GRAPH11004

DOIMF015R11001

Printed in Malaysia 19 July 2011 Eng

 INTAKE AND EXHAUST 15
INTAKE AND EXHAUST /3

INTAKE AND EXHAUST FRM0150151511001

OPERATION
SAGA
CODE DESCRIPTION
1515 INTAKE LINE GENERAL
151521 10 INTAKE HOSE ... REPLACEMENT 0.2
1586 SOLENOID VALVE GENERAL FRM0150158611001

158602 10 VARIABLE AIR CONTROL SOLENOID VALVE ... REPLACEMENT 0.2

158612 10 ONE WAY VALVE ... REPLACEMENT 0.2

Printed in Malaysia 19 July 2011 Eng

15 INTAKE AND EXHAUST
/4 INTAKE AND EXHAUST

NOTE

Printed in Malaysia 19 July 2011 Eng

 CLUTCH 21
Content /1

21 CLUTCH
GRAPHICAL ILLUSTRATIONS ........................................................ 21/2

CLUTCH ................................................................................. 21/3

Printed in Malaysia 19 July 2011 Eng

21 CLUTCH
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM021GRAPH11001

DOIMF021R11001

Printed in Malaysia 19 July 2011 Eng

 CLUTCH 21
CLUTCH /3

CLUTCH FRM0210211111001

OPERATION
SAGA
CODE DESCRIPTION
2111 CLUTCH DISC & COVER ASSY GENERAL
211110 10 CLUTCH DISC ... REPLACEMENT 3.1
Incl
Transmission assy-R&I
Clutch cover assy-R&I
Additional time allowance

G1 ... < 5MTT200A> Transmission 1.1

211120 10 CLUTCH COVER ASSY ... REPLACEMENT 3.1
Incl
Transmission assy-R&I
Additional time allowance

G1 ... < 5MTT200A> Transmission 1.1

2120 CLUTCH CONTROL GENERAL FRM0210212011001

212090 10 CONCENTRIC SLAVE CYLINDER ADAPTER ... REPLACEMENT 0.3

Incl
Air Bleeding
212091 10 CONCENTRIC SLAVE CYLINDER ... REPLACEMENT 2.6
Incl
Air Bleeding
Transmission assy -Loose

Printed in Malaysia 19 July 2011 Eng

21 CLUTCH
/4 CLUTCH

NOTE

Printed in Malaysia 19 July 2011 Eng

 MANUAL TRANSMISSION 22
Content /1

22 MANUAL TRANSMISSION
GRAPHICAL ILLUSTRATIONS ........................................................ 22/2

5MTT200A .............................................................................. 22/4

MANUAL TRANSMISSION ........................................................... 22/6

Printed in Malaysia 19 July 2011 Eng

22 MANUAL TRANSMISSION
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM022GRAPH11001

DOIMF022R11001

Printed in Malaysia 19 July 2011 Eng

 MANUAL TRANSMISSION 22
GRAPHICAL ILLUSTRATIONS /3

DOIMF022R11002

Printed in Malaysia 19 July 2011 Eng

22 MANUAL TRANSMISSION
/4 5MTT200A

5MTT200A FRM022GROUP11001

GROUP WORK A :CLUTCH HOUSING AND RELATED PARTS

– Clutch housing plug – Taper bearing outer
ring
– Differential oil seal – Clutch housing dow-
el
– Input shaft oil seal – Reverse idler shaft
– Clutch housing – Output shaft front
bearing outer ring
– Reverse relay arm – Speedometer assy
– Breather pipe – Bolt
– Shift shaft bush – Magnet
– Shift shaft relay bush – Reverse light switch
assy
– Output shaft funnel – Drail oil plug
GROUP WORK B : DIFFERENTIAL AND RELATED PARTS
– Differential taper rolling bearing – Planet pinion shaft
– Speedometer drive gear – Planet pinion
– Bolt – Differential side gear
– Final drive driven gear – Differential case
– Retainer ring
GROUP WORK C : INPUT SHAFT AND RELATED PARTS
– Input shaft front bearing – Input shaft
– Input shaft rear bearing
GROUP WORK D :FORK ASSYAND RELATED PARTS
– st nd
1 / 2 gear fork assy – Shift shaft assy
– rd th
3 / 4 gear fork assy – Interlock plate
– th
5 / Rev gear fork shaft assy
GROUP WORK E : REVERSE GEAR AND RELATED PARTS
– Reverse idler gear – E type retainer ring
– Reverse gear back spring – Check gate assy
– Reverse shift lever – Bolt
GROUP WORK F : DIFFERENTIAL ASSEMBLY AND RELATED PARTS
– Retainer ring – st nd
1 / 2 gear syn-
chronizer inner ring
– Output shaft rear bearing – synchronizer cone
ring
– th
4 speed ring gear – st nd
1 / 2 gear syn-
chronizer outer ring
– rd th th
3 / 4 5 synchronizer ring – Retainer ring
– Retainer ring – st nd
1 / 2 gear syn-
chronizer spring

Printed in Malaysia 19 July 2011 Eng

 MANUAL TRANSMISSION 22
5MTT200A /5

GROUP WORK F : DIFFERENTIAL ASSEMBLY AND RELATED PARTS

– rd th
3 / 4 gear synchronizer spring – st nd
1 / 2 gear syn-
chronizer slider
– rd th
3 / 4 gear synchronizer slider – st nd
1 / 2 gear syn-
chronizer hub
– rd th
3 / 4 gear synchronizer hub – st nd
1 / 2 gear syn-
chronizer sleeve
– rd th
3 / 4 gear synchronizer sleeve – st
1 speed ring gear
– rd
3 speed driven gear – Retainer ring
– Thrust ring – Output shaft front
bearing inner ring
– Thrust washer – Output ring
– rd
2 speed driven gear
GROUP WORK G : TRANSMISSION CASE AND RELATED PARTS
– Taper bearing outer ring – Shift control arm
– Taper washer – Shift shaft oil seal
– Fork bush – Select lever
– Transmission case – Shift shaft boot
– Differential oil seal – Shift shaft screw
– Stud – Shift lever
– Input shaft fastening ring – Interlock retainer
seat assy
– Output shaft fastening ring – E type retainer ring
– Shift shaft bush
GROUP WORK H : REAR COVER AND RELATED PARTS
– Stud – th
5 speed driven gear
– Bolt – Spring pin
– Rear cover – th
5 gear fork assy
– Retainer ring – Snap ring
– th
5 gear spacer – th
5 speed drive gear
– th
5 gear synchronizer assy

Printed in Malaysia 19 July 2011 Eng

22 MANUAL TRANSMISSION
/6 MANUAL TRANSMISSION

MANUAL TRANSMISSION FRM0220221111001

OPERATION
SAGA
CODE DESCRIPTION
2211 TRANSMISSION CONTROL GENERAL
221112 10 T/M SHIFT LEVER KNOB ... REPLACEMENT 0.2
221171 10 T/M CONTROL CABLE ... REPLACEMENT 1.1
Incl
Floor console assy-R&I
Additional time allowance.

G1 ... < 5MTT200A> Transmission 0.3

2220 TRANSMISSION UNIT GENERAL FRM0220222011001

222010 10 T/M ASSY ... REPLACEMENT 3.0

Incl
Drive shaft assy-R&I
222010 20 T/M ASSY ... OVERHAUL 5.0
Incl
Transmission assy-R&I
Defective parts-replacement
222010 9A T/M GROUP WORK (A) 4.3
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1... <5MTT200A> T/M 0.7

222010 9B T/M GROUP WORK (B) 3.8
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1... <5MTT200A> T/M 0.5

222010 9C T/M GROUP WORK (C) 5.0
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1...<5MTT200A> T/M – 0.8

222010 9D T/M GROUP WORK (D) 3.5
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1... <5MTT200A> T/M 0.6

222010 9E T/M GROUP WORK (E) 3.7
Incl
Transmission assy-R&I
Defective parts-replacement

Printed in Malaysia 19 July 2011 Eng

 MANUAL TRANSMISSION 22
MANUAL TRANSMISSION /7

OPERATION
SAGA
CODE DESCRIPTION
Additional time allowance

G1... <5MTT200A> T/M 0.4

222010 9F T/M GROUP WORK (F) 4.3
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1... <5MTT200A> T/M 0.4

222010 9G T/M GROUP WORK (G) 4.5
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1... <5MTT200A> T/M 0.1

222010 9H T/M GROUP WORK (H) 5.0
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

G1... <5MTT200A> T/M – 0.2

2221 TRANSMISSION CASE & HOUSING GENERAL FRM0220222111001

222116 80 T/M DIFFERENTIAL SIDE OIL SEAL ...REPLACEMENT (CLUTCH HOUSING 1.2
SIDE))
Incl
Drive shaft assy-R&I
222116 82 T/M DIFFERENTIAL SIDE OIL SEAL ... REPLACEMENT (TRANSMISSION CASE 1.2
SIDE)
Incl
Drive shaft assy-R&I
2240 TRANSMISSION ATTACHING EQUIPMENT GENERAL
FRM0220224011001

224013 10 SPEEDOMETER DRIVEN GEAR ... REPLACEMENT 0.3

2282 SWITCH GENERAL FRM0220228211001

228201 10 BACK-UP SWITCH ... REPLACEMENT 0.4

Printed in Malaysia 19 July 2011 Eng

22 MANUAL TRANSMISSION
/8 MANUAL TRANSMISSION

NOTE

Printed in Malaysia 19 July 2011 Eng

 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 23
Content /1

23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

GRAPHICAL ILLUSTRATION ......................................................... 23/2

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ............................. 23/4

Printed in Malaysia 19 July 2011 Eng

23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
/2 GRAPHICAL ILLUSTRATION

GRAPHICAL ILLUSTRATION FRM023GRAPH11001

DOIMF023R11001

Printed in Malaysia 19 July 2011 Eng

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 23
GRAPHICAL ILLUSTRATION /3

DOIMF023R11002

Printed in Malaysia 19 July 2011 Eng

23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
/4 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) FRM023GROUP11001

GROUP WORK A : RELATED PARTS

– Flange bolt – Clamp primary cover
– O-ring primary cover – Flange bolt
– Primary cover
GROUP WORK B : RELATED PARTS
– Primary ball bearing – O-ring oil pump
– Primary nut – Oil pump complete
– Disc spring – O-ring oil pump
– Sealing ring oil pump
GROUP WORK C : RELATED PARTS
– Sealing ring plug – Sealing ring
– Plug – O-ring secondary
cover
– O-ring secondary cover – Secondary cover
GROUP WORK D : RELATED PARTS
– Bolt – Speed sensor
– Fixing plate sec.speed sensor – Flange bolt
– Speed sensor sec.complete
GROUP WORK E : RELATED PARTS
– Protection cap connector – Wiring loom vt2
– Holding clip

Printed in Malaysia 19 July 2011 Eng

 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 23
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) /5

OPERATION
SAGA
CODE DESCRIPTION
2311 TRANSMISSION CONTROL GENERAL
231110 10 T/M SELECTOR LEVER ASSY ... REPLACEMENT 0.8
231112 10 T/M SELECTOR HANDLE ... REPLACEMENT 0.6
231118 10 T/M INDICATOR PANEL ... REPLACEMENT 0.4
231131 10 T/M CONTROL (SELECT) CABLE ... REPLACEMENT 1.3
Additional time allowance.

P1 ... Continuously Varible Transmission<CVT> – 0.5

2314 A/T PREVENTIONAL OPERATION ERROR SYSTEM FRM0230231411001

231411 10 SHIFT LOCK LEVER ... REPLACEMENT 0.4

Incl
Floor console assy-R&I
2330 TRANSMISSION UNIT GENERAL FRM0230233011001

233010 10 T/M ASSY ... REPLACEMENT 3.3

Incl
Linkage-adjustment
233010 20 T/M ASSY ... OVERHAUL 4.5
Incl
Transmission assy-R&I
Defective parts-replacement
233010 9A T/M GROUP WORK (A) 5.0
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

P1 ... Continuously Varible Transmission <CVT> – 4.2

Exc
Transmission assy-R&I
233010 9B T/M GROUP WORK (B) 6.1
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

P1 ... Continuously Varible Transmission <CVT> – 4.7

Exc
Transmission assy-R&I
233010 9C T/M GROUP WORK (C) 4.3
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

P1 ... Continuously Varible Transmission <CVT> – 3.4

Exc
Transmission assy-R&I

Printed in Malaysia 19 July 2011 Eng

23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
/6 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

OPERATION
SAGA
CODE DESCRIPTION
233010 9D T/M GROUP WORK (D) 6.5
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

P1 ... Continuously Varible Transmission<CVT> – 5.7

Exc
Transmission assy-R&I
233010 9E T/M GROUP WORK (E) 7.0
Incl
Transmission assy-R&I
Defective parts-replacement
Additional time allowance

P1 ... Continuously Varible Transmission <CVT> – 5.5

Exc
Transmission assy-R&I
2331 TRANSMISSION CASE & HOUSING GENERAL FRM0230233111001

233113 80 T/M DRIVE SHAFT OIL SEAL ... REPLACEMENT (LEFT) 0.8
Incl
Drive shaft assy-R&I
233113 82 T/M DRIVE SHAFT OIL SEAL ... REPLACEMENT (RIGHT) 0.8
Incl
Drive shaft assy-R&I
233141 10 T/M OIL PAN ... REPLACEMENT 1.0
233142 10 T/M OIL PAN GASKET ... REPLACEMENT 1.0
Incl
Oil pan assy-R&I
2337 TRANSMISSION OIL PUMP GENERAL FRM0230233711001

233710 10 T/M OIL PUMP GEAR ASSY ... REPLACEMENT 4.9

233731 10 T/M OIL FILTER ... REPLACEMENT 1.0
Incl
Oil pan assy-R&I
2338 TRANSMISSION VALVE BODY & GOVERNOR GENERAL
FRM0230233811001

233810 10 T/M VALVE BODY ASSY ... REPLACEMENT 1.3

Incl
Oil pan assy-R&I
233875 10 T/M DETENT SPRING COMPLETE ASSY ... REPLACEMENT 1.0
Incl
Oil pan assy-R&I
2351 TRANSFER CASE & CHAIN COVER (REAR CASE) GENERAL
FRM0230235111001

235112 10 T/F CASE INPUT SHAFT OIL SEAL ... REPLACEMENT 3.6

Printed in Malaysia 19 July 2011 Eng

 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 23
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) /7

OPERATION
SAGA
CODE DESCRIPTION
Incl
Transmission assy-R&I
Defective parts-replacement
2375 TRANSMISSION OIL LUBRICATION GENERAL FRM0230237511001

237510 10 T/M OIL HOSE ... REPLACEMENT 0.6

Incl
Front bumper-R&I
Additional time allowance

P1 ... Continuously Varible Transmission<CVT> 0.1

237530 10 T/M OIL COOLER ... REPLACEMENT 0.7
Incl
Front bumper-R&I
2382 SWITCH GENERAL FRM0230238211001

238260 10 SAT (STEPPED AUTOMATIC TRANSMISSION) SWITCH ASSY ... REPLACE- 0.4
MENT
Incl
Floor console assy- R&I
2383 SENSOR AND GAUGE UNIT GENERAL FRM0230238311001

238311 10 INPUT SPEED SENSOR ... REPLACEMENT 1.6

Incl
Primary cover -R&I
238312 10 OUTPUT SPEED SENSOR ... REPLACEMENT 1.6
Incl
Oil pan assy-R&I
2385 CONTROL UNIT GENERAL FRM0230238511001

238501 10 T/M ELC CONTROL UNIT ... REPLACEMENT 0.5

Additional time allowance.

P1 ... Continuously Varible Transmission<CVT> – 0.1

Additional operation.

A9 ... Inspection by PADT- II/Diagnostic tool 0.2

2386 SOLENOID VALVE GENERAL FRM0230238611001

238641 10 SHIFT LOCK SOLENOID ... REPLACEMENT 0.4

Incl
Floor console assy-R&I
2389 ELECTRICAL EQUIPMENT GENERAL (OTHERS) FRM0230238911001

238901 10 GEAR SHIFT LEVER INDICATOR LED BULB ... REPLACEMENT 0.2

Printed in Malaysia 19 July 2011 Eng

23 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
/8 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

NOTE

Printed in Malaysia 19 July 2011 Eng

 POWER PLANT MOUNT 32
Content /1

32 POWER PLANT MOUNT

GRAPHICAL ILLUSTRATIONS ........................................................ 32/2

POWER PLANT MOUNT .............................................................. 32/3

Printed in Malaysia 19 July 2011 Eng

32 POWER PLANT MOUNT
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM032GRAPH11002

DOIMF032R11001

Printed in Malaysia 19 July 2011 Eng

 POWER PLANT MOUNT 32
POWER PLANT MOUNT /3

POWER PLANT MOUNT FRM0320321211002

OPERATION
SAGA
CODE DESCRIPTION
3212 ENGINE SUPPORT GENERAL
321222 10 ENGINE MOUNTING ... REPLACEMENT 0.7
321223 10 T/M MOUNTING ... REPLACEMENT 0.5
Additional time allowance.

G1 ... <5MTT200> Transmission – 0.1

P1 ... Continuously Variable Transmission <CVT> – 0.1

Printed in Malaysia 19 July 2011 Eng

32 POWER PLANT MOUNT
/4 POWER PLANT MOUNT

NOTE

Printed in Malaysia 19 July 2011 Eng

 BRAKES 35
Content /1

35 BRAKES
GRAPHICAL ILLUSTRATIONS ........................................................ 35/2

SERVICE BRAKES ...................................................................... 35/3

Printed in Malaysia 19 July 2011 Eng

35 BRAKES
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM035GRAPH11002

DOIMF035R11001

Printed in Malaysia 19 July 2011 Eng

 BRAKES 35
SERVICE BRAKES /3

SERVICE BRAKES FRM0350358311001

OPERATION
SAGA
CODE DESCRIPTION
3583 SENSOR AND GAUGE UNIT GENERAL
358303 84 SPEED SENSOR (ABS) (FRONT) ... REPLACEMENT (One side) 0.4
Additional operation

A9 ... Inspection by PADT-II 0.2

358303 86 SPEED SENSOR (ABS) (REAR) ... REPLACEMENT (One side) 0.5
Additional operation

A9 ... Inspection by PADT-II 0.2

3585 CONTROL UNIT GENERAL FRM0350358511002

358501 10 ANTI-SKID (ABS) CONTROL UNIT ... REPLACEMENT 0.6

Incl
Air bleeding

Printed in Malaysia 19 July 2011 Eng

35 BRAKES
/4 SERVICE BRAKES

NOTE

Printed in Malaysia 19 July 2011 Eng

 STEERING 37
Content /1

37 STEERING
GRAPHICAL ILLUSTRATIONS ........................................................ 37/2

STEERING ............................................................................... 37/3

Printed in Malaysia 19 July 2011 Eng

37 STEERING
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM037GRAPH11001

DOIMF037R11001

Printed in Malaysia 19 July 2011 Eng

 STEERING 37
STEERING /3

STEERING FRM0370378311001

OPERATION
SAGA
CODE DESCRIPTION
3783 SENSOR AND GAUGE UNIT GENERAL
378309 10 YAW-RATE SENSOR ... REPLACEMENT 0.4
Incl
Floor console assy-R&I
3785 CONTROL UNIT GENERAL FRM0370378511001

378505 10 ELECTRONIC STABILITY CONTROL(ESC) ... REPLACEMENT 0.8

Incl
Steering wheel assy-R&I
Lever/column switch assy-R&I

Printed in Malaysia 19 July 2011 Eng

37 STEERING
/4 STEERING

NOTE

Printed in Malaysia 19 July 2011 Eng

 BODY 42
Content /1

42 BODY
GRAPHICAL ILLUSTRATIONS ........................................................ 42/2

BODY .................................................................................... 42/3

Printed in Malaysia 19 July 2011 Eng

42 BODY
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM042GRAPH11001

DOIMF042R11001

Printed in Malaysia 19 July 2011 Eng

 BODY 42
BODY /3

BODY FRM0420422011001

OPERATION
SAGA
CODE DESCRIPTION
4220 LOOSE PART GENERAL
422018 10 FRONT AIR GUIDE PANEL ... REPLACEMENT 0.6
Incl
Front bumper-R&I
422031 10 REAR SPLASH SHIELD PANEL ... REPLACEMENT (One side) 0.2

Printed in Malaysia 19 July 2011 Eng

42 BODY
/4 BODY

NOTE

Printed in Malaysia 19 July 2011 Eng

 HEATER, AIR CONDITIONER AND VENTILATION 55
Content /1

55 HEATER, AIR CONDITIONER AND VENTILATION

GRAPHICAL ILLUSTRATIONS ........................................................ 55/2

HEATER, AIR CONDITIONER & VENTILATION .................................... 55/3

Printed in Malaysia 19 July 2011 Eng

55 HEATER, AIR CONDITIONER AND VENTILATION
/2 GRAPHICAL ILLUSTRATIONS

GRAPHICAL ILLUSTRATIONS FRM055GRAPH11001

DOIMF055R11001

Printed in Malaysia 19 July 2011 Eng

 HEATER, AIR CONDITIONER AND VENTILATION 55
HEATER, AIR CONDITIONER & VENTILATION /3

HEATER, AIR CONDITIONER & VENTILATION FRM0550551511001

OPERATION
SAGA
CODE DESCRIPTION
5515 AIR CONDITIONER UNIT GENERAL (FRONT)
551514 10 COOLER THERMISTOR ... REPLACEMENT 2.1
Incl
In-panel assy... R&I

Printed in Malaysia 19 July 2011 Eng

55 HEATER, AIR CONDITIONER AND VENTILATION
/4 HEATER, AIR CONDITIONER & VENTILATION

NOTE

Printed in Malaysia 19 July 2011 Eng


00 GENERAL
11 ENGINE
1124 ENGINE FLYWHEEL GENERAL
112410 10 FLYWHEEL ... REPLACEMENT.......
112411 10 FLYWHEEL RING GEAR ...
REPLACEMENT..........................
112422 10 D A M P E R ASSY VT2 ...
REPLACEMENT..........................
1134 ENGINE TIMING BELT GENERAL
113410 10 T I M I N G B E LT (A) ...
REPLACEMENT..........................
1135 ENGINE BELT TENSIONER
113510 10 TIMING BELT TENSIONER ASSY ...
REPLACEMENT..........................
13 FUEL
1383 SENSOR AND GAUGE UNIT GENERAL
138351 10 OXYGEN SENSOR (BEFORE FCC) ...
REPLACEMENT.......................... 13-3
1385 CONTROL UNIT GENERAL
138501 10 MPI CONTROL UNIT ...
REPLACEMENT.......................... 13-3
15 INTAKE AND EXHAUST
1515 INTAKE LINE GENERAL
151521 10 INTAKE HOSE ... REPLACEMENT.... 15-3
1586 SOLENOID VALVE GENERAL
158602 10 VARIABLE AIR CONTROL SOLENOID
VALVE ... REPLACEMENT............. 15-3
158612 10 O N E W AY V A LV E ...
REPLACEMENT.......................... 15-3
21 CLUTCH
2111 CLUTCH DISC & COVER ASSY GENERAL
211110 10 CLUTCH DISC ... REPLACEMENT....
211120 10 CLUTCH COVER ASSY ...
REPLACEMENT..........................
2120 CLUTCH CONTROL GENERAL
212090 10 CONCENTRIC SLAVE CYLINDER
ADAPTER ... REPLACEMENT.........
212091 10 CONCENTRIC SLAVE CYLINDER ...
REPLACEMENT..........................
22 MANUAL TRANSMISSION
2211 TRANSMISSION CONTROL GENERAL
221112 10 T/M SHIFT LEVER KNOB ...
REPLACEMENT..........................
221171 10 T/M CONTROL CABLE ...
REPLACEMENT..........................
2220 TRANSMISSION UNIT GENERAL
222010 10 T/M ASSY ... REPLACEMENT.........
222010 20 T/M ASSY ... OVERHAUL..............
222010 9A T/M GROUP WORK (A)................
222010 9B T/M GROUP WORK (B)................
222010 9C T/M GROUP WORK (C)................
222010 9D T/M GROUP WORK (D)................
222010 9E T/M GROUP WORK (E)................
222010 9F T/M GROUP WORK (F)................
222010 9G T/M GROUP WORK (G)................
222010 9H T/M GROUP WORK (H)................
Printed in Malaysia 19 July 2011 Eng
BULLETIN -
Position Code Index /1
2221 TRANSMISSION CASE & HOUSING GENERAL
222116 80 T/M DIFFERENTIAL SIDE OIL SEAL
...REPLACEMENT (CLUTCH
HOUSING SIDE))......................... 22-7
222116 82 T/M DIFFERENTIAL SIDE OIL SEAL
11-4 ... REPLACEMENT (TRANSMISSION
CASE SIDE)................................ 22-7
11-4 2240 TRANSMISSION ATTACHING EQUIPMENT GENERAL
224013 10 SPEEDOMETER DRIVEN GEAR ...
11-4 REPLACEMENT.......................... 22-7
2282 SWITCH GENERAL
228201 10 B A C K - U P SWITCH ...
11-4 REPLACEMENT.......................... 22-7
23 CONTINUOUSLY VARIABLE TRANSMISSION
11-4
(CVT)
2311 TRANSMISSION CONTROL GENERAL
231110 10 T/M SELECTOR LEVER ASSY ...
REPLACEMENT.......................... 23-7
231112 10 T/M SELECTOR HANDLE ...
REPLACEMENT.......................... 23-7
231118 10 T/M INDICATOR PANEL ...
REPLACEMENT.......................... 23-7
231131 10 T/M CONTROL (SELECT) CABLE ...
REPLACEMENT.......................... 23-7
2314 A/T PREVENTIONAL OPERATION ERROR SYSTEM
231411 10 S H I F T LOCK LEVER ...
REPLACEMENT.......................... 23-7
2330 TRANSMISSION UNIT GENERAL
233010 10 T/M ASSY ... REPLACEMENT......... 23-7
233010 20 T/M ASSY ... OVERHAUL.............. 23-7
233010 9A T/M GROUP WORK (A)................ 23-7
233010 9B T/M GROUP WORK (B)................ 23-7
233010 9C T/M GROUP WORK (C)................ 23-7
233010 9D T/M GROUP WORK (D)................ 23-7
233010 9E T/M GROUP WORK (E)................ 23-7
2331 TRANSMISSION CASE & HOUSING GENERAL
233113 80 T/M DRIVE SHAFT OIL SEAL ...
21-3 REPLACEMENT (LEFT)................. 23-7
233113 82 T/M DRIVE SHAFT OIL SEAL ...
21-3 REPLACEMENT (RIGHT)............... 23-7
233141 10 T/M OIL PAN ... REPLACEMENT..... 23-7
233142 10 T/M OIL PAN GASKET ...
21-3 REPLACEMENT.......................... 23-7
2337 TRANSMISSION OIL PUMP GENERAL
21-3 233710 10 T/M OIL PUMP GEAR ASSY ...
REPLACEMENT.......................... 23-7
233731 10 T/M OIL FILTER ... REPLACEMENT... 23-7
2338 TRANSMISSION VALVE BODY & GOVERNOR GENERAL
233810 10 T/M VALVE BODY ASSY ...
REPLACEMENT.......................... 23-7
22-7
233875 10 T/M DETENT SPRING COMPLETE
ASSY ... REPLACEMENT............... 23-7
22-7
2351 TRANSFER CASE & CHAIN COVER (REAR CASE) GENERAL
235112 10 T/F CASE INPUT SHAFT OIL SEAL ...
22-7
REPLACEMENT.......................... 23-7
22-7
2375 TRANSMISSION OIL LUBRICATION GENERAL
22-7
237510 10 T/M OIL HOSE ... REPLACEMENT.... 23-7
22-7
237530 10 T / M OIL COOLER ...
22-7
REPLACEMENT.......................... 23-7
22-7
2382 SWITCH GENERAL
22-7
238260 10 SAT (STEPPED AUTOMATIC
22-7
TRANSMISSION) SWITCH ASSY ...
22-7
REPLACEMENT.......................... 23-7
22-7
2383 SENSOR AND GAUGE UNIT GENERAL
- BULLETIN
/2 Position Code Index

238311 10 INPUT SPEED SENSOR ...

REPLACEMENT.......................... 23-7
238312 10 OUTPUT SPEED SENSOR ...
REPLACEMENT.......................... 23-7
2385 CONTROL UNIT GENERAL
238501 10 T/M ELC CONTROL UNIT ...
REPLACEMENT.......................... 23-7
2386 SOLENOID VALVE GENERAL
238641 10 SHIFT LOCK SOLENOID ...
REPLACEMENT.......................... 23-7
2389 ELECTRICAL EQUIPMENT GENERAL (OTHERS)
238901 10 GEAR SHIFT LEVER INDICATOR LED
BULB ... REPLACEMENT............... 23-7

32 POWER PLANT MOUNT

3212 ENGINE SUPPORT GENERAL
321222 10 ENGINE MOUNTING ...
REPLACEMENT.......................... 32-3
321223 10 T / M MOUNTING ...
REPLACEMENT.......................... 32-3

35 BRAKES
3583 SENSOR AND GAUGE UNIT GENERAL
358303 84 SPEED SENSOR (ABS) (FRONT) ...
REPLACEMENT (One side)........... 35-3
358303 86 SPEED SENSOR (ABS) (REAR) ...
REPLACEMENT (One side)........... 35-3
3585 CONTROL UNIT GENERAL
358501 10 ANTI-SKID (ABS) CONTROL UNIT ...
REPLACEMENT.......................... 35-3

37 STEERING
3783 SENSOR AND GAUGE UNIT GENERAL
378309 10 YAW-RATE SENSOR ...
REPLACEMENT.......................... 37-3
3785 CONTROL UNIT GENERAL
378505 10 ELECTRONIC STABILITY
CONTROL(ESC) ... REPLACEMENT.. 37-3

42 BODY
4220 LOOSE PART GENERAL
422018 10 FRONT AIR GUIDE PANEL ...
REPLACEMENT.......................... 42-3
422031 10 REAR SPLASH SHIELD PANEL ...
REPLACEMENT (One side)........... 42-3

55 HEATER, AIR CONDITIONER AND VENTILATION

5515 AIR CONDITIONER UNIT GENERAL (FRONT)
551514 10 COOLER THERMISTOR ...
REPLACEMENT.......................... 55-3

Printed in Malaysia 19 July 2011 Eng

 BULLETIN -
Position Code Index /3

NOTE

Printed in Malaysia 19 July 2011 Eng

Printed in Malaysia 19 July 2011 Eng
SAGA Model YR 2011 English Edition RDCE-08M040-05 July 2011 Printed in Malaysia