LTG 2005-1 (0922)

Labor Time Guide
(Chairman, Korando, Musso, Musso sports, Rexton, Stavic)
SECTION INDEX
A. GENERAL INFORMATION A - 1
1. ENGINE D - 19
FOREWORD (D-Diesel, G-Gasoline) G - 103
This Labor Time Guide has been prepared for the purpose 2. SUSPENSION 2 - 177
of implementing the terms of the current Dealer Sales and
Service Agreement and is intended solely for the purpose
of computing the compensation payable by SsangYong 3. DRIVE LINE & AXLE 3 - 213
Motor Co.,Ltd. to the authorized SsangYong dealers for
the performance of warranty, policy and campaign adjust-
ment and other work authorized and performed for the ac- 4. BRAKES 4 - 221
count of SsangYong Motor Co., Ltd.
This use of this guide for any other purpose is neither
5. TRANSMISSION &
intended not authorized by SsangYong Motor Co., Ltd. 5 - 251
Please read the introduction of this guide thoroughly to
TRANSFER CASE
acquaint with SsangYong warranty system.
6. STEERING 6 - 319
All time allowances in this guide are subject to change at
any time by SsangYong Motor Co., Ltd. based on time
7. H.V.A.C (Heating, Ventilation
studies by the company related to improved methods, 7 - 335
techniques or equipment or other advances in the industry.
& Air Conditioning)
8. RESTRAINTS 8 - 355
9. BODY & ACCESSORIES 9 - 369
10. PAINT 10 - 513

PYUNGTAEK, KOREA
11. OTHERS 11 - 526

SECTION A
GENERAL INFORMATION
1.INTRODUCTION ..................................................................................... 5
2.HOW TO READ THIS MANUAL .............................................................. 6
3.HOW TO USE THIS MANUAL ................................................................ 9
4.PAINT REPAIR ......................................................................................10
5.DEFECT CODE .....................................................................................11
6.ABBREVIATION ....................................................................................13
7.MAIN GROUP CODE .............................................................................14
GENERAL INFORMATION A
1. INTRODUCTION
1-1. PAGE LAYOUT
This Labor Time Guide is designed for convenient and accurate use. In order to provide easy location of operations,
the layout has been structured in reading sequence with the corresponding illustration.
1-2. TYPES OF OPERATION
Major Operation
The Labor Operation Codes consist of seven digits. All operation numbers having “0” in the seven digit of operation
number are classified as “major” operations. A major operation time allowance is sufficient to do the work described
as a single operation.
Supplementary Operation (Adds)

All operation numbers having an alphabetical letter in the seventh digit of the operation number are classified as
“Supplementary” operations. These operations cannot be used as single operation and must be used as additions to
the major operation.
1-3. TIME ALLOWANCES

The time allowances published in this guide have been determined by performing the operation a sufficient number of
times to establish an average time or to determine that a fair and equitable time has been developed. Standard
technician’s hand tools and dealer essential and available tools are used in performing time studies. No power
operated tools are used for time studies. Procedures outlined in Service Manuals, other Service Publications and
standard 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 additional allowance to provide
for operating variables. Time allowances include time to remove and reinstall manufacturer optiones and accessories
but do not include time to remove and reinstall special or aftermarket equipment.
“Repair diagnosis” time is include in all published labor time operations when it is required to perform the operation.
It is the responsibility of the dealer’s qualified service staff to assist technicians in “customer problem analysis” and
“symtom diagnosis”.
5
A GENERAL INFORMATION
2. HOW TO READ THIS MANUAL
1B-D DIESEL ENGINE MECHANICAL
111
6
7 6
ENGINE UNIT 111

CM MU/MU-S/KO RX ST
Operation
NO. Opertion Description 661 662 661 662
Code - - XDi XDi
NA,LA NA,LA NA,LA NA,LA
1 GASKET, CYLINDER HEAD - REPLACE 1312300 - - 5.0 5.0 5.0 5.0 - -
2 HEAD, CYLINDER - REPLACE 1312500 - - 5.0 5.0 5.0 5.0 - -
HEAD, CYLINDER - OVERHAUL 1312600 - - 7.6 7.6 7.6 7.6 - -
3 VALVE (ONE CYLINDER) - REPLACE 1312700 - - 7.6 7.6 7.6 7.6 - -
C - Valves (each additional) 131270C - - 0.1 0.1 0.1 0.1 - -
2 3B 3A 4 5
6
1) Section
Refer to the main group code in this chapter.
2) Illustration Number
The illustration number corresponds to the reference number on the illustration.
3) Operation Description
3A. Major Operation
The description corresponding to each operation number names the parts or component concerned, and describes
what kind of operation is to be performed.
3B. Supplementary Operation

The description corresponding to each operation number names the parts or component concerned, and describes
the additional operation for removing and reinstalling optional equipment such as power steering, air conditioning,
etc., when major operation is performed on the vehicle with optional equipment.
4) Operation Code
The operation code consist of seven digits.
Main group code

Basic code
Auxiliary code
Main Group Code

The main group code consists of 3 digits which indicates the area of the vehicle where the repair was performed.
Basic Code
The basic code is a 3-digit serial number to each specific operation.
Auxiliary Code
The Auxiliary Code indicates the type of repairs as shown below :
Auxiliary Code Description

0 Major operation
A
B
.
Supplementary operation
.
.
7
Major Operation
The numeric code “0” represents a major operation.
Supplementary Operation (ADD)

The numerical code “A”~“R” represents supplementary work of where time is required additionally for the incidental
repair work of the parts or components related to the originally intended repair.
5) Operation Times
The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1hour and 6 minutes).
Enter the operation time on the warranty claim in the same manner.
6) Model Code
This code represents the vehicle model.
Vehicle model
CM : Chairman
MU : Musso
MU-S : Musso Sports
KO : Korando
RX : Rexton
ST : STAVIC
7) Engine Type
This designation represents engine types.
2.0 : M161 Gasoline Engine (G20D)
661 NA/LA : OM 661 Diesel Engine
662 NA/LA : OM 662 Diesel Engine
XDi : D27DT(Direct Injection Diesel Engine)
8
3. HOW TO USE THIS MANUAL

The operation time in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1hour and 6 minutes).
Enter the operation time on the warranty claim in this manner.
Example : (When supplementary work is performed in addition to the intended repair)
Model : CM
Major operation : Valve replacement
Supplementary Work : Valves (Each Additional)
Step 1 : First find ENGINE MECHANICAL – CYLINDER HEAD in MAIN GROUP INDEX and then the page (Engine
1C-15) for valve from among them.
Step 2 : On page Engine 1C-15, note the operation code for Valve. (Replacement)
1312700 VALVE - REPLACE 7.0

131270C VALVES (EACH ADDITIONAL) 0.1
Operation Time Total 7.1
Operation CM MU/MU-S/KO RX ST
NO. Opertion Description
Code 2.0/2.3 2.8/3.2 2.0/2.3 2.8/3.2 2.0/2.3 2.8/3.2 2.3 3.2
1 GASKET, CYLINDER HEAD - REPLACE 1312300 6.3 6.3 5.6 6.0 5.6 6.0 - -
2 HEAD, CYLINDER - REPLACE 1312500 6.3 6.3 6.3 6.3 6.3 6.3 - -
HEAD, CYLINDER - OVERHAUL 1312600 8.4 8.6 8.4 8.6 8.4 8.6 - -
3 VALVE (ONE CYLINDER) - REPLACE 1312700 6.8 7.0 8.4 8.6 8.4 8.6 - -
C - Valves (each additional) 131270C 0.1 0.1 0.1 0.1 0.1 0.1 - -
Major operation : VALVE - REPLACE 1312700 7.0
Supplementary Work : C - Valves (each additional) 131270C 0.1
Operation Code 1312700 & 131270C
Operation Time Total 7.0 + 0.1 = 7.1
9
4. PAINT REPAIR
4-1. INSTRUCTION
The time allowances herein for painting operations are established on the basis of techniques and material required
for quality work both in appearance and durability.
The basis for determining the paint time allowances is a “Paintable Surface”.
1. After dents have been removed from sheet metal parts and the parts welded they are stored to their neutral
shape.
2. Welding and soldering joints, overlapping seams formed by partial replacement and surfaces smoothed with
fillers are ground down using P80-120 grain sandpaper.
3. And when the painter does not need to apply more than 3 coats of knife-edge putty to the surfaces to be painted.
4-2. LABOR TIME

The time allowances for paint work consider all cases such as material preparation time, actual working process, and
material allowances, which are necessary for a proper and professional paint job. It shall be noted material allow-
ances are converted to hours and included in the operation time, also.
According to the character of paint process and size of area to be painted, the kinds and quantity of the material will
be varied in the course of paint.
The material allowances consist of mixed paint and additional material such as masking tape, sanding paper, clean-
ing solvent and etc. needed for the operation of each step.
INCLUDES ; moving the vehicle / mixing all materials / color blending / equipment cleaning / color spray sample /
repainting time on clear coat / masking / sanding / cleaning / spraying / removing of the masking and
polishing.
EXCLUDES ; removal and reinstallation of body attaching parts.
4-3. REPAIR TYPE
Type Description
COLOR COAT PAINT EXPOSED SURFACES
Top-coat entire surface, including small dents that have been straightened(without filling in). Its operation
should be used when correcting painting conditions such as thin paint, color mismatch or surface scratches
not extending beyond the prime coat.
REFINISH PAINT NEW PART
This operation involves sanding out a defect to expose a local area of bare metal, prime locally and then
apply color coat.
This applies to those paint repairs that require a repair to the prime coat before the color coat is applied.
POLISHING POLISH THE SURFACES
4-4. HOW TO USE OPERATION CODE ON PARTIAL PAINTING

Use the operation code of the relevant part and enter “P” on PF column in Ssangyong Claim Report.
For example, in case of partial painting on hood in CHAIRMAN model, make out Ssangyong Claim Report as follows;
PF OPERATION CODE HOUR

P 9836080 3.1
10
5. DEFECT CODE
5-1. NATURE CODE
N01 Hard start, no start N43 Excessive shock

N02 Poor idle N44 Poor release
N03 Surge, hesitate, stumble N45 Unusual tire wear
N04 Engine noise, engine knoking noise N46 Misaligned or mismatched
N05 Choke malfunction N47 Weak
N06 Engine stalled (general) N48 Hard to turn
N07 Excessive fuel consumption N49 Impossible to turn
N08 Excessive oil consumption N50 Vehicle bouncing
N09 Overheated N51 Deteriorated
N10 Shift shock N52 Distorsion, rainbow, waving
N11 Engine run-on N53 Color mismatched
N12 Flooded, overflowing N54 Defective chrom plate, defective painting
N13 Poor acceleration, uneven acceleration N55 Rust, corrosion, perforation
N14 Abnormal combustion N56 Glazed
N15 Lack of engine power N57 Loose, poor fit
N16 Percolation N58 Bubbles
N17 Improper exhaust gas (black smoke, white smoke) N59 Vehicle vibration
N18 Backfire, afterfire N60 Excessive vibration
N19 Vapor lock N61 Dead battery
N20 Blocked N62 Inaccurate (meter, gauge, etc.)
N21 Shuddering, pulsation, vibration, chattering N63 Poor sound (horn, radio, etc.)
N22 Slippage (slipping) N64 Overcharged, discharged
N23 Difficult engagement N65 Electrical failures
N24 Difficult disengagement N66 Blown fuse
N25 Abnormal shifts N67 Warning light on
N26 Impossible shifts N68 Intermittent operation
N27 Squeaking, squealing, abnormal(wind)noise N69 Pulls to left or right
N28 Dragging N70 Poor AM reception / interference
N29 Pulls N71 Oil leak, oil entering
N30 Stalled while driving N72 Water leak, water entering
N31 Stalled while idling N73 Leaks-other (air, fuel, refrigerant, vacuum)
N32 Stalled between shifts N74 Poor FM reception / interference
N33 Stalling during sudden braking N75 Radio / CD does not operate properly
N34 Fails to reach normal operating temperature N76 Tape deck does not operate properly
N35 RPM too low N77 Improper memory
N36 RPM too high N78 Improper volume control
N37 Jumping-out N80 Head lamp improperly aimed
N38 Improper synchronizing N82 Loosening, failing-off, sagged
N39 Oil diluted N83 Gas leak, gas entering
N40 Misfire N84 Improper opening and/or closing
N41 Sponge pedal N85 Grabbed
N42 Unstable steering N86 Poor maneuverability
11
N87 Insufficient brake N94 Special policy

N88 Brake judder N95 Glass cracked
N90 Color rainbow, color waving N96 Glass broken
N91 Interference or hitting N97 Glass chipped
N92 Inoperative N98 Glass scratched
N93 High/low operating effort N99 Undefined
5-2. CAUSE CODE
R01 Scored, scratched or chipped R19 Improperly machined

R02 Frozen (temperature) R20 Faulty casting
R03 Peeling, comimg-off R21 Improper clearance, back lash, free play
R04 Rusty, corroded R22 Lack of lubricants
R05 Split, cut or torn R23 Improper welding or soldering, welding or solder-
ing omitted
R06 Broken or cracked R24 Improper tightening, fit or assembly
R07 Porous, pin holes, cavity R25 Sticks, binds, seized
R08 Bent, kinky, twisted, distorted, wraped or wrinkled R26 Foreign material, clogged
R09 Stripped - bolts, holes, nuts R27 Improper sealing, sealer omitted or skipped
R10 Soiled R28 Improper adjustment
R11 Weakened, loss of tension or resilience R31 Incorrect part
(spring, cushion, etc.)
R12 Abnormal wear R32 Improperly installed
R13 Out of balance R33 Improperly routed
R14 Out of round R34 Missing part
R15 Loose or improper connection R35 Flaw in material
R16 Open circuit or short circuit R36 Contaminants
R17 Burnt or burned - out R99 Undefined
R18 Grounded or shorted
5-3. PAINT CODE
P01 Oversprayed, drip P19 Atmospheric fallout

P02 Undersprayed, bare P20 Polishing mark, sanding mark
P03 Color mismatched P21 Touch up
P04 Low Gloss P22 Dust, dirt
P05 Mottled, cloudy P23 Poor welding
P06 Sags or runs P24 Rust
P07 Pin hole P25 Blistered
P11 Peeling, scaling P26 Chipped
P12 Orange peel P27 Cracked
P13 Slow drying P30 Surface scratch
P14 Thin no paint P31 Scab corrosion
P15 Wavy P32 Dent
P16 Tape mark, touch mark P33 Rust perforation
P17 Chemical damage P34 Discolored, faded
P18 Acid rain P99 Undefined
12
6. ABBREVIATION
A/C Air conditioning MAP Manifold absolute pressure
ABD Antilock brake differential MAT Manifold air temperature
ADJ Adjust M/T Manual transaxle
ASSY Assembly OH Overhaul
A/T Auto transaxle PLA Plating
CC Color coat print POL Polishing
CHK Check RAD Radiator
CLN Clean REF Refinish paint
DOHC Double overhead camshaft REKES Remote keyless entry system
ECS Electrical control system RI Reinstall
EGR Exhaust gas recirculation RP Replacement
IAC Idle air control TPS Throttle position sensor
I/P Instrument panel T/C Transfer case
L.C.R.V Load conscious reducing valve T.O.D Torque on demand
13
7. MAIN GROUP CODE

The first 3 digits of 7 digit code classify the units to be serviced into main groups.
SECTION SUB - SECTION MAIN GROUP CODE PAGE

1. ENGINE 1B-D Disel Engine Mech. 111 Engine unit (21p)
113 Belt system
121 Engine block
122 Crankshaft & piston
123 Oil pan & pump
131 Cylinder head
132 Cam support & shaft
133 Timing cover & chain drive
136 Injection pipe
138 Engine & transaxle mount
139 Vacuum system
1D-D Engine Cooling 141 Radiator (47p)
143 Cooling fan
144 Oil cooler
145 Radiator hose & pipe
148 Thermostat & water pump
1E-D Engine Electrical 154 Alternator unit (59p)
156 Starter
157 Battery
158 Fuse & relay
1F-D Engine Controls 170 Fuel filter line (69p)
171 Fuel tank
172 Fuel line
174 Injection pump
182 Accelerator control
1G-D Engine Intake & Exhaust 190 Common rail system (83p)
191 Air intake system
193 Intake manifold
194 Exhaust manifold
196 Exhaust pipe line
197 Turbo charger assembly
198 Sensors
1C-G Gasoline Engine Mech. 111 Engine unit (105p)
113 Belt system
121 Engine block
122 Crankshaft & piston
123 Oil pan & pump
131 Cylinder head
132 Cam support & shaft
133 Timing cover & chain drive
138 Engine & transaxle mount
139 Vacuum system
14

1. ENGINE 1D-G Engine Cooling 141 Radiator (127p)
143 Cooling fan
144 Oil cooler
145 Radiator hose & pipe
148 Thermostat & water pump
1E-G Engine Electrical 151 Ignition cable (139p)
154 Alternator unit
156 Starter
157 Battery
158 Fuse & relay
1F-G Engine Controls 171 Fuel tank (151p)
172 Fuel line & oil line
173 Canister & fuel vacuum
181 Fuel injection
182 Accelerator control
186 Emission control
1G-G Engine Intake & Exhaust 191 Air intake system (167p)
193 Intake manifold
194 Exhaust manifold
196 Exhaust pipe line
2. SUSPENSION 2C Front Suspension 213 Knuckle & hub (179p)
214 Front shock absorber
215 Control arm
216 Torsion bar
217 ECS
218 Sub frame
219 EAS
2D Rear Suspension 231 Rear axle & stabilizer (197p)
232 Rear shock absorber
233 Steering damper
234 Sub frame
2E Tires & Wheel 241 Wheels (209p)
242 TPMS
3. DRIVE LINE & 3A Drive Line & Axle 321 Axle shaft parts (215p)
AXLE 323 Propeller shaft
4. BRAKES 4A Hydraulic Brake 425 Brake pipe (223p)
428 Brake pedal & mount
4B Master Cylinder & Booster 431 Master cylinder & booster (229p)
4D Front Brake 445 Front brake (233p)
4E Rear Brake 456 Rear brake (237p)
4F Anti-Lock Brake System 462 ABS system (243p)
4G Parking Brake 478 Parking brake (247p)
479 EPB
15

5. TRANSMISSION 5A Auto Transmission Controls 519 Auto Transmission Controls (255p)
& TRANSFER 5B BTR M74 Auto Transmission 541 BTR M74 I (259p)
CASE
542 BTR M74 II
543 BTR M74 III
544 BTR M74 IV
5C W4A040 Auto Transmission 546 W4A040 A/T I (269p)
547 W4A040 A/T II
548 W4A040 A/T III
549 W4A040 A/T IV
5D W5A330 Auto Transmission 551 W5A330 A/T I (281p)
556 W5A330 A/T II
557 W5A330 A/T III
558 W5A330 A/T IV
559 W5A330 A/T V
5E Five-Speed Manual 561 Manual Transmission (293p)
Transmission 563 Transmission gear
566 Gear shift cover & fork
569 Shift control
5F Clutch 581 Clutch parts (303p)
582 Hydraulic clutch
583 Clutch pedal
5G Transfer Case 592 Transfer case (part time) (311p)
593 T.O.D
595 Transfer case (full time)
6. STEERING 6A Power Steering System 621 Power steering gear (321p)
623 Power steering pipe line
6E Steering Wheel & Column 641 Steering wheel (327p)
643 Steering column
647 Tie rod
7. H.V.A. C (Heating, 7A H.V.A.C (Air Distribution) 711 Air distribution (337p)
Ventilation & Air 713 Evaporator
Conditioning)
714 Blower
7B H.V.A.C (Control) 732 Compressor (345p)
733 Compressor mount
734 A/C hose & pipe line
735 A/C control switch & sensor
8. RESTRAINTS 8A Seat Belts 812 Front seat belt (357p)
822 Rear seat belt
8B S.R.S (Supplemental Inflatable 832 Air bag system (363p)
Restraints) 833 Immobilizer
9. BODY & ACCES- 9A Body Wiring System 911 Wiring harness (371p)
SORIES 9B Lighting System 916 Front lamp (377p)
918 Rear lamp
16

9. BODY & ACCES- 9D Wiper & Washer System 921 Washer system (383p)
SORIES 923 Wiper system
9E Inst. Driver System 925 Instrument cluster (389p)
9F Audio & Anti-theft System 928 Electrical parts (393p)
929 Stics & auto cruise
9G Interior Trim 931 Instrument panel (407p)
932 Switch
933 Instrument parts
934 Console
935 Front door trim
936 Rear door trim
938 Pillar trim
939 Floor carpet & panel
9H Seats 941 Front seat (431p)
942 Rear seat
9L Glass & Mirrors 946 Glass & outside mirrors (437p)
9M Exterior Parts 951 Emblem & lettering (443p)
952 Mud guard
9O Bumpers & Fascias 956 Front bumper (451p)
957 Rear bumper
9P Doors 961A Front door & lock (457p)
961B Front window lifter
961C Front weatherstrip
963A Rear door & lock
963B Rear window lifter
963C Rear weatherstrip
965 Electric door lock
966 Fuel filler lock
967 Trunk lid lock & tailgate lock
968 Car lock
9Q Roof 971 Headlining & roof panel (479p)
972A Sunshade & inside mirror
972B Sun roof
9R Body Front End 973 Hood panel (489p)
974 Front panel
975 Fender panel
976 Dash panel & cowl
977 Grille
9S Body Rear End 978 Trunk lid panel & spoiler (503p)
979 Side trim
10. PAINT 10A PAINT - CHAIRMAN LIMOUSINE, CHAIRMAN (515p)
MUSSO & MUSSO SPORTS
KORANDO
REXTON
STAVIC
11. OTHERS 11 Others Others (526p)
17
SECTION 1-D
DIESEL ENGINE
1B-D. DIESEL ENGINE MECHANICAL .................................................... 21

1D-D. ENGINE COOLING ....................................................................... 47
1E-D. ENGINE ELECTRICAL .................................................................. 59
1F-D. ENGINE CONTROLS .................................................................... 69
1G-D. ENGINE INTAKE & EXHAUST ...................................................... 83
1B-D. DIESEL ENGINE MECHANICAL 1B-D
111. ENGINE UNIT .......................................................................... 22
113. BELT SYSTEM ....................................................................... 24
121. ENGINE BLOCK ..................................................................... 26
122. CRANKSHAFT & PISTON ...................................................... 28
123. OIL PAN & PUMP.................................................................... 32
131. CYLINDER HEAD.................................................................... 34
132. CAM SUPPORT & SHAFT...................................................... 36
133. TIMING COVER & CHAIN DRIVE .......................................... 38
136. INJECEION PIPE .................................................................... 40
138. ENGINE & TRANSAXLE MOUNT .......................................... 42
139. VACUUM SYSTEM ................................................................. 44

111
22
DIESEL ENGINE MECHANICAL 1B-D
ENGINE UNIT 111

CM MU/MU-S/KO RX ST
Operation
NO. Operation Description 661 662 661 662
Code - - XDi XDi
1 ENGINE ASSEMBLY (M/T) - OVERHAUL 1110100 - - 16.0 16.2 16.0 16.2 14.2 14.2
ENGINE ASSEMBLY (A/T) - OVERHAUL 1110300 - - 16.0 16.2 16.0 16.2 14.2 14.2
2 ENGINE ASSEMBLY (M/T) - REPLACE 1110800 - - 8.3 8.3 8.3 8.3 9.7 9.7
ENGINE ASSEMBLY (A/T) - REPLACE 1110900 - - 9.3 9.3 9.3 9.3 9.7 9.7
CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 23

113
24
BELT SYSTEM 113

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 BELT, PULLEY - REPLACE 1132210 - - 0.5 0.5 0.5 0.5 0.4 0.4
2 PULLEY ASSEMBLY, IDLER - REPLACE 1132500 - - 0.5 0.5 0.5 0.5 0.5 0.5
3 SPRING ASSEMBLY, TENSION - REPLACE 1132510 - - 0.3 0.3 0.3 0.3 - -
4 LEVER ASSEMBLY, SPRING TIGHTENER - REPLACE 1132520 - - 0.3 0.3 0.3 0.3 - -
5 SHOCK ABSORBER ASSEMBLY - REPLACE 1132530 - - 0.3 0.3 0.3 0.3 0.4 0.5
6 LEVER ASSEMBLY, TIGHTENER - REPLACE 1132540 - - 0.6 0.6 0.6 0.6 - -
7 PULLEY ASSEMBLY, BELT TIGHTENER - REPLACE 1132550 - - 0.5 0.5 0.5 0.5 - -
8 PULLEY, COOLING FAN - REPLACE 1132600 - - - - - - 0.7 0.7
9 SEALING, CRANKSHAFT (FRONT) - REPLACE 1132700 - - - - - - 1.5 1.5
10 TENSIONER ASSY, BELT - REPLACE 1132800 - - - - - - 0.5 0.5
11 TIMING CASE & GASKET - REPLACE 1132900 - - - - - - 12.2 12.2

121
26
ENGINE BLOCK 121

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 OIL LEVEL INDICATOR AND/OR O-RING - REPLACE 1210200 - - 0.2 0.2 0.2 0.2 0.2 0.2
2 TUBE, OIL LEVEL INDICATOR - REPLACE 1210300 - - 0.3 0.3 0.3 0.3 0.3 0.3
3 PLUG, EXPANSION - REPLACE 1210700 - - 4.1 4.1 4.1 4.1 4.1 4.1
A - Replace each additional 121070A - - 0.1 0.1 0.1 0.1 0.1 0.1
4 PLUG, CYLINDER BLOCK DRAIN - REPLACE 1210800 - - 0.3 0.3 0.3 0.3 0.3 0.3
5 BLOCK, CYLINDER - REPLACE 1211100 - - 16.0 16.2 16.0 16.2 16.2 16.2
6 BALL, PLUG OIL CHANNEL - REPLACE 1211200 - - 1.0 1.0 1.0 1.0 1.0 1.0
7 SEMI BLOCK (SHORT BLOCK), CYLINDER - REPLACE 1211110 - - 13.7 13.9 13.7 13.9 16.8 16.8
8 SEALING, CRANKSHAFT (REAR) - REPLACE 1211300 - - 5.4 5.4 5.4 5.4 5.4 5.4

122-1
28
CRANKSHAFT & PISTON 122-1

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 SEAL(S), CRANKSHAFT REAR MAIN (A/T) - REPLACE 1220200 - - 6.2 6.2 6.2 6.2 - -
SEAL(S), CRANKSHAFT REAR MAIN (M/T) - REPLACE 1220400 - - 5.4 5.4 5.4 5.4 - -
2 COVER, CRANKSHAFT SEALING (A/T) - REPLACE 1220410 - - 3.4 3.4 3.4 3.4 - -
COVER, CRANKSHAFT SEALING (M/T) - REPLACE 1220420 - - 2.4 2.4 2.4 2.4 - -
3 DAMPER, CRANKSHAFT VIBRATION - REPLACE 1220500 - - 2.8 2.8 2.8 2.8 - -
4 BEARING, CRANKSHAFT MAIN (ONE) - REPLACE 1220600 - - 15.5 15.5 15.5 15.5 13.4 13.4
5 BEARING, CRANKSHAFT THRUST - REPLACE 1220610 - - 15.5 15.5 15.5 15.5 14.2 14.2
6 BEARING, CONNECTING ROD (ONE) - REPLACE 1220800 - - 15.5 15.5 15.5 15.5 - -
7 BEARING, GROOVED BALL (M/T) - REPLACE 1220900 - - 5.4 5.4 5.4 5.4 5.4 5.4
BEARING, GROOVED BALL (A/T) - REPLACE 1220910 - - 5.6 5.6 5.6 5.6 - -
8 CRANKSHAFT (M/T) - REPLACE 1221100 - - 13.4 13.4 13.4 13.4 - -
D - Replace one piston ring 122110D - - 0.4 0.4 0.4 0.4 - -
E - Replace all piston rings 122110E - - 1.2 1.2 1.2 1.2 - -
F - Replace one connecting rod 122110F - - 0.5 0.5 0.5 0.5 - -
G - Replace all connecting rods 122110G - - 1.6 1.6 1.6 1.6 - -
9 CRANKSHAFT(A/T) - REPLACE 1221200 - - 15.5 15.5 15.5 15.5 - -
D - Replace one piston ring 122120D - - 0.4 0.4 0.4 0.4 - -
E - Replace all piston rings 122120E - - 1.2 1.2 1.2 1.2 - -
F - Replace one connecting rod 122120F - - 0.5 0.5 0.5 0.5 - -
G - Replace all connecting rods 122120G - - 1.0 1.0 1.0 1.0 - -
10 PISTON, ROD AND/OR RINGS (ONE) - REPLACE 1221500 - - 15.5 15.5 15.5 15.5 - -
11 BUSHING, CONNECTING ROD - REPLACE 1221540 - - 15.5 15.5 15.5 15.5 - -
12 FLYWHEEL (M/T) - REPLACE 1221700 - - 5.4 5.4 5.4 5.4 5.4 5.4
A - Flywheel ring gear (M/T) 122170A - - 0.8 0.8 0.8 0.8 0.8 0.8
13 FLYWHEEL (A/T) - REPLACE 1221900 - - 6.3 6.3 6.3 6.3 6.3 6.3
A - Flywheel ring gear (AT) 122190A - - 0.8 0.8 0.8 0.8 0.8 0.8
14 BEARING, DMF - REPLACE 1222100 - - 5.4 5.6 5.4 5.6 - -
15 RING, PISTION – REPLACE 1222200 - - - - - - 15.6 15.6
A - Replace each additional 122220A - - - - - - 0.2 0.2
16 PIN, PISTON - REPLACE 1222300 - - - - - - 16.2 16.2
17 SNAP RING, PISTON - REPLACE 1222400 - - - - - - 16.2 16.2
18 PISTON - REPLACE 1222500 - - - - - - 15.5 15.5
19 BUSHING, CONNECTING ROD - REPLACE 1222600 - - - - - - 16.2 16.2
20 CONNECTING, ROD - REPLACE 1222700 - - - - - - 16.2 16.2

122-2
30
CRANKSHAFT & PISTON 122-2

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
21 BEARING, CONNECTING ROD - REPLACE 1222800 - - - - - - 16.0 16.0
22 CRANKSHAFT - REPLACE 1222900 - - - - - - 15.0 15.0

123
32
OIL PAN & PUMP 123

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE 1231300 - - 0.6 0.6 0.6 0.6 0.6 0.6
2 PAN AND/OR GASKET, OIL - REPLACE 1231500 - - 3.6 3.6 5.0 5.0 5.0 5.0
PAN AND/OR GASKET, OIL (A/T) - REPLACE 1231510 - - 3.6 3.6 5.0 5.0 5.0 5.0
3 PUMP, ENGINE OIL - REPLACE 1231700 - - 4.0 4.0 4.0 4.0 4.0 4.0
PUMP, ENGINE OIL - OVERHAUL 1231710 - - 5.7 5.7 5.7 5.7 - -
4 SENSOR, OIL PRESSURE GAUGE - REPLACE 1231900 - - 0.4 0.4 0.4 0.4 - -
5 OIL SEAL, CRANKSHAFT (FRONT) - REPLACE 1232300 - - 2.9 2.9 2.9 2.9 - -
6 SPROCKET, OIL PUMP - REPLACE 1232600 - - 4.2 4.2 4.2 4.2 4.2 4.2
7 STRAINER ASSEMBLY, OIL - REPLACE 1232610 - - 4.2 4.2 4.2 4.2 - -
8 COVER, OIL PUMP - REPLACE 1232650 - - 4.2 4.2 4.2 4.2 - -
9 CHAIN, OIL PUMP ROLLER - REPLACE 1232670 - - 4.2 4.2 4.2 4.2 4.2 4.2
10 OIL JET - REPLACE 1232680 - - 4.0 4.0 4.0 4.0 4.0 4.0
11 TENSIONER, OIL PUMP ROLLER CHAIN - REPLACE 1232690 - - 4.2 4.2 4.2 4.2 4.2 4.2
12 VALVE, OIL PRESSURE RELIEF - REPLACE 1232700 - - 4.2 4.2 4.2 4.2 - -
13 SHAFT, OIL PUMP DRIVE - REPLACE 1232800 - - 4.2 4.2 4.2 4.2 - -
14 PLATE, OIL BUFFLE - REPLACE 1234100 - - 4.4 4.4 4.4 4.4 4.4 8.7
15 GUIDE TUBE, OIL LEVEL - REPLACE 1235000 - - - - - - 0.4 0.4
16 GAUGE, OIL LEVEL - REPLACE 1235100 - - - - - - 0.2 0.2

131
34
CYLINDER HEAD 131

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 GASKET, CYLINDER HEAD - REPLACE 1312300 - - 5.0 5.0 5.0 5.0 7.0 7.0
GASKET, CYLINDER HEAD - OVERHAUL 1312310 - - - - - - 7.0 7.0
2 HEAD, CYLINDER - REPLACE 1312500 - - 5.0 5.0 5.0 5.0 4.9 4.9
HEAD, CYLINDER - OVERHAUL 1312600 - - 7.6 7.6 7.6 7.6 5.2 5.2
3 VALVE (ONE CYLINDER) - REPLACE 1312700 - - 7.6 7.6 7.6 7.6 5.2 5.2
A - Valves (each additional) 131270A - - 0.1 0.1 0.1 0.1 0.1 0.1
4 GUIDE, VALVE-REPLACE 1312800 - - 5.3 5.3 5.3 5.3 - -
A - Valves (each additional) 131280A - - 0.3 0.3 0.3 0.3 - -
5 SEAL, VALVE GUIDE - REPLACE 1312810 - - 3.0 3.0 3.0 3.0 3.0 3.0
6 SPRING CAP AND/OR SEAL, VALVE - REPLACE 1312900 - - 3.0 3.0 3.0 3.0 3.0 3.0
7 LIFTER, VALVE - REPLACE 1313600 - - 2.0 2.0 2.0 2.0 - -
A - Valves (each additional) 131360A - - 0.1 0.1 0.1 0.1 - -
8 PLUG, CYLINDER HEAD CORE HOLE - REPLACE 1313700 - - 0.2 0.2 0.2 0.2 - -
A - Replace each additional 131370A - - 0.1 0.1 0.1 0.1 - -
9 BOLT, CYLINDER HEAD (ONE) - REPLACE 1313800 - - 1.0 1.0 1.0 1.0 1.2 1.2
10 PLUG, CORE HALL SCREW - REPLACE 1315100 - - 0.5 0.5 0.5 0.5 - -
11 VALVE, THERMO - REPLACE 1315200 - - 0.5 0.5 0.5 0.5 - -
12 CONNECTOR - REPLACE 1315240 - - 0.5 0.5 0.5 0.5 - -
13 BALL, FRONT OIL PASSAGE - REPLACE 1315300 - - 1.0 1.0 1.0 1.0 - -
14 PLUG, REAR OIL PASSAGE - REPLACE 1315500 - - 0.3 0.3 0.3 0.3 - -
15 CAP, CAMSHAFT BEARING - REPLACE 1315600 - - 1.0 1.0 1.0 1.0 2.2 2.2
16 PRECHAMBER (1EA) - REPLACE 1311700 - - 0.5 0.5 0.5 0.5 - -
17 FINGER FOLLOWER 1314000 - - - - - - 3.0 3.0
18 ADJUSTER, CAMSHAFT - REPLACE 1314100 - - - - - - 3.0 3.0
19 VALVE COTTER - REPLACE 1314200 - - - - - - 3.0 3.0
20 RETAINER, VALVE SPRING - REPLACE 1314300 - - - - - - 3.0 3.0

132
36
CAM SUPPORT & SHAFT 132

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 COVER, CYLINDER HEAD - REPLACE 1322110 - - 0.5 0.5 0.5 0.5 1.9 1.9
2 PIPE & HOSE, CYLINDER HEAD COVER BREATHER 1322200 - - 0.5 0.5 0.5 0.5 - -
- REPLACE
3 CAMSHAFT - REPLACE 1322300 - - 1.8 1.8 1.8 1.8 2.2 2.2
4 PIN, CAMSHAFT - REPLACE 1322610 - - 0.7 0.7 0.7 0.7 - -
5 CAP AND/OR GASKET, OIL FILLER - REPLACE 1322700 - - 0.2 0.2 0.2 0.2 0.2 0.2
6 OIL, SEPERATOR ASSY - REPLACE 1322800 - - - - - - 0.2 0.2
7 BRACKET, OIL SEPERATOR - REPLACE 1322900 - - - - - - 0.2 0.2
8 HOSE, BLOW BY INLET - REPLACE 1323000 - - - - - - 0.2 0.2
HOSE, BLOW BY INLET - RECLAMPING 1323001 - - - - - - 0.2 0.2
9 HOSE, BLOW BY OUTLET - REPLACE 1323100 - - - - - - 0.2 0.2
10 HOSE, OIL RETURN - REPLACE 1323200 - - - - - - 0.2 0.2
11 SEALING, VENTILATION - REPLACE 1322720 - - 0.3 0.3 0.3 0.3 - -

133
38
TIMING COVER & CHAIN DRIVE 133

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 PULLEY, CRANKSHAFT - REPLACE 1332100 - - 0.9 0.9 0.9 0.9 - -
2 COVER AND/OR GASKET, TIMING - REPLACE 1332200 - - 13.2 13.2 13.2 13.2 - -
3 BELT OR CHAIN, TIMING - REPLACE 1332500 - - 5.2 5.2 5.2 5.2 5.4 5.4
4 SPROCKET, CRANKSHAFT TIMING - REPLACE 1333100 - - 13.5 13.7 13.5 13.7 - -
5 HUB OR VIBRATION DAMPER - REPLACE 1333140 - - 3.4 3.4 3.4 3.4 - -
6 SPROCKET, CAMSHAFT TIMING - REPLACE 1333300 - - 1.0 1.0 1.0 1.0 2.4 2.4
7 RAIL, CYLINDER HEAD SLIDING - REPLACE 1336100 - - 1.0 1.0 1.0 1.0 - -
8 PIN, SLIDING RAIL - REPLACE 1336200 - - 1.0 1.0 1.0 1.0 - -
9 RAIL, CLAMPING SLIDING - REPLACE 1336500 - - 1.0 1.0 1.0 1.0 - -
10 RAIL, SLIDING - REPLACE 1336700 - - 5.2 5.2 5.2 5.2 - -
11 CHAIN TIGHTENER - REPLACE 1337300 - - 0.5 0.5 0.5 0.5 0.3 0.3
12 WASHER, CHAIN TIGHTENER - REPLACE 1337500 - - 0.5 0.5 0.5 0.5 - -
13 RAIL ASSY, SLIDING - REPLACE 1332600 - - - - - - 5.4 5.4
14 RAIL ASSY, GUIDE UPER - REPLACE 1332700 - - - - - - 2.0 2.0

136
40
INJECEION PIPE 136

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 NOZZLE - REPLACE 1365100 - - 0.2 0.2 0.2 0.2 - -
NOZZLE - OVERHAUL 1365200 - - 0.4 0.4 0.4 0.4 - -
2 HOLDER ASSY, NOZZLE - REPLACE 1365300 - - 0.2 0.2 0.2 0.2 - -
3 PIPE, INJECTION - REPLACE 1365400 - - 0.3 0.3 0.3 0.3 - -
4 BRACKET, INJECTION PIPE - REPLACE 1365500 - - 0.3 0.3 0.3 0.3 - -
5 CLIP, INJECTION PIPE BRACKET - REPLACE 1365600 - - 0.3 0.3 0.3 0.3 - -
6 PLUG, PRE - HEATING - REPLACE 1365800 - - 1.0 1.0 1.0 1.0 0.3 0.3

138
42
ENGINE & TRANSAXLE MOUNT 138

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 MOUNT, ENGINE (FRONT) - REPLACE One 1380200 - - 0.5 0.5 0.5 0.5 0.5 0.5
Two 1380210 - - 1.0 1.0 1.0 1.0 1.0 1.0
2 BRACKET, ENGINE MOUNT (FRONT) - REPLACE
One 1380400 - - 0.8 0.8 0.8 0.8 0.5 0.5
Two 1380410 - - 1.2 1.2 1.2 1.2 0.9 0.9
3 STOPPER, ENGINE MOUNTING - REPLACE 1380420 - - 0.5 0.5 0.5 0.5 - 0.3
4 CROSS MEMBER, REAR ENGINE MOUNTING - 1380440 - - 0.6 0.6 0.6 0.6 - 0.3
REPLACE
5 CROSS MEMBER, FRONT AXLE MOUNTING - RE- 1380600 - - 0.5 0.5 0.5 0.5 - 0.6
PLACE
6 INSULATOR, HEAT SHIELD - REPLACE 1384500 - - 0.3 0.3 0.3 0.3 - -

139
44
VACUUM SYSTEM 139

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 VACUUM PUMP ASSEMBLY AND/OR GASKET - RE- 1390100 - - 1.0 1.0 1.0 1.0 1.9 1.9
PLACE
2 BRANCH OF FITTING (3 - WAY) - REPLACE 1390300 - - 0.3 0.3 0.3 0.3 - -
3 BRANCH OF FITTING (4 - WAY) - REPLACE 1390500 - - 0.3 0.3 0.3 0.3 - -
4 PIPE, VACUUM PBC - REPLACE 1390900 - - 0.3 0.3 0.3 0.3 - -
5 SOLENOID (1EA) - REPLACE 1391100 - - 0.2 0.2 0.2 0.2 - -
6 VACUUM HOSE, FUEL CUT - REPLACE 1391200 - - 0.5 0.5 0.5 0.5 - -

1D-D. ENGINE COOLING
141. RADIATOR ............................................................................... 48 1D-D
143. COOLING FAN ........................................................................ 50
144. OIL COOLER ........................................................................... 52
145. RADIATOR HOSE & PIPE ...................................................... 54
148. THERMOSTAT & WATER PUMP .......................................... 56

1D-D ENGINE COOLING
141
48
ENGINE COOLING 1D-D
RADIATOR 141
CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 COOLANT - REPLACE 1410100 - - 0.5 0.5 0.5 0.5 0.5 0.5
2 COCK OR PLUG, RADIATOR DRAIN - REPLACE 1410300 - - 1.0 1.0 1.0 1.0 1.0 1.0
3 RADIATOR ASSEMBLY - REPLACE 1410500 - - 1.6 1.6 1.6 1.6 1.0 0.6
4 COOLING SYSTEM - FLUSH 1411700 - - 0.6 0.6 0.6 0.6 0.5 0.5

1D-D ENGINE COOLING
143
50
ENGINE COOLING 1D-D
COOLING FAN 143

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 SHROUD, RADIATOR FAN - REPLACE 1430700 - - 0.5 0.5 0.5 0.5 0.5 0.5
2 BLADE, FAN - REPLACE 1431600 - - 0.7 0.7 0.7 0.7 0.5 0.5
3 CLUTCH, FAN - REPLACE 1431700 - - 0.7 0.7 0.7 0.7 0.9 0.9

1D-D ENGINE COOLING
144
52
ENGINE COOLING 1D-D
OIL COOLER 144

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 COOLER ASSEMBLY, OIL - REPLACE 1440500 - - 0.7 0.7 0.7 0.7 - -
2 PIPE, OIL COOLER - REPLACE One 1441100 - - 0.8 0.8 0.8 0.8 - -
Two 1441110 - - 1.2 1.2 1.2 1.2 - -

1D-D ENGINE COOLING
145
54
ENGINE COOLING 1D-D
RADIATOR HOSE & PIPE 145

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 HOSE, OVERFLOW - REPLACE 1450300 - - 0.3 0.3 0.3 0.3 - -
2 RESERVOIR, RADIATOR COOLANT - REPLACE 1450400 - - 0.3 0.3 0.3 0.3 0.3 0.3
3 BRACKET, RADIATOR COOLANT, RESERVOIR - 1450410 - - 0.5 0.5 0.5 0.5 - -
REPLACE
4 HOSE, MAKE UP - REPLACE 1450600 - - 0.3 0.3 0.3 0.3 0.3 0.3
5 HOSE, UPPER ENGINE COOLANT - REPLACE 1450700 - - 0.5 0.5 0.5 0.5 0.5 0.5
6 HOSE, LOWER ENGINE COOLANT - REPLACE 1450800 - - 0.5 0.5 0.5 0.5 0.5 0.5
7 HOSE AND/OR TUBE, DEAERATION - REPLACE 1451400 - - 0.3 0.3 0.3 0.3 0.3 0.3
8 HOSE, INLET HEATER - REPLACE 1453100 - - 1.0 1.0 1.0 1.0 - -
9 HOSE, OUTLET HEATER - REPLACE 1453200 - - 1.0 1.0 1.0 1.0 - -
10 CAP ASSY - RESERVOIR TANK - REPLACE 1450420 - - 0.1 0.1 0.1 0.1 0.2 0.2

1D-D ENGINE COOLING
148
56
ENGINE COOLING 1D-D
THERMOSTAT & WATER PUMP 148

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 THERMO VALVE - REPLACE 1480100 - - 0.5 0.5 0.5 0.5 - -
2 THERMOSTAT AND/OR GASKET DIESEL - REPLACE 1480400 - - 1.0 1.0 1.0 1.0 0.2 0.2
3 PORT AND/OR GASKET, COOLANT OUTLET - RE- 1480600 - - 1.0 1.0 1.0 1.0 0.7 0.7
PLACE
4 WATER PUMP AND/OR GASKET - REPLACE 1481200 - - 2.2 2.2 2.2 2.2 1.0 0.8
5 FLANGE, WATER PUMP - REPLACE 1481250 - - 0.5 0.5 0.5 0.5 0.7 0.7
6 HOUSING, WATER PUMP - REPLACE 1481260 - - 2.2 2.2 2.2 2.2 1.9 1.9
7 PULLEY, WATER PUMP - REPLACE 1481270 - - 0.3 0.3 0.3 0.3 0.5 0.5
8 IMPELLER, WATER PUMP - REPLACE 1481280 - - 3.2 3.2 3.2 3.2 - -
9 SEAL, WATER PUMP MECHANICAL - REPLACE 1481700 - - 2.2 2.2 2.2 2.2 - -
10 BEARING, WATER PUMP - REPLACE 1481800 - - 0.5 0.5 0.5 0.5 - -
11 SENSOR, WATER PUMP TEMPERATURE - REPLACE 1482200 - - 0.3 0.3 0.3 0.3 0.4 0.4

1E-D. ENGINE ELECTRICAL
154. ALTERNATOR UNIT ............................................................... 60
156. STARTER ................................................................................ 62
157. BATTERY ................................................................................ 64 1E-D
158. FUSE & RELAY ....................................................................... 66

1E-D ENGINE ELECTRICAL
154
60
ENGINE ELECTRICAL 1E-D
ALTERNATOR UNIT 154

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 PULLEY AND/OR FAN, ALTERNATOR - REPLACE 1540100 - - 0.5 0.5 0.5 0.5 0.5 0.5
2 BEARING, ALTERNATOR-REPLACE
Front 1540300 - - 1.3 1.3 1.3 1.3 - -
Rear 1540500 - - 1.3 1.3 1.3 1.3 - -
3 ALTERNATOR ASSEMBLY - REPLACE 1541700 - - 0.8 0.8 0.8 0.8 0.8 0.8
ALTERNATOR ASSEMBLY - OVERHAUL 1541900 - - 1.5 1.5 1.5 1.5 1.5 1.5
4 BRACKET, ALTERNATOR MOUNTING - REPLACE 1544100 - - 1.2 1.2 1.2 1.2 1.2 1.2

156
62
STARTER 156
CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 MOTOR ASSEMBLY, STARTER DIESEL - REPLACE 1561000 - - 0.5 0.5 0.5 0.5 0.5 0.5
2 SWITCH, STARTER MOTOR MAGNETIC - REPLACE 1562700 - - 0.7 0.7 0.7 0.7 0.7 0.7

157
64
BATTERY 157
CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 BATTERY - REPLACE 1570300 - - 0.2 0.2 0.2 0.2 0.2 0.2
2 RETAINER AND/OR BOLTS, BATTERY - REPLACE 1570500 - - 0.2 0.2 0.2 0.2 0.2 0.2
3 CARRIER, BATTERY - REPLACE 1571100 - - 0.3 0.3 0.3 0.3 0.3 0.3
4 CABLE - BATTERY GROUND 1571200 - - 0.2 0.2 0.2 0.2 0.2 0.2

158
66
FUSE & RELAY 158

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 RELAY - REPLACE
Fog Lamp 1580200 - - 0.2 0.2 0.2 0.2 0.2 0.2
Enable (ABS) 1580500 - - 0.2 0.2 0.2 0.2 0.2 0.2
Window Wiper Motor 1580900 - - 0.2 0.2 0.2 0.2 0.2 0.2
Head Lamp 1581100 - - 0.2 0.2 0.2 0.2 0.2 0.2
Other Relays 1581500 - - 0.2 0.2 0.2 0.2 0.2 0.2
Turn Signal 1582100 - - 0.2 0.2 0.2 0.2 0.2 0.2
Preheating Time 1582200 - - 0.3 0.3 0.3 0.3 0.2 0.2
2 COVER, FUSE BOX - REPLACE 1582300 - - 0.2 0.2 0.2 0.2 0.2 0.2
3 BOX, REALY & FUSE - REPLACE 1582700 - - 0.6 0.6 0.6 0.6 0.6 0.6
4 FUSE - REPLACE 1583700 - - 0.2 0.2 0.2 0.2 0.2 0.2
5 CONTROL UNIT - P/WINDOW AUTO DOWN 1584700 0.3 0.3 0.3 0.3 0.4 0.4 0.5 0.5
- REPLACE

1F-D. ENGINE CONTROLS
170. FUEL FILTER & LINE ............................................................. 70
171. FUEL TANK ............................................................................. 72
172. FUEL LINE ............................................................................... 74
174. INJECTION PUMP .................................................................. 78
182. ACCELERATOR CONTROL .................................................. 80 1F-D

1F-D ENGINE CONTROLS
170
70
ENGINE CONTROLS 1F-D
FUEL FILTER & LINE 170

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 FILTER ASSY, FUEL - REPLACE 1700100 - - - - - - 0.2 0.2
2 BRACKET, FUEL FILTER - REPLACE 1700200 - - - - - - 0.7 0.7
3 PUMP, FUEL PRIMING - REPLACE 1700300 - - - - - - 0.2 0.2
4 HOSE, PRIMING PUMP TO FILTER - REPLACE 1700400 - - - - - - 0.1 0.1
5 HOSE, FUEL RETURN - REPLACE 1700500 - - - - - - 0.1 0.1
6 HOSE, SUPPLY PIPE TO PRIMING PUMP - REPLACE 1700600 - - - - - - 0.1 0.1
7 TUBE ASSY, FUEL FILTER TO PUMP - REPLACE 1700700 - - - - - - 0.1 0.1
8 TUBE ASSY, FUEL FILTER - REPLACE 1700800 - - - - - - 0.1 0.1
9 WATER SEPERATOR - REPLACE 1700910 - - - - - - 0.2 0.2
10 WATER SEPERATOR - HOSE 1700920 - - - - - - 0.1 0.1

171
72
FUEL TANK 171

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 AIR BLEEDING, FUEL 1710400 - - 0.5 0.5 0.5 0.5 0.5 0.5
2 NECK, FUEL TANK FILLER - REPLACE 1710500 - - 0.7 0.7 0.7 0.7 0.7 0.7
3 TANK, FUEL - REPLACE 1710900 - - 1.3 1.3 1.3 1.3 1.3 1.3
4 UNIT, FUEL SENDER - REPLACE 1711700 - - 1.4 1.4 0.5 0.5 0.5 0.5
5 HOSE, AIR BLEEDER - REPLACE 1712000 - - 0.7 0.7 0.7 0.7 0.7 0.7
6 PROTECTOR, FUEL TANK - REPLACE 1712200 - - 0.3 0.3 0.3 0.3 0.3 0.3
7 HOSE, AIR VENT - REPLACE 1713500 - - 0.7 0.7 0.7 0.7 0.7 0.7
8 CAP, FUEL TANK - REPLACE 1713600 - - 0.2 0.2 0.2 0.2 0.2 0.2

172-1
74
FUEL LINE 172-1

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 HOUSING, OIL FILTER - REPLACE 1720200 - - 1.5 1.5 1.5 1.5 0.5 0.5
2 COVER, OIL FILTER HOUSING - REPLACE 1720230 - - 0.2 0.2 0.2 0.2 0.2 0.2
3 FILTER AND/OR O-RING, OIL - REPLACE 1720240 - - 0.4 0.4 0.4 0.4 0.2 0.2
4 GASKET, OIL FILTER HOUSING - REPLACE 1720250 - - 0.5 0.5 0.5 0.5 0.5 0.5
5 SEAT, OIL FILTER VALVE - REPLACE 1720270 - - 1.7 1.7 1.7 1.7 - -
6 THERMOSTAT, OIL FILTER - REPLACE 1720280 - - 2.0 2.0 2.0 2.0 - -
7 BYPASS VALVE - REPLACE 1720290 - - 2.0 2.0 2.0 2.0 - -
8 FILTER, FUEL ELEMENT - REPLACE 1720300 - - 0.2 0.2 0.2 0.2 - -
9 BRACKET, FUEL FILTER - REPLACE 1720310 - - 0.7 0.7 0.7 0.7 - -
10 TUBE AND/OR HOSE ASSEMBLY, FUEL - REPLACE 1720320 - - 0.3 0.3 0.3 0.3 - -
11 VALVE, 2WAY CHECK - REPLACE 1720330 - - 0.5 0.5 0.5 0.5 - -
12 HOSE, FUEL RETURN OR SUPPLY - REPLACE 1720340 - - 0.3 0.3 0.3 0.3 - -
13 PIPE, FUEL RETURN - REPLACE 1720700 - - 0.7 0.7 0.7 0.7 0.7 0.7
14 PIPE, FUEL SUPPLY - REPLACE 1720760 - - 0.7 0.7 0.7 0.7 0.7 0.7
15 FILTER, PRE - REPLACE 1722810 - - 0.2 0.2 0.2 0.2 - -
16 ANOTHER, HOSE, FUEL - REPLACE 1720870 - - 0.3 0.3 0.3 0.3 - -
17 VALVE, SHUT OFF - REPLACE 1720880 - - 0.4 0.4 0.4 0.4 - -
18 COOLER ASSY, OIL - REPLACE 1720950 - - 1.2 1.2 1.2 1.2 0.8 0.9
19 COOLER GASKET, OIL - REPLACE 1720960 - - 0.7 0.7 0.7 0.7 0.8 0.8
20 HOSE, COIL COOLER - REPLACE 1720970 - - 0.7 0.7 0.7 0.7 0.5 0.5

172-2
76
FUEL LINE 172-2

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 HOUSING, OIL FILTER - REPLACE 1720200 - - 1.5 1.5 1.5 1.5 0.5 0.5
2 COVER, OIL FILTER HOUSING - REPLACE 1720230 - - 0.2 0.2 0.2 0.2 0.2 0.2
3 FILTER AND/OR O-RING, OIL - REPLACE 1720240 - - 0.4 0.4 0.4 0.4 0.2 0.2
4 GASKET, OIL FILTER HOUSING - REPLACE 1720250 - - 0.5 0.5 0.5 0.5 0.5 0.5
5 SEAT, OIL FILTER VALVE - REPLACE 1720270 - - 1.7 1.7 1.7 1.7 - -
6 THERMOSTAT, OIL FILTER - REPLACE 1720280 - - 2.0 2.0 2.0 2.0 - -
7 BYPASS VALVE - REPLACE 1720290 - - 2.0 2.0 2.0 2.0 - -
8 FILTER, FUEL ELEMENT - REPLACE 1720300 - - 0.2 0.2 0.2 0.2 - -
9 BRACKET, FUEL FILTER - REPLACE 1720310 - - 0.7 0.7 0.7 0.7 - -
10 TUBE AND/OR HOSE ASSEMBLY, FUEL - REPLACE 1720320 - - 0.3 0.3 0.3 0.3 - -
11 VALVE, 2WAY CHECK - REPLACE 1720330 - - 0.5 0.5 0.5 0.5 - -
12 HOSE, FUEL RETURN OR SUPPLY - REPLACE 1720340 - - 0.3 0.3 0.3 0.3 - -
13 PIPE, FUEL RETURN - REPLACE 1720700 - - 0.7 0.7 0.7 0.7 0.7 0.7
14 PIPE, FUEL SUPPLY - REPLACE 1720760 - - 0.7 0.7 0.7 0.7 0.7 0.7
15 FILTER, PRE - REPLACE 1722810 - - 0.2 0.2 0.2 0.2 - -
16 ANOTHER, HOSE, FUEL - REPLACE 1720870 - - 0.3 0.3 0.3 0.3 - -
17 VALVE, SHUT OFF - REPLACE 1720880 - - 0.4 0.4 0.4 0.4 - -
18 COOLER ASSY, OIL - REPLACE 1720950 - - - - - - 0.8 0.8
19 COOLER GASKET, OIL - REPLACE 1720960 - - - - - - 0.8 0.8
20 HOSE, COIL COOLER - REPLACE 1720970 - - - - - - 0.5 0.5

174
78
INJECTION PUMP 174

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 INJECTION PUMP ASSEMBLY - REPLACE 1740100 - - 3.8 3.8 3.8 3.8 - -
INJECTION PUMP ASSEMBLY - OVERHAUL 1740200 - - 10.7 10.7 10.7 10.7 - -
2 PUMP, FUEL FEED - REPLACE 1742400 - - 1.0 1.0 1.0 1.0 - -
PUMP, FUEL FEED - OVERHAUL 1742500 - - 1.2 1.2 1.2 1.2 - -
3 TDC SENSOR BRACKET - REPLACE 1742800 - - 0.7 0.7 0.7 0.7 - -
4 UNIT AND/OR O-RING, ENGINE STOP - REPLACE 1743100 - - 0.7 0.7 0.7 0.7 - -
5 CAM, INJECTION - REPLACE 1743200 - - 0.7 0.7 0.7 0.7 - -
6 SEAL, INJECTION PUMP - REPLACE 1743300 - - 3.8 3.8 3.8 3.8 - -
7 TIMER ASSEMBLY, INJECTION - REPLACE 1743400 - - 3.0 3.0 3.0 3.0 - -
8 POTENTIOMETER - REPLACE 1743500 - - 0.5 0.5 0.5 0.5 - -
9 INJECTION PUMP SIDE COVER 1740260 - - 0.4 0.4 0.4 0.4 - -
INJECTION PUMP SIDE COVER 1740261 - - 0.6 0.6 0.6 0.6 - -
(with immobilizer system)

182
80
ACCELERATOR CONTROL 182

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 CABLE, ACCELERATOR CONTROL - REPLACE 1820300 - - 0.4 0.4 0.4 0.4 - -
2 PEDAL, ACCELERATOR - REPLACE 1820500 - - 0.4 0.4 0.4 0.4 - -
3 SPRING, THROTTLE RETURN - REPLACE 1820700 - - 0.2 0.2 0.2 0.2 - -
4 PAD, ACCELERATOR PEDAL - REPLACE 1821100 - - 0.2 0.2 0.2 0.2 - -
5 LEVER, ACCELERATOR CONTROL - REPLACE 1822310 - - 0.4 0.4 0.4 0.4 - -
6 SPRING, ACCELERATOR CONTROL - REPLACE 1822330 - - 0.4 0.4 0.4 0.4 - -
7 BRACKET, ACCELERATOR CONTROL LEVER 1822340 - - 0.4 0.4 0.4 0.4 - -
BEARING - REPLACE
8 ROD, CONNECTING - REPLACE 1822350 - - 0.2 0.2 0.2 0.2 - -
9 LEVER, ANGULAR - REPLACE 1822370 - - 0.5 0.5 0.5 0.5 - -
10 LEVER, REVERSING - REPLACE 1822380 - - 0.5 0.5 0.5 0.5 - -
11 ROD, ANGULAR PUMP LEVER - REPLACE 1822390 - - 0.2 0.2 0.2 0.2 - -
12 LEVER, SLOTTED GATE - REPLACE 1822400 - - 0.3 0.3 0.3 0.3 - -
13 BRACKET, ANGULAR LEVER BEARING - REPLACE 1822410 - - 0.5 0.5 0.5 0.5 - -
14 SWITCH, MIRO - REPLACE 1822500 - - 0.5 0.5 0.5 0.5 - -
15 DEMPER, ACCELERATOR - REPLACE 1822600 - - 0.3 0.3 0.3 0.3 - -
16 MODULE, ACCELERATOR PEDAL - REPLACE 18206600 - - - - - - 0.3 0.3

1G-D. ENGINE INTAKE & EXHAUST
190. COMMON RAIL SYSTEM ...................................................... 84
191. AIR INTAKE SYSTEM ............................................................. 86
193. INTAKE MANIFOLD ................................................................ 88
194. EXHAUST MANIFOLD ............................................................ 92
196. EXHAUST PIPE LINE ............................................................. 94
197. TURBO CHARGER ASSEMBLY ........................................... 98
198. SENSORS .............................................................................. 100 1G-D

1G-D ENGINE INTAKE & EXHAUST
190
84
ENGINE INTAKE & EXHAUST 1G-D
COMMON RAIL SYSTEM 190

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 PIPE ASSY, FUEL - REPLACE 1900100 - - - - - - 0.2 0.2
2 PIPE, HIGH PRESSURE PUMP - REPLACE 1900200 - - - - - - 0.2 0.2
3 HOSE, FUEL RETURN - REPLACE 1900300 - - - - - - 0.1 0.1
4 PUMP ASSY, FUEL - REPLACE 1900400 - - - - - - 3.5 3.5
5 BRACKET, FUEL PUMP - REPLACE 1900500 - - - - - - 0.7 0.7
6 HOLDER, INJECTOR - REPLACE 1900600 - - - - - - 0.3 0.3
7 SPROCKET, PUMP - REPLACE 1900410 - - - - - - 2.8 2.8
8 BEARING HOUSING, PUMP - REPLACE 1900420 - - - - - - 2.9 2.9
9 BEARING SHAFT, PUMP - REPLACE 1900430 - - - - - - 3.2 3.2
10 GASKET, FUEL PUMP - REPLACE 1900440 - - - - - - 3.3 3.3
11 HOUSING BOLT - REPLACE 1900450 - - - - - - 3.0 3.0
12 COMMON RAIL - REPLACE 1900000 - - - - - - 0.5 0.5
13 INJECTOR ASSY, FUEL - REPLACE 1900150 - - - - - - 0.3 0.4

191
86
AIR INTAKE SYSTEM 191

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 AIR CLEANER - REPLACE 1910300 - - 0.5 0.5 0.5 0.5 0.3 0.3
2 BRACKET, AIR CLEANER HOUSING MOUNTING - 1910350 - - 0.7 0.7 0.7 0.7 - -
REPLACE
3 FILTER, AIR CLEANER - REPLACE 1910500 - - 0.2 0.2 0.2 0.2 0.2 0.2
4 DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE 1910700 - - 0.3 0.3 0.3 0.3 - -
5 METER, AIR METER - REPLACE 1911320 - - - - - - 0.2 0.2

193-1
88
INTAKE MANIFOLD 193-1

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 MANIFOLD, INTAKE DIESEL - REPLACE 1930250 - - 1.2 1.2 1.2 1.2 1.6 1.6
2 VALVE AND/OR GASKET, EGR - REPLACE 1930700 - - 0.7 0.7 0.7 0.7 0.2 0.2
3 ELECTRIC SWITCH VALVE - REPLACE 1930710 - - 0.5 0.5 0.5 0.5 - -
4 UNIT, EGR CONTROL - REPLACE 1930720 - - 0.5 0.5 0.5 0.5 - -
5 HOSE, EGR VACUUM OUTLET - REPLACE 1930730 - - 0.5 0.5 0.5 0.5 0.2 0.2
6 SCREW, INTAKE MANIFOLD MOUNTING - REPLACE 1932110 - - 0.3 0.3 0.3 0.3 - -
7 GASKET, INTAKE MANIFOLD - REPLACE 1933100 - - 1.2 1.2 1.2 1.2 1.6 1.6
8 DUCT, INTAKE - REPLACE 1934100 - - 0.3 0.3 0.3 0.3 - -
9 GASKET, INTAKE DUCT - REPLACE 1934150 - - 0.3 0.3 0.3 0.3 - -
10 BRACKET, INTAKE MANIFOLD - REPLACE 1935000 - - - - - - 0.5 0.5
11 PIPE ASSY, EGR - REPLACE 1935100 - - - - - - 0.2 0.2
12 GASKET, EGR PIPE - REPLACE 1935200 - - - - - - 0.2 0.2
13 PIPE ASSY, EGR (LH) - REPLACE 1935300 - - - - - - 0.2 0.2
14 PIPE ASSY, EGR (RH) - REPLACE 1935400 - - - - - - 0.2 0.2
15 MODULATOR, VACUUM - REPLACE 1935500 - - 0.2 0.2 0.2 0.2 0.2 0.2

193-2
90
INTAKE MANIFOLD 193-2

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 MANIFOLD, INTAKE DIESEL - REPLACE 1930250 - - 1.2 1.2 1.2 1.2 1.6 1.6
2 VALVE AND/OR GASKET, EGR - REPLACE 1930700 - - 0.7 0.7 0.7 0.7 0.2 0.2
3 ELECTRIC SWITCH VALVE - REPLACE 1930710 - - 0.5 0.5 0.5 0.5 0.5 0.5
4 UNIT, EGR CONTROL - REPLACE 1930720 - - 0.5 0.5 0.5 0.5 0.2 0.2
5 HOSE, EGR VACUUM OUTLET - REPLACE 1930730 - - 0.5 0.5 0.5 0.5 0.2 0.2
6 SCREW, INTAKE MANIFOLD MOUNTING - REPLACE 1932110 - - 0.3 0.3 0.3 0.3 - -
7 GASKET, INTAKE MANIFOLD - REPLACE 1933100 - - 1.2 1.2 1.2 1.2 1.6 1.6
8 DUCT, INTAKE - REPLACE 1934100 - - 0.3 0.3 0.3 0.3 - -
9 GASKET, INTAKE DUCT - REPLACE 1934150 - - 0.3 0.3 0.3 0.3 - -
10 BRACKET, INTAKE MANIFOLD - REPLACE 1935000 - - - - - - 0.5 0.5
11 PIPE ASSY, EGR - REPLACE 1935100 - - - - - - 0.2 0.2
12 GASKET, EGR PIPE - REPLACE 1935200 - - - - - - 0.2 0.2
13 PIPE ASSY, EGR (LH) - REPLACE 1935300 - - - - - - 0.2 0.2
14 PIPE ASSY, EGR (RH) - REPLACE 1935400 - - - - - - 0.2 0.2
15 MODULATOR, VACUUM - REPLACE 1935500 - - 0.2 0.2 0.2 0.2 0.2 0.2

194
92
EXHAUST MANIFOLD 194

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 MANIFOLD AND/OR GASKET, EXHAUST - REPLACE 1940400 - - 1.0 1.0 1.0 1.0 1.0 1.0
2 NUT, EXHAUST MANIFOLD - REPLACE 1940900 - - - - - - 0.2 0.2

196-1
94
EXHAUST PIPE LINE 196-1

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 HANGER AND/OR CLAMP, EXHAUST SYSTEM-RE- 1960300 - - 0.5 0.5 0.5 0.5 0.5 0.5
PLACE
2 PIPE, FRONT EXHAUST - REPLACE 1960900 - - 0.5 0.5 0.5 0.5 0.5 0.5
3 HEAT SHIELD, CENTER MUFFLER - REPLACE 1961420 - - 0.5 0.5 0.5 0.5 0.5 0.5
4 MUFFLER - REPLACE 1962100 - - 0.5 0.5 0.5 0.5 0.5 0.5
5 EXHAUST SYSTEM (COMPLETE) - REPLACE 1962500 - - 1.2 1.2 1.2 1.2 1.2 1.2
6 PIPE, TAIL - REPLACE 1962600 - - 0.5 0.5 0.5 0.5 0.5 0.5
7 CONVERTER - REPLACE 1961500 - - 0.5 0.5 0.5 0.5 0.5 0.5

196-2
96
EXHAUST PIPE LINE 196-2

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 HANGER AND/OR CLAMP, EXHAUST SYSTEM-RE- 1960300 - - 0.5 0.5 0.5 0.5 0.5 0.5
PLACE
2 PIPE, FRONT EXHAUST - REPLACE 1960900 - - 0.5 0.5 0.5 0.5 0.5 0.5
3 HEAT SHIELD, CENTER MUFFLER - REPLACE 1961420 - - 0.5 0.5 0.5 0.5 0.5 0.5
4 MUFFLER - REPLACE 1962100 - - 0.5 0.5 0.5 0.5 0.5 0.5
5 EXHAUST SYSTEM (COMPLETE) - REPLACE 1962500 - - 1.2 1.2 1.2 1.2 1.2 1.2
7 CONVERTER - REPLACE 1961500 - - 0.5 0.5 0.5 0.5 0.5 0.5

197
XDi
98
TURBO CHARGER ASSEMBLY 197

CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 TURBO CHARGER ASSEMBLY - REPLACE 1970100 - - 1.5 1.5 1.5 1.5 0.8 0.8
2 INTERCOOLER ASSEMBLY - REPLACE 1970500 - - 1.4 1.4 1.4 1.4 - -
3 TUBE-OIL SUPPLY - REPLACE 1970110 - - 0.4 0.4 0.4 0.4 0.4 0.4
4 TUSE-OIL RETURN - REPLACE 1970120 - - 0.5 0.5 0.5 0.5 1.4 1.4
5 INTERCOOLER - TURBO 1970510 - - 0.8 0.8 0.8 0.8 0.3 0.3
6 HOSE AND DUCT - REPLACE 1970520 - - 0.2 0.2 0.2 0.2 0.2 0.2
7 GASKET, OIL RETURN - REPLACE 1970130 - - - - - - 0.3 0.3

198
100
SENSORS 198
CM MU/MU-S/KO RX ST
Operation
Code - - XDi XDi
1 SENSOR, CRANKSHAFT POSITION - REPLACE 1980100 - - - - - - 0.1 0.1
2 SENSOR ASSY - CAM POSITION 1980200 - - - - - - 0.1 0.1
3 SENSOR, KNOCK - REPLACE 1980300 - - - - - - 0.3 0.3
4 SENSOR ASSY - COOLANT 1980400 - - - - - - 2.3 2.3
5 SENSOR, 8P - REPLACE 1980700 - - - - - - 0.6 0.6
6 ECU, ENGINE - REPLACE 1980600 - - - - - - 0.2 0.2
7 SENSOR ASSY, ENGINE SPEED - REPLACE 1980800 - - 0.3 0.3 0.3 0.3 - -

SECTION 1-G
GASOLINE ENGINE
1C-G. GASOLINE ENGINE MECHANICAL ........................................... 105

1D-G. ENGINE COOLING .................................................................... 127
1E-G. ENGINE ELECTRICAL ............................................................... 137
1F-G. ENGINE CONTROLS ................................................................. 149
1G-G. ENGINE INTAKE & EXHAUST ................................................... 165
1C-G. GASOLINE ENGINE MECHANICAL 1C-G
111. ENGINE UNIT ........................................................................ 106
113. BELT SYSTEM ..................................................................... 108
121. ENGINE BLOCK ................................................................... 110
122. CRANKSHAFT & PISTON .................................................... 112
123. OIL PAN & PUMP.................................................................. 114
131. CYLINDER HEAD.................................................................. 116
132. CAM SUPPORT & SHAFT.................................................... 118
133. TIMING COVER & CHAIN DRIVE ........................................ 120
138. ENGINE & TRANSAXLE MOUNT ........................................ 122
139. VACUUM SYSTEM ............................................................... 124

1C-G GASOLINE ENGINE MECHANICAL
111
106
GASOLINE ENGINE MECHANICAL 1C-G
ENGINE UNIT 111

CM MU/MU-S/KO RX ST
Operation
NO. Operation Description 2.0/ 2.8/ 2.0/ 2.8/ 2.0/ 2.8/
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 ENGINE ASSEMBLY (M/T) - OVERHAUL 1110100 - - 24.2 27.0 24.2 26.0 24.2 26.0
ENGINE ASSEMBLY (A/T) - OVERHAUL 1110300 21.0 23.5 23.2 26.0 23.2 26.0 23.2 26.0
2 ENGINE ASSEMBLY (M/T) - REPLACE 1110800 - - 7.7 7.9 7.7 8.0 7.7 8.0
ENGINE ASSEMBLY (A/T) - REPLACE 1110900 7.0 7.0 8.7 8.7 8.7 8.7 8.7 8.7

113
108
BELT SYSTEM 113

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 POLY-BELT - REPLACE 1132210 0.2 0.2 0.5 0.5 0.5 0.5 0.5 0.5
2 PULLEY, AUTO TENSIONER - REPLACE 1132410 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
3 TIGHTENER ASSEMBLY, BELT - REPLACE 1132550 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
4 SHOCK ABSORBER, TENSIONER - REPLACE 1132560 0.5 - 0.5 - 0.5 - 0.5 -

121
110
ENGINE BLOCK 121

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 OIL LEVEL INDICATOR AND/OR O-RING - REPLACE 1210200 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
2 TUBE, OIL LEVEL INDICATOR - REPLACE 1210300 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
3 PLUG, EXPANSION - REPLACE 1210700 7.6 7.6 4.1 4.4 4.1 4.4 4.4 4.4
A - Replace each additional 121070A 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
4 PLUG, CYLINDER BLOCK DRAIN - REPLACE 1210800 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
5 PLUG, OIL GALLERY - REPLACE 1210900 8.8 9.5 - - - - - -
6 BLOCK, CYLINDER - REPLACE 1211100 21.5 23.5 23.2 26.0 23.2 26.0 26.0 26.0
7 SEMI BLOCK (SHORT BLOCK), CYLINDER - REPLACE 1211110 17.5 19.0 19.2 21.5 19.2 21.5 21.5 21.5

122
112
CRANKSHAFT & PISTON 122

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 SEAL (S), CRANKSHAFT REAR MAIN (A/T) - REPLACE 1220200 6.0 6.3 6.3 6.3 6.3 6.3 6.3 6.3
SEAL (S), CRANKSHAFT REAR MAIN (M/T) - REPLACE 1220400 - - 5.4 5.4 5.4 5.4 5.4 5.4
2 COVER, CRANKSHAFT SEALING (A/T) - REPLACE 1220410 6.0 6.3 6.3 6.3 6.3 6.3 6.3 6.3
COVER, CRANKSHAFT SEALING (M/T) - REPLACE 1220420 - - 5.4 5.4 5.4 5.4 5.4 5.4
3 DAMPER, CRANKSHAFT VIBRATION - REPLACE 1220500 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8
4 BEARING, CRANKSHAFT MAIN (ONE) - REPLACE 1220600 9.7 10.7 9.7 9.7 9.7 9.7 9.7 9.7
5 BEARING, CRANKSHAFT THRUST - REPLACE 1220610 10.3 11.3 10.3 10.3 10.3 10.3 10.3 10.3
6 BEARING, CONNECTING ROD (ONE) - REPLACE 1220800 10.8 10.8 10.8 10.8 10.8 10.8 10.8 10.8
7 CRANKSHAFT (M/T) - REPLACE 1221100 - - 13.8 13.8 13.8 13.8 13.8 13.8
D - Replace one piston ring 122110D - - 0.4 0.4 0.4 0.4 0.4 0.4
E - Replace all piston rings 122110E - - 1.2 1.2 1.2 1.2 1.2 1.2
F - Replace one connecting rod 122110F - - 0.5 0.5 0.5 0.5 0.5 0.5
G - Replace all connecting rods 122110G - - 1.2 1.2 1.2 1.2 1.2 1.2
8 CRANKSHAFT (A/T) - REPLACE 1221200 11.3 10.3 17.0 18.0 17.0 18.0 17.0 18.0
D - Replace one piston ring 122120D 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
E - Replace all piston rings 122120E 1.3 1.3 1.2 1.2 1.2 1.2 1.2 1.2
F - Replace one connecting rod 122120F 0.5 0.6 0.5 0.6 0.5 0.6 0.5 0.6
G - Replace all connecting rods 122120G 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
9 PISTON, ROD AND/OR RINGS (ONE) - REPLACE 1221500 13.7 16.0 19.5 19.5 19.5 19.5 19.5 19.5
10 BUSHING, CONNECTING ROD - REPLACE 1221540 14.2 16.5 19.5 19.5 19.5 19.5 19.5 19.5
11 FLYWHEEL (M/T) - REPLACE 1221700 - - 5.3 5.3 5.3 5.3 5.3 5.3
A - Flywheel ring gear 122170A - - 0.8 0.8 0.8 0.8 0.8 0.8
12 FLYWHEEL (A/T) - REPLACE 1221900 6.0 6.3 6.3 6.3 6.3 6.3 6.3 6.3
A - Flywheel ring gear 122190A 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
13 BEARING, PILOT - REPLACE 1222100 5.4 5.4 5.6 5.6 5.6 5.6 5.6 5.6
14 BEARING, GROOVED BALL(M/T)-REPLACE 1222110 5.4 5.4 5.6 5.6 5.6 5.6 5.6 5.6

123
114
OIL PAN & PUMP 123

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE 1231300 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
2 PAN AND/OR GASKET, OIL - REPLACE 1231500 9.1 9.8 5.0 5.0 5.0 5.0 5.0 5.0
PAN AND/OR GASKET, OIL (AUTO) - REPLACE 1231510 7.9 8.6 5.0 5.0 5.0 5.0 5.0 5.0
3 SWITCH AND/OR GASKET, OIL LEVEL - REPLACE 1231600 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
4 PUMP, ENGINE OIL - REPLACE 1231700 9.0 9.0 4.0 4.0 4.0 4.0 4.0 4.0
PUMP, ENGINE OIL - OVERHAUL 1231710 9.5 9.5 5.7 5.7 5.7 5.7 5.7 5.7
5 SWITCH, OIL PRESSURE GAUGE - REPLACE 1231900 0.7 0.7 0.4 0.4 0.4 0.4 0.4 0.4
6 OIL SEAL, CRANKSHAFT (FRONT) - REPLACE 1232300 7.7 9.2 3.7 3.9 3.7 3.9 3.7 3.9
7 SPROCKET, OIL PUMP - REPLACE 1232600 9.2 9.2 5.6 5.6 5.6 5.6 5.6 5.6
8 STRAINER ASSEMBLY, OIL - REPLACE 1232610 9.2 9.2 5.6 5.6 5.6 5.6 5.6 5.6
9 CHAIN, OIL PUMP ROLLER - REPLACE 1232670 9.2 9.2 5.6 5.6 5.6 5.6 5.6 5.6
10 TENSIONER, OIL PUMP ROLLER CHAIN - REPLACE 1232690 9.2 9.2 5.6 5.6 5.6 5.6 5.6 5.6
11 VALVE, OIL PRESSURE RELIEF - REPLACE 1232700 9.2 9.2 5.6 5.6 5.6 5.6 5.6 5.6
12 SHAFT, OIL PUMP DRIVE - REPLACE 1232800 9.2 9.2 5.6 5.6 5.6 5.6 5.6 5.6
13 PLATE, OIL BAFFLE - REPLACE 1234100 8.7 8.7 5.6 5.6 5.6 5.6 5.6 5.6

131
116
CYLINDER HEAD 131

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 GASKET, CYLINDER HEAD - REPLACE 1312300 6.3 6.3 5.6 6.0 5.6 6.0 5.6 6.0
2 HEAD, CYLINDER - REPLACE 1312500 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3
HEAD, CYLINDER - OVERHAUL 1312600 8.4 8.6 8.4 8.6 8.4 8.6 8.4 8.6
3 VALVE (ONE CYLINDER) - REPLACE 1312700 6.8 7.0 8.4 8.6 8.4 8.6 8.4 8.6
A - Valves (each additional) 131270A 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
4 GUIDE, VALVE - REPLACE 1312800 6.3 6.3 6.3 6.3 6.3 6.3 6.3 6.3
5 SEAL, VALVE GUIDE - REPLACE 1312810 2.2 2.2 6.6 6.6 6.6 6.6 6.6 6.6
6 SPRING CAP AND/OR SEAL, VALVE - REPLACE 1312900 6.8 7.0 6.6 6.6 6.6 6.6 6.6 6.6
7 LIFTER, VALVE - REPLACE 1313600 2.8 3.0 2.0 2.0 2.0 2.0 2.0 2.0
8 PLUG, CYLINDER HEAD CORE HOLE - REPLACE 1314700 1.5 1.5 0.9 1.4 0.9 1.4 0.9 1.4
9 BOLT, CYLINDER HEAD (ONE) - REPLACE 1313800 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
10 CAP, CAMSHAFT BEARING - REPLACE 1315600 0.9 0.9 1.2 1.2 1.2 1.2 1.2 1.2

132
118
CAM SUPPORT & SHAFT 132

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 COVER AND/OR GASKET, CYLINDER HEAD - RE- 1322110 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
PLACE
2 COVER, CYLINDER HEAD FRONT - REPLACE 1322210 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1
3 CAMSHAFT - REPLACE 1322300 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2
4 PIN, CAMSHAFT - REPLACE 1322610 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
5 CAP OR SEAL, OIL FILLER - REPLACE 1322700 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
6 SEALING, SPARK PLUG HOLE - REPLACE 1322710 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
7 SEALING, VENTILATION - REPLACE 1322720 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

133
120
TIMING COVER & CHAIN DRIVE 133

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 PULLEY, CRANKSHAFT - REPLACE 1332100 2.8 2.8 2.0 4.0 2.0 4.0 2.0 4.0
2 COVER AND/OR GASKET, TIMING - REPLACE 1332200 8.8 9.5 5.8 5.8 5.8 5.8 5.8 5.8
3 BELT OR CHAIN, TIMING - REPLACE 1332500 5.2 5.6 5.2 5.6 5.2 5.6 5.2 5.6
4 SPROCKET, CRANKSHAFT TIMING - REPLACE 1333100 8.8 9.5 14.0 16.0 14.0 16.0 14.0 16.0
5 HUB OR VIBRATION DAMPER - REPLACE 1333140 3.4 3.4 3.4 3.4 3.4 3.4 3.4 3.4
6 SPROCKET, CAMSHAFT TIMING - REPLACE 1333300 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
7 ADJUST ASSEMBLY - REPLACE 1333400 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0
8 MAGNET, CAMSHAFT ADJUST - REPLACE 1333430 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
9 SENSOR, CRANKSHAFT POSITION - REPLACE 1333700 0.7 0.7 0.6 0.6 0.6 0.6 0.6 0.6
10 SENSOR, CAMSHAFT POSITION - REPLACE 1333800 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
11 RAIL, CLAMPING SLIDING - REPLACE 1336500 9.4 9.4 1.5 1.5 1.5 1.5 1.5 1.5
12 RAIL, SLIDING - REPLACE 1336700 9.4 9.4 5.2 5.6 5.2 5.6 5.2 5.6
13 RAIL, UPPER SLIDING - REPLACE 1336900 1.5 1.5 1.2 1.2 1.2 1.2 1.2 1.2
14 CHAIN TIGHTENER - REPLACE 1337300 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
15 WASHER, CHAIN TIGHTENER - REPLACE 1337500 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

138
122
ENGINE & TRANSAXLE MOUNT 138

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 MOUNT, ENGINE (FRONT) - REPLACE One 1380200 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Two 1380210 0.8 0.8 0.8 1.0 0.8 1.0 0.8 1.0
2 BRACKET, ENGINE MOUNT (FRONT) - REPLACE
One 1380400 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Two 1380410 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
3 STOPPER ENGINE MOUNTING - REPLACE 1380420 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 CROSS MEMBER, ENGINE MOUNTING REAR - 1380440 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
REPLACE
5 CROSS MEMBER, FRONT AXLE MOUNTING - RE- 1380600 - - 0.6 0.6 0.6 0.6 0.6 0.6
PLACE
6 INSULATOR, HEAT SHIELD - REPLACE 1384500 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

139
124
VACUUM SYSTEM 139

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 VALVE, PURGE CONTROL - REPLACE 1391300 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.5
2 VACUUM HOSE AND/OR TUBE - REPLACE 1391310 0.6 0.6 0.5 0.5 0.5 0.5 0.5 0.5

1D-G. ENGINE COOLING
141. RADIATOR ............................................................................. 128 1D-G
143. COOLING FAN ...................................................................... 130
144. OIL COOLER ......................................................................... 132
145. RADIATOR HOSE & PIPE .................................................... 134
148. THERMOSTAT & WATER PUMP ........................................ 136

1D-G ENGINE COOLING
141
128
ENGINE COOLING 1D-G
RADIATOR 141
CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 COOLANT - REPLACE 1410100 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
2 COCK OR PLUG, RADIATOR DRAIN - REPLACE 1410300 0.2 0.2 1.0 1.0 1.0 1.0 1.0 1.0
3 RADIATOR ASSEMBLY - REPLACE 1410500 0.9 0.9 1.6 1.6 1.6 1.6 1.6 1.6
4 COOLING SYSTEM - FLUSH 1411700 0.2 0.2 0.6 0.6 0.6 0.6 0.6 0.6

1D-G ENGINE COOLING
143
130
ENGINE COOLING 1D-G
COOLING FAN 143

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 DEFLECTOR AND/OR SEAL (LOWER) - REPLACE 1430500 0.3 0.3 0.8 0.8 0.8 0.8 0.8 0.8
2 SHROUD, RADIATOR FAN (ONE PIECE) - REPLACE 1430700 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.5
3 BLADE, FAN - REPLACE 1431600 0.3 0.3 0.7 0.7 0.7 0.7 0.7 0.7
4 CLUTCH, FAN - REPLACE 1431700 1.1 1.1 0.7 0.7 0.7 0.7 0.7 0.7
5 PULLEY, FAN BELT IDLE - REPLACE 1431900 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
6 BRACKET, COOLING FAN - REPLACE 1431910 - 4.1 - 4.1 - 4.1 - 4.1

1D-G ENGINE COOLING
144
132
ENGINE COOLING 1D-G
OIL COOLER 144

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 OIL COOLER REINFORCEMENT 1443010 - 3.6 - 3.6 - 3.6 - 3.6
2 OIL COOLER ASSEMBLY - REPLACE 1443020 - 3.8 - 3.8 - 3.8 - 3.8
3 OIL COOLER GASKET - REPLACE 1443030 - 3.9 - 3.9 - 3.9 - 3.9
4 PIPE, OIL COOLANT - REPLACE 1443040 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
5 RING, OIL COOLANT - REPLACE 1443050 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
6 OUTLET HOSE OIL COOLANT - REPLACE 1443060 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7

1D-G ENGINE COOLING
145
134
ENGINE COOLING 1D-G
RADIATOR HOSE & PIPE 145

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 HOSE, OVERFLOW - REPLACE 1450300 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
2 RESERVOIR, RADIATOR COOLANT - REPLACE 1450400 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
3 BRACKET, RADIATOR COOLANT, RESERVOIR - RE- 1450410 - - 0.5 0.5 0.5 0.5 0.5 0.5
PLACE
4 HOSE, MAKE UP - REPLACE 1450600 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
5 HOSE, UPPER ENGINE COOLANT - REPLACE 1450700 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
6 HOSE, LOWER ENGINE COOLANT - REPLACE 1450800 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
7 CHOSE AND/OR TUBE, DEAERATION - REPLACE 1451400 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
8 HOSE, INLET HEATER - REPLACE 1453100 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
9 HOSE, OUTLET HEATER - REPLACE 1453200 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
10 CAP ASSY - RESERVOIR TANK - REPLACE 1450420 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

1D-G ENGINE COOLING
148
136
ENGINE COOLING 1D-G
THERMOSTAT & WATER PUMP 148

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 THERMOSTAT AND/OR GASKET - REPLACE 1480500 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
2 PORT AND/OR GASKET, COOLANT OUTLET - RE- 1480600 0.7 0.7 1.0 1.0 1.0 1.0 1.0 1.0
PLACE
3 FLANGE, WATER PUMP - REPLACE 1481250 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 PULLEY, WATER PUMP - REPLACE 1481270 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
5 IMPELLER, WATER PUMP - REPLACE 1481280 2.0 2.0 4.2 4.2 4.2 4.2 4.2 4.2
6 SEAL, WATER PUMP MECHANICAL - REPLACE 1481700 1.2 1.2 3.2 3.2 3.2 3.2 3.2 3.2
7 WATER PUMP - REPLACE 1482100 2.0 2.0 4.2 4.2 4.2 4.2 4.2 4.2
8 SENSOR, WATER PUMP TEMPERATURE - REPLACE 1482200 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
9 PORT, COOLING WATER DUTLET - REPLACE 1482210 0.6 0.6 0.8 0.8 0.8 0.8 0.8 0.8
10 PIPE, HOT WATER INLET - REPLACE 1482220 0.5 0.5 0.9 0.9 0.9 0.9 0.9 0.9

1E-G. ENGINE ELECTRICAL
151. IGNITION CABLE.................................................................. 140
154. ALTERNATOR UNIT ............................................................. 142
156. STARTER .............................................................................. 144 1E-G
157. BATTERY .............................................................................. 146
158. FUSE & RELAY ..................................................................... 148

1E-G ENGINE ELECTRICAL
151
140
ENGINE ELECTRICAL 1E-G
IGNITION CABLE 151

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 WIRES, SPARK PLUG(ONE OR TWO) DOHC - RE- 1510200 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
PLACE
WIRES, SPARK PLUG(ALL) DOHC - REPLACE 1510500 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
2 PLUGS, SPARK(ONE OR TWO) DOHC - REPLACE 1510900 0.4 0.5 0.4 0.5 0.4 0.5 0.4 0.5
PLUGS, SPARK(ALL) DOHC - REPLACE 1511200 0.5 0.7 0.5 0.7 0.5 0.7 0.5 0.7
3 COIL, IGNITION CONTROL DOHC - REPLACE 1511400 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
4 PLUG, COUPLING - REPLACE 1511600 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
5 COVER, PROTECTION - REPLACE 1512000 0.2 0.2 0.2 - 0.2 - 0.2 -

154
142
ALTERNATOR UNIT 154

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 PULLEY AND/OR FAN, ALTERNATOR - REPLACE 1540100 0.6 0.6 0.5 0.5 0.5 0.5 0.5 0.5
2 BEARING, ALTERNATOR-REPLACE
Front 1540300 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
Rear 1540500 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
3 ALTERNATOR ASSEMBLY - REPLACE 1541700 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
ALTERNATOR ASSEMBLY - OVERHAUL 1541900 1.4 1.4 1.5 1.5 1.5 1.5 1.5 1.5
4 BRACKET, ALTERNATOR MOUNTING - REPLACE 1544100 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

156
144
STARTER 156
CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 MOTOR ASSEMBLY, STARTER DOHC - REPLACE 1560900 1.2 1.2 1.0 1.0 1.0 1.0 1.0 1.0
2 SWITCH, STARTER MOTOR MAGNETIC - REPLACE 1562700 1.5 1.5 1.2 1.2 1.2 1.2 1.2 1.2

157
146
BATTERY 157
CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 BATTERY - REPLACE 1570300 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
2 RETAINER AND/OR BOLTS, BATTERY - REPLACE 1570500 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.2
3 CARRIER, BATTERY - REPLACE 1571100 - - 0.3 0.3 0.3 0.3 0.3 0.3
4 CABLE - BATTERY GROUND 1571200 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.2

158
148
FUSE & RELAY 158

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 RELAY - REPLACE
Fog Lamp 1580200 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Enable (ABS) 1580500 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Window Wiper Motor 1580900 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Head Lamp 1581100 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Other Relays 1581500 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Turn Signal 1582100 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
2 COVER, FUSE BOX - REPLACE 1582300 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
3 BOX, RELAY & FUSE - REPLACE 1582700 0.7 0.7 0.6 0.6 0.6 0.6 0.6 0.6
4 FUSE - REPLACE 1583700 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
5 CONTROL UNIT P/WINDOW AUTO DOWN - REPLACE 1584700 0.3 0.3 0.3 0.3 0.4 0.4 0.5 0.5

1F-G. ENGINE CONTROLS
171. FUEL TANK ........................................................................... 152
172. FUEL LINE & OIL LINE ........................................................ 154
173. CANISTER & FUEL VACUUM .............................................. 158
181. FUEL INJECTION ................................................................. 160
182. ACCELERATOR CONTROL ................................................ 163 1F-G

186. EMISSION CONTROL .......................................................... 164
1F-G ENGINE CONTROLS
171
152
ENGINE CONTROLS 1F-G
FUEL TANK 171

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 PUMP, FUEL AND/OR GAUGE, ORING - REPLACE 1710300 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
2 AIR BLEEDING, FUEL 1710400 - - 0.5 0.5 0.5 0.5 0.5 0.5
3 NECK, FUEL TANK FILLER - REPLACE 1710500 - - 0.7 0.7 0.7 0.7 0.7 0.7
4 TANK, FUEL - REPLACE 1710900 1.1 1.1 1.3 1.3 1.3 1.3 1.3 1.3
5 GROMMET, FUEL FILLER - REPLACE 1711300 0.2 0.2 - - - - - -
6 PROTECTOR, FUEL TANK - REPLACE 1712200 - - 0.3 0.3 0.3 0.3 0.3 0.3
7 VALAE, ROLLOVER - REPLACE 1712410 0.3 0.3 - - - - - -
8 HOSE, AIR VENT - REPLACE 1713500 - - 0.7 0.7 0.7 0.7 0.7 0.7
9 CAP, FUEL TANK - REPLACE 1713600 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

172-1
154
FUEL LINE & OIL LINE 172-1

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 HOUSING, OIL FILTER - REPLACE 1720200 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
2 COVER, OIL FILTER HOUSING - REPLACE 1720230 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
3 FILTER, OIL - REPLACE 1720240 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 GASKET, OIL FILTER - REPLACE 1720250 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
5 FILTER, FUEL ELEMENT - REPLACE 1720300 0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.2
6 BRACKET, FUEL FILTER - REPLACE 1720310 0.4 0.4 - - - - - -
7 VALVE, 2WAY CHECK - REPLACE 1720330 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
8 HOSE, FUEL RETURN OR SUPPLY - REPLACE 1720340 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
9 PIPE, FUEL VAPOR - REPLACE 1720600 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
10 PIPE, FUEL RETURN - REPLACE 1720700 1.0 1.0 0.7 0.7 0.7 0.7 0.7 0.7
11 PIPE, FUEL SUPPLY - REPLACE 1720760 1.0 1.0 0.7 0.7 0.7 0.7 0.7 0.7
12 ANOTHER HOSE, FUEL - REPLACE 1720870 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
A - Additional another hose, fuel 172087A 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
13 HOSE, FUEL(TANK TO PIPE) - REPLACE 1721300 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
A - Additional hose, fuel (tank to pipe) 172130A 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
14 HOSE, 2WAY CHECK VALVE INLET - REPLACE 1723400 0.2 0.2 - - - - - -

172-2
156
FUEL LINE & OIL LINE 172-2

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 HOUSING, OIL FILTER - REPLACE 1720200 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
2 COVER, OIL FILTER HOUSING - REPLACE 1720230 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
3 FILTER, OIL - REPLACE 1720240 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 GASKET, OIL FILTER - REPLACE 1720250 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
5 FILTER, FUEL ELEMENT - REPLACE 1720300 0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.2
6 BRACKET, FUEL FILTER - REPLACE 1720310 0.4 0.4 - - - - - -
7 VALVE, 2WAY CHECK - REPLACE 1720330 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
8 HOSE, FUEL RETURN OR SUPPLY - REPLACE 1720340 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
9 PIPE, FUEL VAPOR - REPLACE 1720600 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
10 PIPE, FUEL RETURN - REPLACE 1720700 1.0 1.0 0.7 0.7 0.7 0.7 0.7 0.7
11 PIPE, FUEL SUPPLY - REPLACE 1720760 1.0 1.0 0.7 0.7 0.7 0.7 0.7 0.7
12 ANOTHER HOSE, FUEL - REPLACE 1720870 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
A - Additional another hose, fuel 172087A 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
13 HOSE, FUEL(TANK TO PIPE) - REPLACE 1721300 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
A - Additional hose, fuel (tank to pipe) 172130A 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
14 HOSE, 2WAY CHECK VALVE INLET - REPLACE 1723400 0.2 0.2 - - - - - -

173
158
CANISTER & FUEL VACUUM 173

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 HOSE OR PIPE,2WAY CHECK VALVE TO CANISTER 1731410 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.3
- REPLACE
2 CANISTER, FUEL VAPOR - REPLACE 1731500 0.3 0.3 0.4 0.4 0.4 0.4 0.4 0.4
3 PIPE,CANISTER TO PURGE CONTROL VALVE - 1731910 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
REPLACE
4 SOLENOID,EVAP EMISSION PURGE - REPLACE 1732700 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

181
160
FUEL INJECTION 181

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 BODY, THROTTLE DOHC - REPLACE 1810300 1.8 1.8 0.8 0.8 0.8 0.8 0.8 0.8
2 REGULATOR AND/OR GASKETS DOHC - REPLACE 1810900 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
3 INJECTOR, FUEL (ONE OR ALL) DOHC - REPLACE 1811200 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1
4 RAIL, FUEL DOHC - REPLACE 1811400 1.1 1.1 1.0 1.0 1.0 1.0 1.0 1.0
5 RING SEAL, CONNETOR ASSY FUEL SUPPLY 1811500 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
6 PIPE ASSY, FUEL RETURN - REPLACE 1811600 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
7 CONNECTOR ASSY, FUEL PRESSURE- REPLACE 1811700 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

182
162
ACCELERATOR CONTROL 182

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 CABLE, ACCELERATOR CONTROL - REPLACE 1820300 0.4 0.4 0.4 0.4 - - - -
2 PEDAL, ACCELERATOR - REPLACE 1820500 0.2 0.2 0.4 0.4 - - - -
3 MODULE, ACCELERATOR PEDAL - REPLACE 1820600 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.3
4 SPRING, THROTTLE RETURN - REPLACE 1820700 0.2 0.2 0.2 0.2 - - - -
5 PAD, ACCELERATOR PEDAL - REPLACE 1821100 0.4 0.4 0.2 0.2 0.2 0.2 0.2 0.2
6 ARM AND GUIDE, ACCELERATOR CABLE - REPLACE 1821200 0.6 0.6 - - - - - -
7 BRACKET, ACCELERATOR PEDAL MOUNT - RE- 1821230 0.5 0.5 0.4 0.4 - - - -
PLACE
8 LEVER, ACCELERATOR CONTROL - REPLACE 1822310 - - 0.3 0.3 - - - -
9 SPRING, ACCELERATOR CONTROL - REPLACE 1822330 - - 0.2 0.2 - - - -
10 BRACKET, ACCELERATOR CONTROL LEVER BEAR- 1822340 - - 0.5 0.5 - - - -
ING - REPLACE
11 ROD, CONNECTING - REPLACE 1822350 - - 0.3 0.3 - - - -
12 LEVER, REVERSING - REPLACE 1822380 - - 0.4 0.4 - - - -
13 LEVER, SLOTTED GATE - REPLACE 1822400 - - 0.4 0.4 - - - -

186
164
EMISSION CONTROL 186

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 SENSOR, KNOCK - REPLACE 1861300 1.6 1.6 0.8 0.8 0.8 0.8 0.8 0.8
A - Additional sensor, knock 186130A - - - 0.8 - 0.8 - 0.8
2 ECU (ENGINE) - REPLACE 1862110 0.5 0.5 0.8 0.8 0.8 - 0.8 0.8
3 SENSOR, AIR TEMPERATURE - REPLACE 1862120 - - 0.8 0.8 - - - -
4 SENSOR, ACCELERATOR - REPLACE 1862130 1.2 1.2 - - - - -

1G-G. ENGINE INTAKE & EXHAUST
191. AIR INTAKE SYSTEM ........................................................... 168
193. INTAKE MANIFOLD .............................................................. 170
194. EXHAUST MANIFOLD .......................................................... 172
196. EXHAUST PIPE LINE ........................................................... 174
1G-G
1G-G ENGINE INTAKE & EXHAUST
191
168
ENGINE INTAKE & EXHAUST 1G-G
AIR INTAKE SYSTEM 191

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 AIR CLEANER - REPLACE 1910300 0.6 0.6 0.5 0.5 0.5 0.5 0.5 0.5
2 BRACKET, AIR CLEANER HOUSING MOUNTING- 1910350 - - 0.7 0.7 0.7 0.7 0.7 0.7
REPLACE
3 FILTER, AIR CLEANER - REPLACE 1910500 0.4 0.4 0.2 0.2 0.2 0.2 0.2 0.2
4 DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE 1910700 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.3
5 SENSOR, MAT - REPLACE 1910900 0.4 0.4 0.4 0.4 - - - -
6 HOUSING, INLET AIR - REPLACE 1911310 0.7 0.7 - - 0.5 0.5 0.5 0.5
7 METER, AIR MASS - REPLACE 1911320 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
8 DUCT INT AIR - REPLACE 1910800 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

193
170
INTAKE MANIFOLD 193

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 MANIFOLD, INTAKE LOWER - REPLACE 1930220 2.1 2.1 1.3 1.3 1.3 1.3 1.3 1.3
2 GASKET, UPPER INTAKE MANIFOLD - REPLACE 1930210 - - 0.7 0.7 0.7 0.7 0.7 0.7
3 MANIFOLD, INTAKE UPPER - REPLACE 1930230 1.5 1.5 2.3 2.3 2.3 2.3 2.3 2.3
4 FLAP, RESONANCE - REPLACE 1932200 - 1.6 - 1.6 - 1.6 - 1.6
5 PACKING - REPLACE 1932400 - 1.6 - 1.6 - 1.6 - 1.6
6 SENSOR ASSY, MAP - REPLACE 1932700 - - - - 0.2 - 0.2 -
7 ADAPTOR, MAP SENSOR - REPLACE 1932800 - - - - 0.3 - 0.3 -

194
172
EXHAUST MANIFOLD 194

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 MANIFOLD AND/OR GASKET EXHAUST DOHC- 1940300 0.8 1.4 0.8 1.4 0.8 1.4 0.8 1.4
REPLACE
2 SENSOR, OXYGEN DOHC - REPLACE 1940600 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
3 COVER, EXHAUST MANIFOLD UPPER - REPLACE 1940810 0.8 - 0.8 - 0.5 0.6 0.5 0.6
4 COVER, EXHAUST MANIFOLD LOWER - REPLACE 1940830 1.4 - 1.4 - 0.4 0.4 0.4 0.4

196
174
EXHAUST PIPE LINE 196

CM MU/MU-S/KO RX ST
Operation
Code 2.3 3.2
2.3 3.2 2.3 3.2 2.3 3.2
1 HANGER AND/OR CLAMP, EXHAUST SYSTEM-RE- 1960300 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
PLACE
2 PIPE, FRONT EXHAUST - REPLACE 1960900 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
3 SHIELD, CONVERTER - REPLACE 1961300 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 HEAT SHIELD, FRONT - REPLACE 1961400 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
5 HEAT SHIELD, CENTER - REPLACE 1961410 0.5 0.5 - - - - - -
6 HEAT SHIELD, CENTER MUFFLER - REPLACE 1961420 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
7 HEAT SHIELD, REAR - REPLACE 1961430 0.5 0.5 - - - - - -
8 CONVERTER - REPLACE 1961500 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6
9 MUFFLER - REPLACE 1962100 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
10 EXHAUST SYSTEM (COMPLETE) - REPLACE 1962500 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
12 GASKET 1962700 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
A - Additional - Gasket 196270A 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

SECTION 2
SUSPENSION
2C. FRONT SUSPENSION .................................................................... 179

2D. REAR SUSPENSION ...................................................................... 197
2E. TIRES & WHEEL ............................................................................ 209
2C. FRONT SUSPENSION 2C
213. KNUCKLE & HUB ................................................................. 180
214. FRONT SHOCK ABSORBER .............................................. 186
215. CONTROL ARM .................................................................... 188
216. TORSION BAR ...................................................................... 190
217. ECS ........................................................................................ 192
218. SUB FRAME .......................................................................... 194

2C FRONT SUSPENSION
213-1
180
FRONT SUSPENSION 2C
KNUCKLE & HUB 213-1

Model
Operation
NO. Operation Description MU/
Code CM KO RX ST
MU-S
1 WHEEL ALIGNMENT 2130300 1.0 1.0 1.0 1.0 1.0
2 HUB, FRONT - REPLACE
Right 2130400 1.1 - - - -
Left 2130410 1.1 - - - -
Both 2130420 1.9 - - - -
3 HUB AND RBRAKE DISC - REPLACE
Right 2130470 - 1.2 1.2 1.2 1.2
Left 2130480 - 1.2 1.2 1.2 1.2
Both 2130490 - 2.2 2.2 2.2 2.2
4 BEARING, FRONT HUB INNER AND/OR OUTER - REPLACE
Right 2130710 2.3 1.5 1.5 1.5 1.5
Left 2130720 2.3 1.5 1.5 1.5 1.5
Both 2130730 4.1 2.7 2.7 2.7 2.7
5 HUB, AUTO VACUUM LOCKING - OVERHAUL
Right 2130770 - 0.5 0.5 0.5 0.5
Left 2130780 - 0.5 0.5 0.5 0.5
Both 2130790 - 0.9 0.9 0.9 0.9
6 HUB, AUTO VACUUM LOCKING - REPLACE
Right 2130800 - 0.4 0.4 0.4 0.4
Left 2130810 - 0.4 0.4 0.4 0.4
Both 2130820 - 0.7 0.7 0.7 0.7
7 VACUUM, LOCKING HUB - ADJUST 2130840 - 0.5 0.5 0.5 0.5
8 HUB GAP - ADJUST
Right 2130870 - 0.4 0.4 0.4 0.4
Left 2130880 - 0.4 0.4 0.4 0.4
Both 2130890 - 0.7 0.7 0.7 0.7
9 WASHER AND/OR NUT, FRONT LOCKING HUB - REPLACE
Right 2130900 - 0.4 0.4 0.4 0.4
Left 2130910 - 0.4 0.4 0.4 0.4
Both 2130920 - 0.7 0.7 0.7 0.7
10 VALVE, LOCKING HUB SOLENOID - REPLACE 2130950 - 0.2 0.2 0.2 0.2
11 KNUCKLE ASSEMBLY, STEERING - REPLACE
Right 2131100 1.9 1.2 1.2 1.2 1.2
Left 2131200 1.9 1.2 1.2 1.2 1.2
Both 2131300 3.4 2.0 2.0 2.0 2.0
12 ARM, STEERING KNUCKLE - REPLACE
Right 2131310 2.2 - - - -
Left 2131320 2.2 - - - -
Both 2131330 4.0 - - - -

2C FRONT SUSPENSION
213-2
182
FRONT SUSPENSION 2C
KNUCKLE & HUB 213-2

Model
Operation
Code CM KO RX ST
MU-S
13 SEAL, KNUCKLE OIL - REPLACE
Right 2131400 - 1.2 1.2 1.2 1.2
Left 2131410 - 1.2 1.2 1.2 1.2
Both 2131420 - 2.0 2.0 2.0 2.0
14 BEARING, KNUCKLE - REPLACE
Right 2131430 - 1.2 1.2 1.2 1.2
Left 2131440 - 1.2 1.2 1.2 1.2
Both 2131450 - 2.0 2.0 2.0 2.0
15 ROTOR ASSEMBLY, FRONT - REPLACE
Right 2131500 0.8 - - - -
Left 2131600 0.8 - - - -
Both 2131700 1.4 - - - -
16 SHIELD, FRONT DISC BRAKE - REPLACE
Right 2132100 0.8 0.9 0.9 0.9 0.9
Left 2132200 0.8 0.9 0.9 0.9 0.9
Both 2132300 1.4 1.6 1.6 1.6 1.6
17 NUT, FRONT HUB CLAMPING - REPLACE
Right 2133310 0.3 - - - -
Left 2133320 0.3 - - - -
Both 2133330 0.5 - - - -
18 SEAL, FRONT OIL HUB - REPLACE
Right 2133500 1.2 1.2 1.2 1.2 1.2
Left 2133600 1.2 1.2 1.2 1.2 1.2
Both 2133700 2.0 2.0 2.0 2.0 2.0
19 FLANGE, FRONT HUB - REPLACE
Right 2133710 - 0.4 0.4 0.4 0.4
Left 2133720 - 0.4 0.4 0.4 0.4
Both 2133730 - 0.6 0.6 0.6 0.6
20 HOSE, VACUUM, LOCKING HUB - REPLACE 2133750 - 0.3 0.3 0.3 0.3
21 CAP, FRONT HUB - REPLACE
Right 2133760 - 0.2 0.2 0.2 0.2
Left 2133770 - 0.2 0.2 0.2 0.2
Both 2133780 - 0.3 0.3 0.3 0.3
22 ROTOR ASSEMBLY (BRAKE DISC) - REPLACE
Right 2131510 0.8 0.8 0.8 0.8 0.8
Left 2131610 0.8 0.8 0.8 0.8 0.8
Both 2131710 1.4 1.4 1.4 1.4 1.4

2C FRONT SUSPENSION
213-3
184
FRONT SUSPENSION 2C
KNUCKLE & HUB 213-3

Model
Operation
Code CM KO RX ST
MU-S
23 TOOTH WHEEL, ABS - REPLACE
Right 2135100 - 1.2 1.2 1.2 1.2
Left 2135200 - 1.2 1.2 1.2 1.2
Both 2135300 - 2.0 2.0 2.0 2.0

2C FRONT SUSPENSION
214
186
FRONT SUSPENSION 2C
FRONT SHOCK ABSORBER 214

Model
Operation
Code CM KO RX ST
MU-S
1 SPRING, FRONT COIL - REPLACE
Right 2140100 0.7 - - 0.8 0.8
Left 2140200 0.7 - - 0.8 0.8
Both 2140300 1.3 - - 1.5 1.5
2 STOPPER, REBOUND - REPLACE
Right 2141300 1.2 - - - -
Left 2141310 1.2 - - - -
Both 2141320 2.2 - - - -
3 SEAT AND/OR INSULATOR - REPLACE
Right 2141500 1.2 0.5 0.5 0.8 0.8
Left 2141600 1.2 0.5 0.5 0.8 0.8
Both 2141700 2.2 0.9 0.9 1.5 1.5
4 DAMPER STRUT ASSEMBLY - REPLACE
Right 2142300 1.0 - - - -
Left 2142310 1.0 - - - -
Both 2142320 1.8 - - - -
5 BUMPER, STOPPER - REPLACE
Right 2142330 0.9 - - 0.8 0.8
Left 2142340 0.9 - - 0.8 0.8
Both 2142350 1.6 - - 1.5 1.5
6 BOOT, DAMPER STRUT - REPLACE
Right 2142360 0.9 - - 0.8 0.8
Left 2142370 0.9 - - 0.8 0.8
Both 2142380 1.6 - - 1.5 1.5
7 SHOCK ABSORBER - REPLACE
Right 2143100 - 0.5 0.5 0.8 0.8
Left 2143200 - 0.5 0.5 0.8 0.8
Both 2143300 - 0.9 0.9 1.5 1.5
8 SHOCK ABSORBER & SPING ASSEMBLY - REPLACE
Right 2140600 - - - 0.6 0.6
Left 2140610 - - - 0.6 0.6
Both 2140620 - - - 1.0 1.0
9 SHOCK ABSORBER YOKE - REPLACE
Right 2140800 - - - 0.4 -
Left 2140810 - - - 0.4 -
Both 2140820 - - - 0.7 -

2C FRONT SUSPENSION
215
188
FRONT SUSPENSION 2C
CONTROL ARM 215

Model
Operation
Code CM KO RX ST
MU-S
1 LINK AND/OR BUSHING, FRONT STABILIZER - REPLACE
Right 2150100 0.3 0.3 0.3 0.3 0.3
Left 2150200 0.3 0.3 0.3 0.3 0.3
Both 2150300 0.5 0.5 0.5 0.5 0.5
2 STABILIZER, FRONT - REPLACE 2150500 0.6 0.8 0.8 0.5 0.5
3 CAM BOLT, FRONT LOWER ARM MOUNTING - REPLACE
Right 2151800 0.3 - - 0.3 0.3
Left 2151810 0.3 - - 0.3 0.3
Both 2151820 0.5 - - 0.5 0.5
4 BUSHING, FRONT CONTROL ARM - REPLACE
Right 2152400 1.4 - - - -
Left 2152500 1.4 - - - -
Both 2152600 2.5 - - - -
5 ARM ASSEMBLY, FRONT UPPER CONTROL - REPLACE
Right 2154000 - 1.5 1.5 0.6 0.6
Left 2154100 - 1.5 1.5 0.6 0.6
Both 2154200 - 2.7 2.7 1.2 1.2
6 END AND/OR BUSHING, FRONT UPPER CONTROL ARM - REPLACE
Right 2154210 - 0.8 0.8 - -
Left 2154220 - 0.8 0.8 - -
Both 2154230 - 1.4 1.4 - -
7 BUSHING, FRONT UPPER CONTROL ARM - REPLACE
Right 2154230 - 1.6 1.6 0.8 0.4
Left 2154240 - 1.6 1.6 0.8 0.4
Both 2154250 - 2.9 2.9 1.5 0.4
8 BUSHING, FRONT LOWER CONTROL ARM - REPLACE
Right 2154260 - 1.6 1.6 1.2 1.2
Left 2154270 - 1.6 1.6 1.2 1.2
Both 2154280 - 2.9 2.9 2.2 2.2
9 ARM ASSEMBLY, FRONT LOWER CONTROL - REPLACE
Right 2154500 1.2 1.5 1.5 1.1 1.1
Left 2154600 1.2 1.5 1.5 1.1 1.1
Both 2154700 2.0 2.7 2.7 2.0 2.0
10 END, FRONT LOWER CONTROL ARM - REPLACE
Right 2154800 - 0.8 0.8 - -
Left 2154810 - 0.8 0.8 - -
Both 2154820 - 1.4 1.4 - -

2C FRONT SUSPENSION
216
190
FRONT SUSPENSION 2C
TORSION BAR 216

Model
Operation
Code CM KO RX ST
MU-S
1 SPRING, TORSION BAR - REPLACE
Right 2160100 - 0.4 0.4 - -
Left 2160110 - 0.4 0.4 - -
Both 2160120 - 0.7 0.7 - -
2 BOLT, TORSION BAR - ADJUST
Right 2160210 - 0.2 0.2 - -
Left 2160220 - 0.2 0.2 - -
Both 2160230 - 0.3 0.3 - -
3 HEIGHT, VEHICLE - ADJUST 2160410 - 0.5 0.5 - -

2C FRONT SUSPENSION
217
192
FRONT SUSPENSION 2C
ECS 217
Model
Operation
Code CM KO RX ST
MU-S
1 ECS ACTUATOR - REPLACE 2170100 0.4 0.4 0.4 - -
2 SENSOR, VERTICAL - REPLACE 2170300 0.3 0.1 0.3 - -
3 SENSOR, LATERAL - REPLACE 2170500 0.3 0.1 0.3 - -
4 ECS (ECU) UNIT - REPLACE 2170700 0.2 0.4 0.3 - -
5 SWITCH, ECS - REPLACE 2170800 0.2 0.2 0.2 - -
6 G SENSOR, ECS - REPLACE
Right 2170900 - 0.3 0.4 - -
Left 2170910 - 0.3 0.4 - -
Both 2170920 - 0.5 0.7 - -

2C FRONT SUSPENSION
218
194
FRONT SUSPENSION 2C
SUB FRAME 218

Model
Operation
Code CM KO RX ST
MU-S
1 SUB FRAME ASSEMBLY - OVER HALL 2180100 - - - - 3.9

2D. REAR SUSPENSION
231. REAR AXLE & STABILIZER ................................................. 198 2D
232. REAR SHOCK ABSORBER ................................................. 202
233. STEERING DAMPER ............................................................ 204
234. SUB FRAME .......................................................................... 206

2D REAR SUSPENSION
231-1
198
REAR SUSPENSION 2D
REAR AXLE & STABILIZER 231-1

Model
Operation
Code CM KO RX ST
MU-S
1 STABILIZER, REAR - REPLACE 2310100 3.4 0.4 0.4 0.4 0.4
2 DAMPER, STABILIZER - REPLACE
Right 2310300 0.3 - - 0.2 0.3
Left 2310310 0.3 - - 0.2 0.3
Both 2310320 0.5 - - 0.4 0.5
3 AXLE ASSEMBLY, REAR - REPLACE 2310900 2.9 4.5 4.5 4.0 2.9
AXLE ASSEMBLY, REAR - OVERHAUL 2310910 6.3 7.5 7.5 6.0 6.3
4 BREATHER AIR - REPLACE 2310930 - 0.2 0.2 0.2 0.2
5 CAP, HUB - REPLACE
Right 2312100 0.2 0.2 0.2 0.2 0.2
Left 2312200 0.2 0.2 0.2 0.2 0.2
Both 2312300 0.3 0.3 0.3 0.3 0.3
6 LINK AND/OR BUSHING, REAR STABILIZER - REPLACE
Right 2314100 0.6 0.3 0.3 0.3 0.6
Left 2314200 0.6 0.3 0.3 0.3 0.6
Both 2314300 1.0 0.5 0.5 0.5 1.0
7 KNUCKLE, REAR (DISC) - REPLACE
ZRight 2315100 2.6 - - - 2.6
Left 2315200 2.6 - - - 2.6
Both 2315300 4.7 - - - 4.7
8 COVER, DIFFERENTIAL BEARING - REPLACE 2315310 3.0 - - - 3.0
9 HOUSING, REAR AXLE - REPLACE 2316300 4.6 5.0 5.0 5.0 4.6
10 SHAFT, REAR AXLE - REPLACE
Right 2316410 1.3 1.5 1.5 1.4 1.3
Left 2316420 1.3 1.5 1.5 1.4 1.3
Both 2316430 2.3 2.7 2.7 2.5 2.3
11 GASKET, REAR DIFFERENTIAL CARRIER - REPLACE 2316630 - 0.8 0.8 0.8 -
12 NUT, LOCK - REPLACE 2316710 2.9 0.6 0.6 0.6 2.9
13 FLANGE, PINION - REPLACE 2316720 2.9 - - - 2.9
14 BEARING, PINION - REPLACE 2316730 2.3 - - - 2.3
15 BEARING, REAR AXLE SHAFT - REPLACE
Right 2316810 1.8 1.5 1.5 1.3 1.8
Left 2316820 1.8 1.5 1.5 1.3 1.8
Both 2316830 3.2 2.7 2.7 2.2 3.2
16 SEAL, DRIVE PINION GEAR OIL - REPLACE 2316850 3.0 - - - 3.0
17 RING, DIFFERENTIAL BEARING COVER - REPLACE 2316860 2.9 - - - 2.9
18 SEAL, REAR AXLE OIL - REPLACE
Right 2316900 3.5 1.2 1.2 1.2 3.5
Left 2317000 3.5 1.2 1.2 1.2 3.5
Both 2317100 6.3 2.2 2.2 2.2 6.3

2D REAR SUSPENSION
231-2
200
REAR SUSPENSION 2D
REAR AXLE & STABILIZER 231-2

Model
Operation
Code CM KO RX ST
MU-S
19 SEAL, REAR AXLE OIL INNER - REPLACE
Right 2317110 3.2 - - - 3.2
Left 2317120 3.2 - - - 3.2
Both 2317130 5.9 - - - 5.9
20 SEAL, REAR AXLE OIL OUTER - REPLACE
Right 2317140 3.2 - - - 3.2
Left 2317150 3.2 - - - 3.2
Both 2317160 5.9 - - - 5.9
21 SHIM, BEARING COVER - REPLACE 2317210 2.9 - - - 2.9
22 OIL SEAL, REAR DIFFERENTIAL PINION GEAR - REPLACE 2317410 - 0.8 0.8 0.8 -
23 BEARING, REAR DIFFERENTIAL CASE - REPLACE 2317440 - 4.0 4.0 4.0 -
24 DRIVE GEAR SET - REPLACE 2317500 - 4.0 4.0 4.0 -
25 COVER, REAR AXLE CASE - REPLACE 2317700 3.0 0.5 0.5 0.5 3.0
26 CASE, DIFFERENTIAL - REPLACE 2317760 3.4 4.0 4.0 4.0 3.4
27 GEAR SET - REPLACE 2317780 3.4 4.0 4.0 4.0 3.4
28 OIL, REAR AXLE - REPLACE 2310920 0.4 0.3 0.3 0.3 0.4

2D REAR SUSPENSION
232
202
REAR SUSPENSION 2D
REAR SHOCK ABSORBER 232

Model
Operation
Code CM KO RX ST
MU-S
1 SPRINGS, REAR COIL - REPLACE
Right 2320100 0.7 1.5 1.5 1.6 0.7
Left 2320300 0.7 1.5 1.5 1.6 0.7
Both 2320400 1.3 2.6 2.6 2.6 1.3
2 SEAT AND/OR INSULATOR - REPLACE
Right 2320700 0.7 1.5 1.5 1.6 0.7
Left 2320800 0.7 1.5 1.5 1.6 0.7
Both 2320900 1.3 2.6 2.6 2.6 1.3
3 SHOCK ABSORBER, REAR - REPLACE
Right 2321100 1.1 0.3 0.3 0.3 1.1
Left 2321200 1.1 0.3 0.3 0.3 1.1
Both 2321300 2.0 0.5 0.5 0.5 2.0
4 BUMPER, SHOCK - REPLACE
Right 2321410 1.1 0.3 0.3 0.3 1.1
Left 2321510 1.1 0.3 0.3 0.3 1.1
Both 2321610 2.0 0.5 0.5 0.5 2.0
5 RUBBER RING, REAR S/ABS - REPLACE
Right 2321630 1.1 - - - 1.1
Left 2321640 1.1 - - - 1.1
Both 2321650 2.0 - - - 2.0
6 ROD AND/OR BUSH, LATERAL - REPLACE 2323500 - 0.4 0.4 0.2 -
7 ARM & BUSH ASSEMBLY, REAR UPPER - REPLACE
Right 2323510 - 0.4 0.4 0.4 -
Left 2323511 - 0.4 0.4 0.4 -
Both 2323512 - 0.6 0.6 0.6 -
8 ARM & BUSH ASSEMBLY, REAR LOWER - REPLACE
Right 2323530 - 0.4 0.4 0.4 -
Left 2323531 - 0.4 0.4 0.4 -
Both 2323532 - 0.6 0.6 0.6 -
9 BUMPER, REAR SUSPENSION - REPLACE
Right 2324100 - 0.2 0.2 0.2 -
Left 2324200 - 0.2 0.2 0.2 -
Both 2324300 - 0.3 0.3 0.3 -

2D REAR SUSPENSION
233
204
REAR SUSPENSION 2D
STEERING DAMPER 233

Model
Operation
Code CM KO RX ST
MU-S
1 LINK, THRUST - REPLACE
Right 2330300 0.9 - - - 0.9
Left 2330310 0.9 - - - 0.9
Both 2330320 1.6 - - - 1.6
2 PROTECTOR, THRUST LINK - REPLACE
Right 2330400 0.9 - - - -
Left 2330410 0.9 - - - -
Both 2330420 1.6 - - - -
3 LINK, REAR CAMBER - REPLACE
Right 2330500 0.9 - - - 0.9
Left 2330510 0.9 - - - 0.9
Both 2330520 1.6 - - - 1.6
4 LINK, REAR TENSION - REPLACE
Right 2330600 0.9 - - - 0.9
Left 2330610 0.9 - - - 0.9
Both 2330620 1.6 - - - 1.6
5 ROD, REAR TRACK - REPLACE
Right 2330700 0.9 - - - 0.9
Left 2330710 0.9 - - - 0.9
Both 2330720 1.6 - - - 1.6
6 LINK, SPRING - REPLACE
Right 2331100 0.9 - - - 0.9
Left 2331110 0.9 - - - 0.9
Both 2331120 1.6 - - - 1.6
7 PROTECTOR, SPRING LINK - REPLACE
Right 2331300 0.2 - - - 0.2
Left 2331310 0.2 - - - 0.2
Both 2331320 0.3 - - - 0.3
8 RUBBER BUSHING, SPRING LINK - REPLACE
Right 2331500 1.2 - - - 1.2
Left 2331510 1.2 - - - 1.2
Both 2331520 2.2 - - - 2.2

2D REAR SUSPENSION
234
206
REAR SUSPENSION 2D
SUB FRAME 234

Model
Operation
Code CM KO RX ST
MU-S
1 RUBBER MOUNTING, SUB FRAME - REPLACE
Front 2340100 2.2 - - - 2.2
Rear 2340300 2.2 - - - 2.2
2 FRAME, REAR SUB - REPLACE 2340500 3.3 - - - 3.3
3 RUBBER BUSH, CROSS MEMBER REAR - REPLACE 2340700 2.0 - - - 2.0
4 STOPPER, SUB FRAME - REPLACE 2340900 2.0 - - - 2.0
5 DAMPER, SIDE MEMBER - REPLACE
Right 2341100 - 0.2 0.2 - -
Left 2341110 - 0.2 0.2 - -
Both 2341120 - 0.3 0.3 - -

2E. TIRES & WHEEL
241. WHEELS ................................................................................ 210
2E
2E TIRES & WHEEL
241
210
TIRES & WHEEL 2E
WHEELS 241
Model
Operation
Code CM KO RX ST
MU-S
1 WHEEL - BALANCE 2410700 0.3 0.3 0.3 0.3 0.3
A - Each additional 241070A 0.2 0.2 0.2 0.2 0.2
2 WHEEL (ONE) - REPLACE 2411100 0.4 0.4 0.4 0.4 0.4
A - Replace each additional 241110A 0.3 0.3 0.3 0.3 0.3
3 TIRE (ONE) - REPLACE 2411300 0.5 0.3 0.3 0.3 0.3
4 STEM, VALVE (ONE) - REPLACE 2411500 0.5 0.5 0.5 0.5 0.5
5 BOLT, WHEEL - REPLACE 2411700 0.2 0.2 0.2 0.2 0.2
6 CAP, WHEEL - REPLACE 2411900 0.2 0.2 0.2 0.2 0.2
7 WINCH ASSY SPARE TIRE - REPLACE 2411800 0.4 0.4 0.4 0.4 0.4

SECTION 3
DRIVE LINE & AXLE
3A. DRIVE LINE & AXLE ....................................................................... 215

3A. DRIVE LINE & AXLE 3A
321. AXLE SHAFT PARTS ............................................................ 216
323. PROPELLER SHAFT ............................................................ 218
321
3A DRIVE LINE & AXLE
321
216
DRIVE LINE & AXLE 3A
AXLE SHAFT PARTS 321

Model
Operation
Code CM KO RX ST
MU-S
1 AXLE ASSEMBLY, FRONT DRIVE - REPLACE 3211100 - 3.2 3.2 3.2 3.2
AXLE ASSEMBLY, FRONT - OVERHAUL 3211310 - 6.1 6.1 6.1 6.2
2 SHAFT ASSY, FRONT AXLE - REPLACE
Right 3211510 - 2.5 2.5 1.5 0.5
Left 3211520 - 2.5 2.5 1.5 0.5
Both 3211530 - 4.5 4.5 - 1.0
3 BEARING, OUTER PINION - REPLACE 3211730 - 2.6 2.6 2.6 2.6
4 BEARING, INNER PINION - REPLACE 3211740 - 2.6 2.6 2.6 2.6
5 GEAR SET (PINION, RING, SIDE), FRONT AXLE - REPLACE 3211750 - 6.1 6.1 6.1 6.1
6 COVER, FRONT AXLE HOUSING - REPLACE 3211760 - 0.5 0.5 0.5 0.5
7 BRACKET, FRONT AXLE MOUNTING - REPLACE
Right 3211770 - 3.2 3.2 3.2 3.2
Left 3211780 - 3.2 3.2 3.2 3.2
Both 3211790 - 3.6 3.6 3.6 3.6
8 BEARING BALL AND/OR SEAL, SHAFT OIL - REPLACE
Right 3211830 - 0.7 0.7 0.7 0.7
Left 3211840 - 0.7 0.7 0.7 0.7
Both 3211850 - 1.2 1.2 1.2 1.2
9 SHAFT, INNER - REPLACE
Right 3211860 - 0.7 0.7 0.7 0.7
Left 3211870 - 0.7 0.7 0.7 0.7
Both 3211880 - 1.2 1.2 1.2 1.2
10 HOSE, AIR BENT - REPLACE 3212100 - 0.5 0.5 0.3 0.3
11 GEAR SET, DRIVE PINION & RING - REPLACE 3212130 - 6.0 6.0 6.0 6.0
12 OIL, FRONT AXLE - REPLACE 3211320 - 0.3 0.3 0.3 0.3
13 BOOT SET, OUTER - REPLACE
Right 3211610 - 3.0 3.0 2.0 2.0
Left 3211620 - 3.0 3.0 2.0 2.0
Both 3211630 - 5.0 5.0 3.5 3.5

3A DRIVE LINE & AXLE
323
218
DRIVE LINE & AXLE 3A
PROPELLER SHAFT 323

Model
Operation
Code CM KO RX ST
MU-S
1 SHAFT, PROPELLER - REPLACE
Both 3230100 1.2 - - - -
Front 3230110 0.7 0.4 0.4 0.4 0.4
Rear 3230120 0.7 0.6 0.6 0.6 0.6
2 JOINT, UNIV, PROPELLER FRONT - REPLACE
One 3230310 - 0.7 0.7 0.7 0.7
Two 3230320 - 1.0 1.0 1.0 1.0
3 JOINT, UNIV, PROPELLER REAR - REPLACE
One 3230330 - 0.7 0.7 0.7 0.7
Two 3230340 - 1.0 1.0 1.0 1.0
4 YOKE, JOINT, FRONT - REPLACE
One 3230510 - 0.7 0.7 0.7 0.7
Two 3230520 - 1.2 1.2 1.2 1.2
5 YOKE, JOINT, REAR - REPLACE
One 3230530 - 0.7 0.7 0.7 0.7
Two 3230540 - 1.2 1.2 1.2 1.2

SECTION 4
BRAKES
4A. HYDRAULIC BRAKE ....................................................................... 223

4B. MASTER CYLINDER & BOOSTER.................................................. 229
4D. FRONT BRAKE............................................................................... 233
4E. REAR BRAKE ................................................................................. 237
4F. ANTI-LOCK BRAKE SYSTEM ......................................................... 243
4G. PARKING BRAKE ........................................................................... 247
4A. HYDRAULIC BRAKE 4A
425. BRAKE PIPE .......................................................................... 224
428. BRAKE PEDAL & MOUNT ................................................... 226

4A HYDRAULIC BRAKE
425
224
HYDRAULIC BRAKE 4A
BRAKE PIPE 425

Model
Operation
Code CM KO RX ST
MU-S
1 HOSE, BRAKE - REPLACE
Right Front 4250100 0.6 0.5 0.5 0.5 0.5
Lef Front 4250200 0.6 0.5 0.5 0.5 0.5
Both Front 4250300 1.1 0.9 0.9 0.9 0.9
Right Rear 4250400 0.6 0.5 0.5 0.4 0.4
Left Rear 4250500 0.6 0.5 0.5 0.4 0.4
Both Rear 4250600 1.1 0.9 0.9 0.7 0.7
2 PIPE, REAR BRAKE - REPLACE
Right 4250800 0.5 0.5 0.5 0.5 0.5
Left 4251100 0.5 0.5 0.5 0.5 0.5
3 PIPE, MASTER CYLINDER TO MODULATOR VALVE FRONT-REPLACE 4251500 0.6 0.5 0.5 0.5 0.5
4 PIPE, MODULATOR TO JUNCTION BLOCK - REPLACE
Right 4251700 0.6 - - - -
Left 4251800 0.6 - - - -
5 PIPE, FRONT BRAKE - REPLACE
Right 4253800 0.6 0.5 0.5 0.7 0.7
Left 4253810 0.6 0.5 0.5 0.7 0.7
Both 4253820 1.1 0.9 0.9 1.2 1.2

4A HYDRAULIC BRAKE
428
226
HYDRAULIC BRAKE 4A
BRAKE PEDAL & MOUNT 428

Model
Operation
Code CM KO RX ST
MU-S
1 PEDAL AND/OR BUSHING, BRAKE - REPLACE 4280100 1.2 1.0 1.0 0.7 0.7
2 SPRING, BRAKE PDEAL RETURN - REPLACE 4280300 0.2 0.2 0.2 0.2 0.2
3 PAD, BRAKE PEDAL - REPLACE 4280500 0.2 0.2 0.2 0.2 0.2
4 SWITCH, STOP LAMP - REPLACE 4280700 0.4 0.2 0.2 0.2 0.2
5 LEVER AND/OR SPRING, BRAKE PEDAL GUIDE - REPLACE 4280800 0.2 - - - -
6 BRACKET, BRAKE PEDAL - REPLACE 4281300 0.4 1.0 1.0 0.9 0.9
7 CABLE, SHIFT LOCK - REPLACE 4281400 0.8 - - - -
8 HOLDER AND CLIP, SHAFT LOCK CABLE - REPLACE 4281600 0.5 - - - -

4B. MASTER CYLINDER & BOOSTER
431. MASTER CYLINDER & BOOSTER ..................................... 230 4B

4B MASTER CYLINDER & BOOSTER
431
230
MASTER CYLINDER & BOOSTER 4B
MASTER CYLINDER & BOOSTER 431

Model
Operation
Code CM KO RX ST
MU-S
1 CYLINDER, BRAKE MASTER - OVERHAUL 4310100 1.5 1.5 1.5 1.5 1.5
CYLINDER, BRAKE MASTER - REPLACE 4310200 0.7 0.7 0.7 0.7 0.7
2 VALVE, BOOSTER CHECK - REPLACE 4310210 - 0.2 0.2 0.2 0.2
3 SEAL, BOOSTER MOUNTING - REPLACE 4310220 0.3 0.3 0.3 0.3 0.3
4 BRAKE SYSTEM - BLEED 4310230 1.2 0.5 0.5 0.5 1.2
5 BOOSTER, VACUUM POWER BRAKE - REPLACE 4310600 0.8 1.5 1.5 0.9 0.8
6 RESERVOIR, BRAKE MASTER CYLINDER - REPLACE 4310800 0.3 0.4 0.4 0.4 0.3
7 BRACKET, L.C.R.V - REPLACE 4310900 - 0.7 0.7 0.7 -
8 L.C.R.V ASSEMBLY - REPLACE 4310910 - 0.3 0.3 0.3 -
9 HOSE, BRAKE BOOSTER VACUUM - REPLACE 4312100 0.3 0.2 0.2 0.2 0.3

4D. FRONT BRAKE
445. FRONT BRAKE ..................................................................... 234
4D
4D FRONT BRAKE
445
234
FRONT BRAKE 4D
FRONT BRAKE 445

Model
Operation
Code CM KO RX ST
MU-S
1 PADS, DISC BRAKE (FRONT) - REPLACE
Both 4450100 0.7 0.7 0.7 0.7 0.7
Right 4450110 0.4 0.4 0.4 0.4 0.4
Left 4450120 0.4 0.4 0.4 0.4 0.4
2 CALIPER ASSEMBLY, FRONT - REPLACE
Right 4450300 0.5 0.5 0.5 0.5 0.5
Left 4450400 0.5 0.5 0.5 0.5 0.5
Both 4450500 0.9 0.9 0.9 0.9 0.9

4E. REAR BRAKE
456. REAR BRAKE ........................................................................ 238
4E
4E REAR BRAKE
456-1
238
REAR BRAKE 4E
REAR BRAKE 456-1

Model
Operation
Code CM KO RX ST
MU-S
1 DRUM, REAR BRAKE - REPLACE
Right 4560100 - 0.6 0.6 0.4 -
Left 4560200 - 0.6 0.6 0.4 -
Both 4560300 - 1.1 1.1 0.7 -
2 SHOES AND LINING, REAR DRUM BRAKE - REPLACE
Both 4560900 - 1.6 1.6 1.3 -
Right 4560910 - 0.9 0.9 0.7 -
Left 4560920 - 0.9 0.9 0.7 -
3 LINING, BRAKE - ADJUST 4560950 - 0.4 0.4 0.4 -
4 SPRING, S/RETURN, H/DOWN, REAR - REPLACE
Right 4561300 - 0.9 0.9 0.4 -
Left 4561400 - 0.9 0.9 0.4 -
Both 4561500 - 1.5 1.5 0.8 -
5 REAR DRUM ASSEMBLY - REPLACE
Right 4562400 - 0.9 0.9 0.4 -
Left 4562410 - 0.9 0.9 0.4 -
Both 4562420 - 1.6 1.6 0.8 -
6 CYLINDER, BRAKE WHEEL - REPLACE
Right 4562900 - 0.8 0.8 0.8 -
Left 4563100 - 0.8 0.8 0.8 -
Both 4563200 - 1.4 1.4 1.4 -
7 PLATE, BRAKE BACKING - REPLACE
Right 4563800 0.8 0.8 0.8 0.8 0.8
Left 4563900 0.8 0.8 0.8 0.8 0.8
Both 4564100 1.4 1.4 1.4 1.4 1.4
8 SLIDING CALIPER, REAR - REPLACE
Right 4564300 0.9 0.9 0.9 0.6 0.9
Left 4564400 0.9 0.9 0.9 0.6 0.9
Both 4564500 1.6 1.6 1.6 1.0 1.6
9 DISC, REAR BRAKE - REPLACE
Right 4565100 0.8 0.5 0.5 0.6 0.8
Left 4565200 0.8 0.5 0.5 0.6 0.8
Both 4565300 1.4 0.9 0.9 1.0 1.4
10 PAD, REAR BRAKE - REPLACE
Right 4566300 0.4 0.8 0.8 0.5 0.4
Left 4566400 0.4 0.8 0.8 0.5 0.4
Both 4566500 0.7 1.0 1.0 0.8 0.7

4E REAR BRAKE
456-2
240
REAR BRAKE 4E
REAR BRAKE 456-2

Model
Operation
Code CM KO RX ST
MU-S
11 HUB, REAR - REPLACE
Right 4566700 1.3 - - - 1.3
Left 4566800 1.3 - - - 1.3
Both 4566900 2.3 - - - 2.3

4F. ANTI-LOCK BRAKE SYSTEM
462. ABS SYSTEM ........................................................................ 244
4F
4F ANTI-LOCK BRAKE SYSTEM
462
244
ANTI-LOCK BRAKE SYSTEM 4F
ABS SYSTEM 462

Model
Operation
Code CM KO RX ST
MU-S
1 SENSOR, WHEEL SPEED, FRONT AND/OR REAR - REPLACE
Right Front 4620100 0.7 0.4 0.4 0.4 0.4
Left Front 4620200 0.7 0.4 0.4 0.4 0.4
Both Front 4620300 1.2 0.7 0.7 0.7 0.7
Right Rear 4620400 0.7 0.4 0.4 0.4 0.4
Left Rear 4620500 0.7 0.4 0.4 0.4 0.4
Both Rear 4620600 1.2 0.7 0.7 0.7 0.7
2 HYDRAULIC MODULATOR ASSEMBLY (ABS, ABD) - REPLACE 4620800 1.2 0.9 0.9 0.9 0.9
3 ECU (ABS) - REPLACE 4620900 0.3 0.3 0.3 0.9 0.9
4 ABS IMPULSERING - REPLACE
Right Front 4620910 - 1.0 1.0 1.0 1.0
Left Front 4620920 - 1.0 1.0 1.0 1.0
Both Front 4620930 - 1.9 1.9 1.9 1.9
Right Rear 4620940 - 1.5 1.5 1.5 1.5
Left Rear 4620950 - 1.5 1.5 1.5 1.5
Both Rear 4620960 - 2.8 2.8 2.8 2.8
5 SENSOR, ACCEL - REPLACE 4620970 - 0.6 0.8 0.8 0.8
6 ESP SENSOR CLUSTER - REPLACE 4620980 - - - - 0.2

4G. PARKING BRAKE
478. PARKING BRAKE ................................................................. 248
4G
4G PARKING BRAKE
478-1
248
PARKING BRAKE 4G
PARKING BRAKE 478-1

Model
Operation
Code CM KO RX ST
MU-S
1 PARKING BRAKE - ADJUST 4780100 - 0.3 0.3 0.3 -
2 GRIP, PARKING BRAKE HANDLE - REPLACE 4780200 - 0.4 0.4 0.5 -
3 CABLE, PARKING BRAKE - REPLACE
Front 4780500 0.8 0.4 0.4 0.4 0.8
Rear Both 4780600 0.7 0.7 0.7 0.7 0.7
4 SPRING, TENSION - REPLACE 4780700 0.4 - - - 0.4
5 BODY, PARKING BRAKE - REPLACE 4781600 0.6 - - - 0.6
6 PEDAL, PARKING BRAKE - REPLACE 4780810 0.5 - - - 0.5
7 DAMPER, PARKING BRAKE - REPLACE 4780830 0.4 - - - 0.4
8 CABLE, RELEASE - REPLACE 4780890 0.9 - - - 0.9
9 CONTROL UNIT, PARKING AID - REPLACE 4781000 0.5 - - 0.7 0.5
10 SENSOR, PARKING BRAKE AID - REPLACE 4781010 1.0 - - 0.6 1.0
11 SHOE ASSY, PARKING BRAKE - REPLACE
Rear Both 4781320 1.5 1.4 1.4 1.4 1.5
Right 4781300 0.9 0.8 0.8 0.8 0.9
Left 4781310 0.9 0.8 0.8 0.8 0.9
12 EQUALIZER, PARKING BRAKE - REPLACE 4781400 0.4 0.6 0.6 0.4 0.4
13 HANDLE, PARKING BRAKE - REPLACE 4781410 0.3 - - - 0.3
14 SWITCH, PARKING BRAKE - REPLACE 4782000 0.4 0.4 0.4 0.5 -

4G PARKING BRAKE
478-2
250
PARKING BRAKE 4G
PARKING BRAKE 478-2

Model
Operation
Code CM KO RX ST
MU-S
1 PARKING BRAKE - ADJUST 4780100 - 0.3 0.3 0.3 -
2 GRIP, PARKING BRAKE HANDLE - REPLACE 4780200 - 0.4 0.4 0.5 -
3 CABLE, PARKING BRAKE - REPLACE
Front 4780500 0.8 0.4 0.4 0.4 0.8
Rear Both 4780600 0.7 0.7 0.7 0.7 0.7
4 SPRING, TENSION - REPLACE 4780700 0.4 - - - 0.4
5 BODY, PARKING BRAKE - REPLACE 4781600 0.6 - - - 0.6
6 PEDAL, PARKING BRAKE - REPLACE 4780810 0.5 - - - 0.5
7 DAMPER, PARKING BRAKE - REPLACE 4780830 0.4 - - - 0.4
8 CABLE, RELEASE - REPLACE 4780890 0.9 - - - 0.9
9 CONTROL UNIT, PARKING AID - REPLACE 4781000 0.5 - - 0.7 0.5
10 SENSOR, PARKING BRAKE AID - REPLACE 4781010 1.0 - - 0.6 1.0
11 SHOE ASSY, PARKING BRAKE - REPLACE
Rear Both 4781320 1.5 1.4 1.4 1.4 1.5
Right 4781300 0.9 0.8 0.8 0.8 0.9
Left 4781310 0.9 0.8 0.8 0.8 0.9
12 EQUALIZER, PARKING BRAKE - REPLACE 4781400 0.4 0.6 0.6 0.4 0.4
13 HANDLE, PARKING BRAKE - REPLACE 4781410 0.3 - - - 0.3
14 SWITCH, PARKING BRAKE - REPLACE 4782000 0.4 0.4 0.4 0.5 -

SECTION 5
TRANSMISSION &
TRANSFER CASE
5A. AUTO TRANSMISSION CONTROLS ............................................... 255
5B. BTR M74 AUTO TRANSMISSION .................................................... 259
5C. W4A040 AUTO TRANSMISSION ..................................................... 269
5D. W5A330 AUTO TRANSMISSION ..................................................... 281
5E. FIVE-SPEED MANUAL TRANSMISSION ......................................... 293
5F. CLUTCH ......................................................................................... 303
5G. TRANSFER CASE........................................................................... 311
5A. AUTO TRANSMISSION CONTROLS 5A
519. AUTO TRANSMISSION CONTROLS .................................. 256

5A AUTO TRANSMISSION CONTROLS
519
256
AUTO TRANSMISSION CONTROLS 5A
AUTO TRANSMISSION CONTROLS 519

Model
Operation
Code CM KO RX ST
MU-S
1 KNOB, SHIFT LEVER - REPLACE 5190100 0.4 0.2 0.2 0.2 0.2
2 ROD, SHIFT CONNECTOR - REPLACE 5190510 1.2 0.6 0.6 0.6 0.6
3 LEVER, SHIFT CONTROL (A/T) - REPLACE 5190700 2.0 0.7 0.7 0.7 0.7
4 SWITCH ASSY, B POSITION - REPLACE 5190710 - 0.5 0.5 - -
5 SWITCH ASSY, P POSITION - REPLACE 5190720 - 0.5 0.5 - -
6 HOUSING, UPPER - REPLACE 5191110 0.5 0.3 0.3 0.6 0.6
7 SOLENOID ASSY (A/T) - REPLACE 5191120 - 0.6 0.6 0.6 0.6
8 LOCK LEVER (A/T) - REPLACE 5191130 - 0.6 0.6 0.6 0.6
9 RELAY, BTSI - REPLACE 5191140 - 0.2 0.2 0.2 0.2
10 SWITCH ASSY, P/WINTER - REPLACE 5191200 - 0.5 0.5 0.5 0.5

5B. BTR M74 AUTO TRANSMISSION
541. BTR M74 I .............................................................................. 260 5B
542. BTR M74 II ............................................................................. 262
543. BTR M74 III ............................................................................ 264
544. BTR M74 IV ............................................................................ 266

5B BTR M74 AUTO TRANSMISSION
541
260
BTR M74 AUTO TRANSMISSION 5B
BTR M74 I 541

Model
Operation
Code CM KO RX ST
MU-S
1 AUTO TRANSMISSION - REPLACE 5410100 - 5.8 5.8 5.8 -
AUTO TRANSMISSION - OVERHAUL 5410200 - 13.2 13.2 13.2 -
2 TORQUE CONVERTER - REPLACE 5410300 - 6.0 6.0 6.0 -
3 SEAL AND/OR HOUSING, CONVERTOR - REPLACE 5410500 - 6.1 6.1 6.1 -
4 T.C.U - REPLACE 5410600 - 0.5 0.5 0.5 -

542
262
BTR M74 II 542

Model
Operation
Code CM KO RX ST
MU-S
1 PUMP ASSEMBLY, FRONT - REPLACE 5420100 - 6.0 6.0 6.0 -
2 SHAFT ASSEMBLY, INPUT - REPLACE 5420300 - 7.2 7.2 7.2 -
3 SHAFT AND HUB ASSEMBLY, OVER DRIVE - REPLACE 5420500 - 7.3 7.3 7.3 -
4 DISC AND CYLINDER ASSEMBLY - REPLACE 5420700 - 7.3 7.3 7.3 -
5 CLUTCH ASSEMBLY - REPLACE 5420900 - 7.5 7.5 7.5 -
6 OUTPUT SHAFT ASSEMBLY - REPLACE 5421100 - 6.9 6.9 6.9 -

543
264
BTR M74 III 543

Model
Operation
Code CM KO RX ST
MU-S
1 SERVO, FRONT - REPLACE 5430100 - 0.6 0.6 0.6 -
2 SERVO, REAR - REPLACE 5430300 - 0.7 0.7 0.7 -
3 OIL SEAL AND/OR MANUAL VALVE DETENT LEVER - REPLACE 5430500 - 0.6 0.6 0.6 -
4 INHIBITOR SWITCH - REPLACE 5430700 - 0.5 0.5 0.5 -
5 ROD ASSEMBLY, ACTUATING - REPLACE 5430900 - 0.7 0.7 0.7 -
6 GASKET, ADAPTER HOUSING - REPLACE 5431100 - 1.2 1.4 1.2 -
7 HOUSING ASSEMBLY, ADAPTER - REPLACE 5431300 - 1.2 1.4 1.2 -
8 OIL SEAL, ADAPTER HOUSING - REPLACE 5431500 - 1.2 1.4 1.2 -

544
266
BTR M74 IV 544

Model
Operation
Code CM KO RX ST
MU-S
1 OIL, A/T - REPLACE 5440100 - 1.4 1.5 1.4 -
2 VALVE BODY - REPLACE 5440300 - 1.5 1.9 1.5 -
VALVE BODY - OVERHAUL 5440400 - 3.1 3.1 3.1 -
3 SOLENOID, VALVE BODY - REPLACE 5440500 - 1.6 1.6 1.6 -
A - Replace each additional 544050A - 0.1 0.1 0.1 -
4 GASKET, OIL PAN - REPLACE 5440700 - 0.9 1.4 0.9 -
5 FILTER, A/T OIL - REPLACE 5440900 - 1.5 1.4 1.5 -
6 PAN, OIL - REPLACE 5441100 - 0.9 1.4 0.9 -
7 WIRING, A/T SOLENOIL - REPLACE 5441300 - 1.1 4.9 1.1 -
8 PIPE, OIL COOLER - REPLACE One 5441400 - 0.4 0.4 0.4 -
Two 5441410 - 0.3 0.3 0.3 -
9 HOSE, OIL COOLER - REPLACE One 5441500 - 0.3 0.3 0.3 -
Two 5441510 - 0.3 0.3 0.3 -

5C. W4A040 AUTO TRANSMISSION
546. W4A040 A/T I .......................................................................... 270
547. W4A040 A/T II ......................................................................... 272
548. W4A040 A/T III ........................................................................ 276 5C
549. W4A040 A/T IV ....................................................................... 278

5C W4A040 AUTO TRANSMISSION
546
270
W4A040 AUTO TRANSMISSION 5C
W4A040 A/T I 546

Model
Operation
Code CM KO RX ST
MU-S
1 AUTO TRANSMISSTION - REPLACE 5460100 - 5.8 5.8 - -
AUTO TRANSMISSTION - OVERHAUL 5460200 - 10.4 10.4 - -
2 CONVERTER, TORQUE - REPLACE 5460300 - 5.9 5.9 - -
3 OIL (A/T) - REPLACE 5460400 - 1.4 1.4 - -

547-1
272
W4A040 A/T II 547-1

Model
Operation
Code CM KO RX ST
MU-S
1 CLUTCH, K1 - REPLACE 5470100 - 6.3 6.3 - -
2 CLUTCH, K2 - REPLACE 5470300 - 7.0 7.0 - -
3 BAND, BRAKE B1, B2 - REPLACE 5470500 - 7.0 7.0 - -
4 CARRIER, PLANETARY - REPLACE 5470700 - 6.9 6.9 - -

547-2
274
W4A040 A/T II 547-2

Model
Operation
Code CM KO RX ST
MU-S
5 COVER, FRONT - REPLACE 5471100 - 6.2 6.2 - -
6 VALVE, VACUUM CONTROL - REPLACE 5471200 - 0.7 0.7 - -
7 SOLENOID, KICK DOWN - REPLACE 5471300 - 0.3 0.3 - -
8 BOX, VACUUM CONTROL - REPLACE 5471400 - 0.8 0.8 - -
9 GEAR, SPEEDOMETER DRIVEN - REPLACE 5471500 - 0.3 0.3 - -
10 SWITCH, STARTER LOCK OUT - REPLACE 5471600 - 0.5 0.5 - -

548
276
W4A040 A/T III 548

Model
Operation
Code CM KO RX ST
MU-S
1 FILTER, A/T OIL - REPLACE 5480100 - 1.5 1.5 - -
2 GUAGE, A/T OIL - REPLACE 5480300 - 0.2 0.2 - -
3 GOVERNOR ASSEMBLY - REPLACE 5480500 - 0.3 0.3 - -
4 LOWER COVER AND/OR PLATE - REPLACE 5480700 - 2.4 2.4 - -
5 VALVE BODY, TRANSMISSTION CONTROL - REPLACE 5480900 - 2.0 2.0 - -
6 OIL PAN AND/OR GASKET - REPLACE 5481100 - 1.2 1.2 - -
7 ADAPTER ASSEMBLY - REPLACE 5481300 - 2.0 2.0 - -

549
278
W4A040 A/T IV 549

Model
Operation
Code CM KO RX ST
MU-S
1 PIPE & TUBE, OIL COOLER - REPLACE
Right 5490100 - 0.4 0.4 - -
Left 5490110 - 0.4 0.4 - -
Both 5490120 - 0.4 0.4 - -
2 HOSE ASSEMBLY, OIL COOLER - REPLACE
Right 5490500 - 0.2 0.2 - -
Left 5490510 - 0.2 0.2 - -
Both 5490520 - 0.2 0.2 - -
3 DIPSTICK ASSEMBLY - REPLACE 5490600 - 0.2 0.2 - -
4 VALVE, CHECK - REPLACE 5490700 - 0.2 0.2 - -
5 TANK, VACUMM SUPLY - REPLACE 5490800 - 0.2 0.2 - -
6 CABLE-CONTROL PRESSURE - REPLACE 5490900 - 0.6 0.6 - -

5D. W5A330 AUTO TRANSMISSION
551. W5A330 A/T I .......................................................................... 282
556. W5A330 A/T II ......................................................................... 284
557. W5A330 A/T III ........................................................................ 286
558. W5A330 A/T IV ....................................................................... 288
559. W5A330 A/T V ......................................................................... 290 5D

5D W5A330 AUTO TRANSMISSION
551
282
W5A330 AUTO TRANSMISSION 5D
W5A330 A/T I 551

Model
Operation
Code CM KO RX ST
MU-S
1 AUTOMATIC TRANSMISSTION (W5A330) - REPLACE 5510100 5.3 - - 5.3 5.3
AUTOMATIC TRANSMISSTION (W5A330) - OVERHAUL 5510110 16.1 - - 16.1 16.1
2 TORQUE CONVERTER - REPLACE 5510200 5.5 - - 5.5 5.5
3 T.C.U - REPLACE 5510300 0.5 - - 0.5 0.5

556
284
W5A330 A/T II 556

Model
Operation
Code CM KO RX ST
MU-S
1 OIL PUMP (A/T) - REPLACE 5560100 6.0 - - 6.0 6.0
2 SEALING, OIL PUMP - REPLACE 5560300 0.5 - - 0.5 0.5
3 CONVERTER HOUSING (A/T) - REPLACE 5560500 6.5 - - 6.5 6.5
4 PLATE, INTERMEDIATE - REPLACE 5560700 6.0 - - 6.0 6.0

557
286
W5A330 A/T III 557

Model
Operation
Code CM KO RX ST
MU-S
1 BAND, BRAKE B1 - OVERHAUL 5570100 8.8 - - 8.8 8.8
2 K1 CLUTCH AND FRONT PLANETARY GEAR - OVERHAUL 5570300 13.1 - - 13.1 13.1
3 CARRIER, PLANETARY - REPLACE 5570500 6.9 - - 6.9 6.9
4 DRIVE SHAFT AND/OR CLUTCH K2 - OVERHAUL 5570700 8.7 - - 8.7 8.7
5 CENTER & REAR PLANETARY GEAR - OVERHAUL 5570900 13.1 - - 13.1 13.1
6 CLUTCH, K3 - OVERHAUL 5571100 8.7 - - 8.7 8.7
7 BAND, BRAKE B2, B3 - REPLACE 5571300 8.8 - - 8.8 8.8
8 BLEEDER, AIR - REPLACE 5572300 0.3 - - 0.3 0.3

558
288
W5A330 A/T IV 558

Model
Operation
Code CM KO RX ST
MU-S
1 LOCK ASSEMBLY - REPLACE 5580100 6.9 - - 6.9 6.9
2 BALL BEARING (A/T) - REPLACE 5580300 3.2 - - 3.2 3.2
3 SEALING, FLANGE - REPLACE 5580500 2.9 - - 2.9 2.9
4 FLANGE - REPLACE 5580700 1.8 - - 1.8 1.8
5 VALVE GEAR, ELECTRIC HYDRAULIC CONT UNIT - REPLACE 5580900 6.1 - - 6.1 6.1
VALVE GEAR, ELECTRIC HYDRAULIC CONT UNIT - OVERHAUL 5581000 8.8 - - 8.8 8.8
6 DETENT - REPLACE 5581100 6.1 - - 6.1 6.1
7 ELECTRICS KIT - REPLACE 5581300 1.8 - - 1.8 1.8
8 VALVE, SOLENOID - REPLACE 5581500 1.8 - - 1.8 1.8
A - Replace each additional 558150A 0.2 - - 0.2 0.2
9 SPRING, DETENT PLATE LEAF - REPLACE 5581700 0.3 - - 0.3 0.3
10 PAN AND/OR GASKET, OIL - REPLACE 5581900 0.8 - - 0.8 0.8
11 FILTER, OIL - REPLACE 5582100 0.9 - - 0.9 0.9
12 BODY, CLAMPING - REPLACE 5582300 0.2 - - 0.2 0.2
13 ADAPTER, PLUG - REPLACE 5582400 0.5 - - 0.5 0.5

559
290
W5A330 A/T V 559

Model
Operation
Code CM KO RX ST
MU-S
1 TUBE (A/T) - REPLACE
Inlet 5590100 0.5 - - 0.5 0.5
Outlet 5590110 0.5 - - 0.5 0.5
2 SHIFT MECHANISM ASSEMBLY - REPLACE 5590410 0.8 - - 0.8 0.8
3 HOSE (A/T) - REPLACE
Inlet 5590500 0.5 - - 0.5 0.5
Outlet 5590510 0.5 - - 0.5 0.5
4 OIL FILLER TUBE - REPLACE 5590600 0.4 - - 0.4 0.4

5E. FIVE-SPEED MANUAL TRANSMISSION
561. MANUAL TRANSMISSION ................................................... 294
563. TRANSMISSION GEAR ........................................................ 296
566. GEAR SHIFT COVER & FORK ............................................ 298
569. SHIFT CONTROL ................................................................. 300
5E
5E FIVE-SPEED MANUAL TRANSMISSION
561
294
FIVE-SPEED MANUAL TRANSMISSION 5E
MANUAL TRANSMISSION 561

Model
Operation
Code CM KO RX ST
MU-S
1 TRANSMISSION ASSEMBLY - REPLACE 5610100 - 5.0 4.0 4.0 4.0
TRANSMISSION ASSEMBLY - OVERHAUL 5610300 - 10.6 10.0 10.0 10.0
2 T/M OIL - REPLACE 5610500 - 0.5 0.3 0.3 0.3
3 PLUG, FILLER AND DRAIN - REPLACE 5611200 - 0.2 0.2 0.2 0.2
4 TRANSMISSION MOUNTING - REPLACE 5611400 - 0.6 0.6 0.6 0.4

563
296
TRANSMISSION GEAR 563

Model
Operation
Code CM KO RX ST
MU-S
1 GEAR, 5TH SPEED DRIVE - REPLACE 5630100 - 10.0 10.0 10.0 10.0
2 SHAFT AND/OR BEARING, TRANSMISSTION COUNTER - REPLACE 5631200 - 10.0 10.0 10.0 10.0
3 SYNCRONIZER ASSY (3RD AND 4TH) - REPLACE 5631510 - 10.0 10.0 10.0 10.0
4 SYNCHRONIZER ASSY (1ST AND 2ND) - REPLACE 5631710 - 10.0 10.0 10.0 10.0
5 SYNCHRONIZER ASSY (5TH) - REPLACE 5631720 - 10.0 10.0 10.0 10.0
6 SHAFT, INPUT DRIVE - REPLACE 5633100 - 6.9 6.9 6.9 6.9
7 GEAR, REVERSE IDLE - REPLACE 5633400 - 10.0 10.0 10.0 10.0
8 BEARING CUP AND CONE - REPLACE 5634000 - 6.9 6.9 6.9 6.9
9 RETAINER AND/OR SEAL, INPUT SHAFT - REPLACE 5633710 - 5.4 5.4 5.4 5.4
10 3RD GEAR AND/OR BEARING - REPLACE 5634110 - 10.0 10.0 10.0 10.0
11 2ND GEAR AND/OR BEARING - REPLACE 5634120 - 10.0 10.0 10.0 10.0
12 1ST GEAR AND/OR BEARING - REPLACE 5634130 - 10.0 10.0 10.0 10.0
13 5TH GEAR AND/OR BEARING - REPLACE 5634140 - 10.0 10.0 10.0 10.0

566
298
GEAR SHIFT COVER & FORK 566

Model
Operation
Code CM KO RX ST
MU-S
1 COVER AND/OR GASKET, TRANSMISSTION - REPLACE 5660100 - 2.5 2.5 2.5 2.5
2 FORK AND/OR SHAFT, SHIFT (1ST AND 2ND) - REPLACE 5660300 - 3.8 3.8 3.8 3.8
3 FORK AND/OR SHAFT, SHIFT (3RD AND 4TH) - REPLACE 5660500 - 3.8 3.8 3.8 3.8
4 FORK AND OR SHAFT, SHIFT (5TH) - REPLACE 5660700 - 6.9 6.9 6.9 6.9
5 LEVER - REPLACE 5661000 - 6.9 6.9 6.9 6.9
6 TRANSMISSTION CASE - REPLACE 5661100 - 5.2 5.2 5.2 5.2
7 SWITCH, BACK UP - REPLACE 5661200 - 0.5 0.5 0.5 0.5
8 EXTENSION - REPLACE 5664000 - 3.2 3.2 3.2 3.2
9 GASKET, EXTENSION - REPLACE 5664100 - 3.2 3.2 3.2 3.2

569
300
SHIFT CONTROL 569

Model
Operation
Code CM KO RX ST
MU-S
1 KNOB, GEARSHIFT LEVER - REPLACE 5690300 - 0.3 0.3 0.2 0.2
2 LEVER, OFFSET - REPLACE 5690400 - 3.8 3.8 3.0 3.0
3 SHIFT MECHANISM ASSEMBLY - REPLACE 5690420 - 0.8 0.8 - -
4 LEVER, SHIFT TO SHAFT - REPLACE 5690430 - 1.0 1.0 - -
5 LEVER, GEARSHIFT CONTROL - REPLACE 5690500 - 0.3 0.3 0.5 0.5
6 BOOT, GEARSHIFT LEVER - REPLACE 5691300 - 0.2 0.3 0.3 0.3
7 CABLE, GEAR SHIFT AND/OR SELECT - REPLACE 5691800 - 0.7 0.8 - -
8 BRACKET, CABLE - REPLACE 5691810 - 0.4 0.4 - -
9 END EYE, GEAR CABLE - REPLACE 5692000 - 0.2 0.2 - -
10 SHIFT ASSY, REMORT - REPLACE 5690600 - 0.7 0.7 0.7 0.7
11 LINK, SHIFT ROD - REPLACE 5690700 - 1.0 1.0 1.0 1.0
12 Clip, pin shIft rod retainer - REPLACE 5690800 - 0.8 0.8 0.8 0.8
A - Replace each additional 569080A - 0.1 0.1 0.1 0.1

5F. CLUTCH
581. CLUTCH PARTS ................................................................... 304
582. HYDRAULIC CLUTCH .......................................................... 306
583. CLUTCH PEDAL ................................................................... 308
5F
5F CLUTCH
581
304
CLUTCH 5F
CLUTCH PARTS 581

Model
Operation
Code CM KO RX ST
MU-S
1 BEARING, CLUTCH RELEASE - REPLACE 5810700 - 4.5 4.5 - -
2 FORK AND/OR BALL STUD, CLUTCH RELEASE - REPLACE 5810900 - 4.5 4.5 - -
3 BOLT, CLUTCH FORK PIVOT - REPLACE 5810910 - 4.5 4.5 - -
4 DISC AND/OR CLUTCH COVER, CLUTCH - REPLACE 5811100 - 5.0 5.0 5.0 5.0
B - TO REPLACE FLYWHEEL 581110B - 0.3 0.3 0.3 0.3
C - TO REPLACE RELEASE BEARING/CYLINDER 581110C - 0.2 0.2 0.2 0.2
5 HOUSING AND GASKET, CLUTCH - REPLACE 5811400 - 4.5 4.5 4.5 4.5
6 CYLINDER ASSY, SLAVE - REPLACE 5810800 - - - 5.2 5.2
7 TUBE, CYLINDER - REPLACE 5810810 - - - 5.2 5.2
8 CLUTCH HOUSING BOOT - REPLACE 5811200 - 0.4 0.4 - -

5F CLUTCH
582
306
CLUTCH 5F
HYDRAULIC CLUTCH 582

Model
Operation
Code CM KO RX ST
MU-S
1 CYLINDER, ACTUATOR CLUTCH MASTER - REPLACE 5820100 - 0.5 0.6 0.5 0.5
CYLINDER, ACTUATOR CLUTCH MASTER - OVERHAUL 5820200 - 0.8 0.8 0.8 0.8
2 PIPE, HYDRAULIC CLUTCH - REPLACE
One 5820500 - 0.8 0.3 0.8 0.8
Two 5820510 - 1.0 0.5 1.0 1.0
3 CYLINDER, HYDRAULIC RELEASE - REPLACE 5820700 - 0.5 0.5 - -
4 DAMPER, CLUTCH - REPLACE 5821100 - 0.3 0.3 0.3 0.3
5 PEAK, TORQUE LIMITER - REPLACE 5821110 - 0.3 0.3 0.3 0.3
6 HOSE, CLUTCH - REPLACE 5821300 - 0.8 0.8 - -
7 OIL, CLUTCH CONTROL - REPLACE 5822300 - 0.4 0.4 0.4 0.4
8 ADAPTER ASSY - REPLACE 5820800 - - - 0.5 0.5

5F CLUTCH
583
308
CLUTCH 5F
CLUTCH PEDAL 583

Model
Operation
Code CM KO RX ST
MU-S
1 CLUTCH PEDAL ASSY - REPLACE 5830100 - 1.0 1.0 1.0 1.0
2 FREE PLAY, CLUTCH PEDAL - ADJUST 5830200 - 0.3 0.2 0.2 0.2
3 SPRING, CLUTCH PEDAL RETURN - REPLACE 5830300 - 0.2 0.2 0.2 0.2
4 COVER, PEDAL PLATE - REPLACE 5830700 - 0.2 0.2 0.2 0.2
5 SHAFT, CLUTCH PEDAL - REPLACE 5830900 - 0.3 0.3 0.3 0.3
6 SWITCH, CLUTCH START - REPLACE 5831100 - 0.3 0.3 0.3 0.3
7 BRACKET, CLUTCH PEDAL - REPLACE 5831300 - 0.7 1.0 1.0 1.0

5G. TRANSFER CASE
591. TRANSFER CASE (PART TIME) ......................................... 312
593. T.O.D ...................................................................................... 314
595. TRANSFER CASE (FULL TIME) .......................................... 316
5G
5G TRANSFER CASE
591
312
TRANSFER CASE 5G
TRANSFER CASE (PART TIME) 591

Model
Operation
Code CM KO RX ST
MU-S
1 T/C ASSEMBLY (PART TIME) - REPLACE 5910100 - 2.0 2.0 2.0 2.0
T/C ASSEMBLY (PART TIME) - OVERHAUL 5910300 - 4.5 4.5 4.5 4.5
2 SHAFT, SHIFT - REPLACE 5910500 - 2.3 2.3 2.3 2.3
3 SPROCKET & BEARING A, DRIVE - REPLACE 5910600 - 2.3 2.3 2.3 2.3
4 HUB, REDUCTION - REPLACE 5911100 - 2.8 2.8 2.8 2.8
5 FORK, REDUCTION SHIFT - REPLACE 5911300 - 2.8 2.8 2.8 2.8
6 FORK, LOCK UP - REPLACE 5911500 - 2.8 2.8 2.8 2.8
7 SHAFT & PUMP - REPLACE 5911700 - 2.8 2.8 2.8 2.8
8 LOCK UP ASSEMBLY - REPLACE 5911800 2.8 2.8 2.8 2.8
9 DAMPER, PLANE - REPLACE 5912900 - 0.2 0.2 0.2 0.2
10 DAMPER, TORSIONAL - REPLACE 5913100 - 0.3 0.3 0.3 0.3
11 PLUG, AIR BLEEDER - REPLACE 5913300 - 0.5 0.5 0.5 0.5
12 SEAL, T/C OIL FRONT - REPLACE
Front 5913500 - 0.5 0.5 0.5 0.5
Rear 5913700 - 0.5 0.5 0.5 0.5
13 MOTOR, T/C DRIVE - REPLACE 5913900 - 0.5 0.5 0.5 0.5
14 UNIT, T/C CONTROL - REPLACE 5914100 - 0.5 0.5 0.5 0.5
15 GASKET, T/C HOUSING - REPLACE 5914300 - 2.3 2.3 2.3 2.3
16 SHAFT, INPUT - REPLACE 5914500 - 2.8 2.8 2.8 2.8
17 CARRIER ASSEMBLY - REPLACE 5914600 - 2.8 2.8 2.8 2.8
18 BEARING, INPUT - REPLACE 5914700 - 2.8 2.8 2.8 2.8
19 ADAPTER ASSEMBLY - REPLACE 5914800 - 2.8 2.8 2.8 2.8
20 SENSOR SPEEDOMETER (T/C) - REPLACE 5915900 - 0.5 0.5 0.5 0.5
21 GEAR, SPEED DRIVE - REPLACE 5920300 - 0.6 0.6 0.6 0.6
22 MAGNET - REPLACE 5920700 - 2.3 2.3 2.3 2.3
23 BEARING, OUTPUT SHAFT - REPLACE 5920900 - 2.8 2.8 2.8 2.8
24 OIL, TRANSFER CASE - REPLACE 5920910 - 0.3 0.3 0.3 0.3

5G TRANSFER CASE
593
314
TRANSFER CASE 5G
T.O.D 593
Model
Operation
Code CM KO RX ST
MU-S
1 T.O.D UNIT- REPLACE 5930100 - 0.5 0.5 0.5 0.5
2 SPEED SENSOR, T.O.D, REAR - REPLACE 5930130 - 0.4 0.4 0.4 0.4
3 SPEED SENSOR, T.O.D, FRONT - REPLACE 5930140 - 0.9 0.9 0.9 0.9

5G TRANSFER CASE
595
316
TRANSFER CASE 5G
TRANSFER CASE (FULL TIME) 595

Model
Operation
Code CM KO RX ST
MU-S
1 T/C ASSEMBLY (FULL TIME) - REPLACE 5950010 - 2.0 2.0 2.0 2.0
T/C ASSEMBLY (FULL TIME) - OVERHAUL 5950020 - 4.5 4.5 4.5 4.5
2 BEARING AND/OR HUB LOCKUP - REPLACE 5950100 - 2.3 2.3 2.3 2.3
3 SHAFT ASSY, INPUT - REPLACE 5950200 - 2.8 2.8 2.8 2.8
4 CARRIER ASSY - REPLACE 5950300 - 2.8 2.8 2.8 2.8
5 HUB, REDUCTION - REPLACE 5950500 - 2.8 2.8 2.8 2.8
6 PUMP ASSY AND/OR SPROCKET - REPLACE 5950700 - 2.8 2.8 2.8 2.8
7 HUB ASSY - REPLACE 5950900 - 2.8 2.8 2.8 2.8
8 SHAFT ASSY, OUTPUT AND/OR GEAR - REPLACE 5951100 - 2.8 2.8 2.8 2.8
9 GEAR ASSY, SUN - REPLACE 5951500 - 2.8 2.8 2.8 2.8
10 FORK, REDUCTION - REPLACE 5951700 - 2.8 2.8 2.8 2.8
11 RAIL, SHIFT - REPLACE 5951900 - 2.8 2.8 2.8 2.8
12 GEAR, RING - REPLACE 5952100 - 2.8 2.8 2.8 2.8
13 FLANGE AND/OR SEALING - REPLACE 5952300 - 0.5 0.5 0.5 0.5
14 SHAFT, SHIFT - REPLACE 5952500 - 2.3 2.3 2.3 2.3
15 SHAFT, OUTPUT - REPLACE 5952700 - 2.8 2.8 2.8 2.8
16 SPROCKET, LWR DRIVE - REPLACE 5952900 - 2.3 2.3 2.3 2.3
17 COVER ASSY, T/C - REPLACE 5953100 - 2.5 2.5 2.5 2.5
18 PLUG, DRAIN - REPLACE 5953300 - 0.5 0.5 0.5 0.5
19 PLUG, SHIPPING - REPLACE 5953500 - 0.5 0.5 0.5 0.5

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Labor Time Guide

(Chairman, Korando, Musso, Musso sports, Rexton, Stavic)

9. BODY & ACCESSORIES 9 - 369

10. PAINT 10 - 513

11. OTHERS 11 - 526

1-2. TYPES OF OPERATION

Supplementary Operation (Adds)

1-3. TIME ALLOWANCES

2. HOW TO READ THIS MANUAL

1B-D DIESEL ENGINE MECHANICAL

ENGINE UNIT 111

3B. Supplementary Operation

Main group code

Main Group Code

Auxiliary Code Description

Supplementary Operation (ADD)

3. HOW TO USE THIS MANUAL

Example : (When supplementary work is performed in addition to the intended repair)

1312700 VALVE - REPLACE 7.0

Major operation : VALVE - REPLACE 1312700 7.0

Supplementary Work : C - Valves (each additional) 131270C 0.1

Operation Code 1312700 & 131270C

Operation Time Total 7.0 + 0.1 = 7.1

4-2. LABOR TIME

4-3. REPAIR TYPE

4-4. HOW TO USE OPERATION CODE ON PARTIAL PAINTING

PF OPERATION CODE HOUR

N01 Hard start, no start N43 Excessive shock

N87 Insufficient brake N94 Special policy

5-2. CAUSE CODE

R01 Scored, scratched or chipped R19 Improperly machined

5-3. PAINT CODE

P01 Oversprayed, drip P19 Atmospheric fallout

7. MAIN GROUP CODE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

SECTION SUB - SECTION MAIN GROUP CODE PAGE

1B-D. DIESEL ENGINE MECHANICAL .................................................... 21

111. ENGINE UNIT .......................................................................... 22

113. BELT SYSTEM ....................................................................... 24

121. ENGINE BLOCK ..................................................................... 26

122. CRANKSHAFT & PISTON ...................................................... 28

123. OIL PAN & PUMP.................................................................... 32

131. CYLINDER HEAD.................................................................... 34

132. CAM SUPPORT & SHAFT...................................................... 36

133. TIMING COVER & CHAIN DRIVE .......................................... 38

136. INJECEION PIPE .................................................................... 40

138. ENGINE & TRANSAXLE MOUNT .......................................... 42

139. VACUUM SYSTEM ................................................................. 44

ENGINE UNIT 111

CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 23

BELT SYSTEM 113

CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 25

ENGINE BLOCK 121

CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 27

CRANKSHAFT & PISTON 122-1

CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 29

CRANKSHAFT & PISTON 122-2

CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 31

OIL PAN & PUMP 123

CM : Chairman, MU : Musso, MU-S : Musso sports, KO : Korando, RX : Rexton, ST : Stavic 33