Professional Documents
Culture Documents
1. GENERAL
Service hour in this manual is carefully set by our professionals who have in-depth skills and expertise required for ser-
vice and have disassembled each component in person. This manual applies adjustment factors on basic service hour,
considering varied conditions by locations and expertise by mechanics.
⑨
① ②
⑧
④ ⑤ ⑥ ⑦
③
FOREWORD
FORWARD
① Group number
This corresponds to the group number in the component list, but it doesn't include a model name and major group num-
ber.
② Group name
This indicates a group name.
③ Illustration
This shows an illustration for warranty among assemblies in the component list. It also indicates numbers for corre-
sponding parts.
④ NO
This is a number to connect a illustration with a service code in the component list.
⑤ Service code
As one service code use used only for one disassembly and assembly operation, the same service code can be used
for multiple time in one model. In other words, only one service code is used for one assembly except for the following
cases:
One service code can be used in several locations in an assembly if a certain work is performed for multiple times.
When the same component is installed on the left and right, the same service code can be used twice for its service.
⑥ Service description
This shows parts to be serviced and service description.
⑦ Service hour
This indicates service hour by each model. Service hour includes time for repair, sealing, assembly, disassembly, oil
draining, replenishment, and cleaning and adjustment after part replacement.
FOREWORD
FORWARD
⑧ Remarks
This shows other necessary information.
⑨ Category
This indicates the corresponding section, either engine or body.
ILLUSTRATIONS
AND
LABOR HOURS
A1500-05-001 CYLINDER BLOCK
6
4
2
3
108
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-010 ENGINE TOTAL ASS`Y - REPLACE 8.0 -
* TE-01-011 ENGINE ASS`Y - OVERHAUL 6.0 -
1 TE-01-110 CYLINDER BLOCK SUB ASS`Y- REPLACE 14.0 -
2 TE-01-112 CYLINDER BLOCK - REPLACE 15.0 -
3 TE-01-113 CAMSHAFT BUSH - REPLACE 12.0 -
4 TE-01-114 CAP TYPE PLUG - REPLACE 0.5 -
5 TE-01-115 CAP TYPE PLUG - REPLACE 3.0 -
6 TE-01-116 PLATE TYPE PLUG - REPLACE 3.0 -
7 TE-01-117 HEAD GASKET - REPLACE 2.1 -
A2300
109
A2300-05-001 CYLINDER BLOCK
4
6
4
5
2
1
3
110
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-015 ENGINE TOTAL ASS`Y - REPLACE - 9.0
* TE-01-016 ENGINE ASS`Y - OVERHAUL - 6.0
1 TE-01-120 CYLINDER BLOCK SUB ASS`Y- REPLACE - 15.0
2 TE-01-121 CYLINDER BLOCK - REPLACE - 16.0
3 TE-01-122 CAMSHAFT BUSH - REPLACE - 12.0
4 TE-01-123 CAP TYPE PLUG - REPLACE - 0.5
5 TE-01-124 CAP TYPE PLUG - REPLACE - 3.0
6 TE-01-125 PLATE TYPE PLUG - REPLACE - 3.0
7 TE-01-126 HEAD GASKET - REPLACE - 2.1
A2300
111
A1500-05-002 GEAR CASE
3 4
112
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-130 FLANGE (GEAR CASE) - REPLACE 8.5 -
2 TE-01-131 GEAR CASE ASS`Y - REPLACE 4.5 -
3 TE-01-132 GEAR CASE - REPLACE 4.5 -
4 TE-01-133 OIL SEAL - REPLACE 3.5 -
5 TE-01-134 COVER - REPLACE 0.1 -
A2300
113
A2300-05-002 GEAR CASE
3 4
5
2
114
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-140 FLANGE (GEAR CASE) - REPLACE - 8.5
2 TE-01-141 GEAR CASE ASS`Y - REPLACE - 4.5
3 TE-01-142 GEAR CASE - REPLACE - 4.5
4 TE-01-143 OIL SEAL - REPLACE - 3.5
5 TE-01-144 COVER - REPLACE - 0.1
A2300
115
A1500-05-003 MOUNTING FLANGE & OIL PAN
116
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-160 ENGINE OIL - REPLACE 0.2 -
1 TE-01-161 FRAME - REPLACE 2.0 -
2 TE-01-162 OIL PAN - REPLACE 0.8 -
A2300
117
A2300-05-003 FLYWHEEL HOUSING & OIL PAN
118
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-170 ENGINE OIL - REPLACE - 0.2
1 TE-01-171 FRAME - REPLACE - 2.0
2 TE-01-172 OIL PAN - REPLACE - 0.8
A2300
119
A1500-05-004 CYLINDER HEAD & HEAD COVER
9
8
10
4
5
1
3
2
6
7
120
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-210 VALVE CLEANCE - ADJUST 1.5 -
1 TE-01-211 CYLINDER HEAD ASS`Y - REPLACE 4.0 -
2 TE-01-212 CYLINDER HEAD SUB ASS`Y - REPLACE 4.0 -
3 TE-01-213 CYLINDER HEAD - REPLACE 4.5 -
4 TE-01-214 VALVE SPRING & COMP - REPLACE 4.5 -
5 TE-01-215 VALVE GUIDE - REPLACE 4.5 -
6 TE-01-216 VALVE SEAT - REPLACE 4.5 -
7 TE-01-217 INTAKE & EXHAUST VALVE - REPLACE 4.5 -
8 TE-01-218 HEAD COVER - REPLACE 0.5 -
9 TE-01-219 PACKING - REPLACE 0.5 -
10 TE-01-220 ROCKER ARM ASS`Y - REMOVE & INSTALL 1.5 -
A2300
121
A2300-05-004 CYLINDER HEAD & HEAD COVER
9
8
10
4
5
1
2 3
6
7
122
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-221 VALVE CLEANCE - ADJUST - 0.6
1 TE-01-222 CYLINDER HEAD ASS`Y - REPLACE - 4.0
2 TE-01-223 CYLINDER HEAD SUB ASS`Y - REPLACE - 4.0
3 TE-01-224 CYLINDER HEAD - REPLACE - 4.5
4 TE-01-225 VALVE SPRING & COMP - REPLACE - 4.5
5 TE-01-226 VALVE GUIDE - REPLACE - 4.5
6 TE-01-227 VALVE SEAT - REPLACE - 4.5
7 TE-01-228 INTAKE & EXHAUST VALVE - REPLACE - 4.5
8 TE-01-229 HEAD COVER - REPLACE - 0.5
9 TE-01-230 PACKING - REPLACE - 0.5
10 TE-01-231 ROCKER ARM ASS`Y - REMOVE & INSTALL - 1.5
A2300
123
A1500-05-005 INTAKE MANIFOLD
124
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-320 INTAKE MANIFOLD - REPLACE 0.5 -
A2300
125
A2325-05-005 INTAKE MANIFOLD
[ USA ] [ EU ]
126
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-330 INTAKE MANIFOLD - REPLACE - 0.5
A2300
127
A1700-05-006 EXHAUST MANIFOLD
128
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-350 EXHAUST MANIFOLD - REPLACE 0.5 -
2 TE-01-351 TURBO CHARGER - REPLACE 0.5 -
A2300
129
A2325-05-006 EXHAUST MANIFOLD
[ USA ] [ EU ]
2
130
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-360 EXHAUST MANIFOLD - REPLACE - 0.5
2 TE-01-361 TURBO CHARGER - REPLACE - 0.5
A2300
131
A1500-05-007 CAM SHAFT & DRIVING GEAR
1
2
4
5
132
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-430 IDLING & INJECTION TIMING - ADJUST 0.5 ←
1 TE-01-431 TAPPET - REPLACE 8.0 ←
2 TE-01-432 PUSH ROD - REPLACE 2.0 ←
3 TE-01-433 CAM SHAFT ASS`Y - REPLACE 8.5 ←
4 TE-01-434 CAM SHAFT - REPLACE 8.5 ←
5 TE-01-435 CAM SHAFT GEAR - REPLACE 8.5 ←
6 TE-01-436 HYD. PUMP DRIVE GEAR & COMP - REPLACE 1.0 ←
A2300
133
A1500-05-008 CRANK SHAFT & PISTON
4
5
2
3
134
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-400 CRANK SHAFT ASS`Y - REPLACE 15.0 -
2 TE-01-401 CRANK SHAFT - REPLACE 15.0 -
3 TE-01-402 CRANL GEAR - REPLACE 5.0 -
4 TE-01-403 THRUST BEARING ASS`Y - REPLACE 15.0 -
5 TE-01-404 MAIN BEARING ASS`Y - REPLACE 15.0 -
A2300
135
A2300-05-008 CRANK SHAFT & PISTON
ͤͩ
4
5
2
3
136
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-410 CRANK SHAFT ASS`Y - REPLACE - 15.0
2 TE-01-411 CRANK SHAFT - REPLACE - 15.0
3 TE-01-412 CRANL GEAR - REPLACE - 5.0
4 TE-01-413 THRUST BEARING ASS`Y - REPLACE - 15.0
5 TE-01-414 MAIN BEARING ASS`Y - REPLACE - 15.0
A2300
137
A1700-05-009 LUBICATION OIL SYSTEM
138
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-640 OIL CONTROL VALVE ASS`Y - REPLACE 0.1 -
2 TE-01-641 ENGINE OIL FILTER - REPLACE 0.1 -
3 TE-01-642 OIL PRESSURE SWITCH - REPLACE 0.1 -
4 TE-01-643 OIL GAUGE - REPLACE 0.1 -
5 TE-01-644 GUIDE - REPLACE 0.1 -
A2300
139
A2325-05-009 LUBICATION OIL SYSTEM
140
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-650 OIL CONTROL VALVE ASS`Y - REPLACE - 0.1
2 TE-01-651 ENGINE OIL FILTER - REPLACE - 0.1
3 TE-01-652 OIL PRESSURE SWITCH - REPLACE - 0.1
4 TE-01-643 OIL GAUGE - REPLACE - 0.1
5 TE-01-654 GUIDE - REPLACE - 0.1
A2300
141
A2300-05-010 BALANCER
142
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-480 BALANCER ASS`Y - REPLACE - 4.0
2 TE-01-481 BALANCER CASE & COMP - REPLACE - 4.0
3 TE-01-482 BALANCER SHAFT GEAR - REPLACE - 4.0
A2300
143
A1700-05-011 COOLING SYSTEM
144
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-700 COOLING PUMP ASS`Y - REPLACE 1.5 -
2 TE-01-701 WATER TEMP. SENSOR - REPLACE 0.1 -
3 TE-01-702 AIR HEATER SENSOR - REPLACE 0.1 -
4 TE-01-703 THERMOSTATE - REPLACE 0.5 -
5 TE-01-704 THERMOSTATE COVER - REPLACE 0.5 -
6 TE-01-705 V-BELT - ADJUST 0.1 -
A2300
145
A2325-05-011 COOLING SYSTEM
146
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-710 COOLING PUMP ASS`Y - REPLACE - 1.5
2 TE-01-711 WATER TEMP. SENSOR - REPLACE - 0.1
3 TE-01-712 AIR HEATER SENSOR - REPLACE - 0.1
4 TE-01-713 THERMOSTATE - REPLACE - 0.5
5 TE-01-714 THERMOSTATE COVER - REPLACE - 0.5
6 TE-01-715 V-BELT - ADJUST - 0.1
A2300
147
A1500-05-012 FUEL INJECTION PUMP
1 4
148
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-800 FUEL PUMP ASS`Y - REPLACE 1.5 ←
2 TE-01-801 VE SUPPORT BRACKET (B) - REPLACE 0.1 ←
3 TE-01-802 VE SUPPORT BRACKET (A) - REPLACE 0.1 ←
4 TE-01-803 SUPPORT (AXLE LEVER) - REPLACE 0.1 ←
5 TE-01-804 HOOK (AXLE LEVER) - REPLACE 0.1 ←
A2300
149
A1500-05-013 FUEL INJECTION SYSTEM & VALVE
150
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-830 FUEL INJECTION VALVE ASS`Y - REPLACE 1.0 -
A2300
151
A2300-05-013 FUEL INJECTION SYSTEM & VALVE
152
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-840 FUEL INJECTION VALVE ASS`Y - REPLACE - 1.0
A2300
153
A1700-05-014 FUEL SYSTEM
154
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
* TE-01-860 FUEL INJECTION PRESSURE - ADJUST 0.8 ←
1 TE-01-861 FUEL FILTER ASS`Y - REPLACE 0.1 ←
2 TE-01-862 FUEL FILTER BRACKET ASS`Y - REPLACE 0.1 ←
3 TE-01-863 HOSE - REPLACE 0.1 ←
A2300
155
A1700-05-15 STARTING MOTOR
156
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-920 STATER - REPLACE 0.3 ←
A2300
157
A1500-05-16 ALTERNATOR & ELECTRIC DEVICE
158
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-940 ALTERNATOR ASS`Y (12V-45A) - REPLACE 0.2 -
2 TE-01-941 BRACKET - REPLACE 0.3 -
3 TE-01-942 PRE-HEATER PLUG - REPLACE 1.0 -
A2300
159
A2325-05-16 ALTERNATOR & ELECTRIC DEVICE
160
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-950 ALTERNATOR ASS`Y (12V-45A) - REPLACE - 0.2
2 TE-01-951 BRACKET - REPLACE - 0.3
3 TE-01-952 PRE-HEATER PLUG - REPLACE - 1.0
A2300
161
A1700-05-17 DPF & MOUNTING OPTION
[ USA ONLY ]
162
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-960 DPF ASS'Y - REPLACE 0.5 -
2 TE-01-961 DPF SUPPORT(B) - REPLACE 0.2 -
3 TE-01-962 DPF BRACKET - REPLACE 0.5 -
4 TE-01-963 DPF SUPPORT(A) - REPLACE 0.2 -
A2300
163
A2325-05-18 DPF & COMPRSSOR MOUNTING
[ EU ONLY ]
164
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-970 DPF ASS'Y - REPLACE - 1.0
A2300
165
A2325-05-19 DPF OPTION
1
[ EU ONLY ]
2
166
HOURS
REF NO JOB CODE DESCRIPTION REMARKS
A1700 A2300
1 TE-01-980 EXHAUST GAS TEMP. SENSOR - REPLACE - 0.1
2 TE-01-981 DPF DIFF, PRESSURE SENSOR & HOSE - REPLACE - 0.1
A2300
167