UV & LCV LABOUR SCHEDULE (W.E.F )

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Gertrude Lane
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1 UV & LCV LABOUR SCHEDULE (W.E.F ) (IA) TD2650 BS II & TD2650 TCIC DI ENGINES EN-1 Dismounting the engine from the vehicle and remounting.this does not comprise of any work on the engine EN-2 Dismounting the engine from the vehicle, completely overhaul and remount. This comprises of stripping down the engine completely, inspecting the parts, sending the engine to machine shop for replacing the liners etc. and also sending the FI pump / alterna also sending the FI pump / alternator / starter for outside work. This does not comprise of charges for machinging or repairs to the FI pump etc. which are to be charged extra. EN-3 Air filter & Engine lubrication system : (a) Clean air cleaner element by pressurised air (b) Replacement of engine oil and spin-on oil filter element ( c) Remove sump, check oil pump pressure and refit (this does not comprise of overhaul of oil pump). (d) Remove sump, remove oil pump, overhaul oil pump and refit. EN-4 Engine setting : (a) Adjusting engine idling speed and nominal speeds (b) Checking engine compression with diesel compression gauge (all 4 cylinders) EN-5 Fuel Injection System : (a) Replacement of single fuel filter insert (this comprises of bleeding the system). ( b) Removal and refitting of feed pump (does not comprise of overhauling of the feed pump). (c )Removal, checking only and refitting of injection nozzle - for one no. (this does not comprise of resetting). (d )Removal, checking, disassembly and resetting of injection nozzle (for one no. only). ( e) Checking of Rotary fuel injection pump timing with adaptor dial gauge on the vehicle (this does not comprise of removal of pump from the vehicle. Also there is no need to remove the lower cowl). (f) Removal of the Rotary FI pump, getting checked / calibrated by MICO, refitting and resetting of timing with adaptor dial gauge. (g) Removal of Rotary FI pump, changing the drive gear, refitting and resetting of timing with adaptor dial gauge. (h) Replace high pressure pipe (single). This comprises of bleeding the system. (i) Replace any single fuel flexible hose / overflow return valve and bleed the system. (j) Replace complete suction tube or overflow return tube and bleed the system. (k) Dismount fuel tank from the vehicle, repair and refit. EN-6 Engine Cooling System : (a) Dismounting radiator with inter cooler replacing any of the lower hoses and refitting. (b) Replace any of the upper hoses - this does not comprise of removal of the radiator. (c ) Remove radiator, replace thermostat valve/replace water pump and refit (this does not comprise of overhauling of water pump). (d) Remove radiator, overhaul water pump and refit

2 EN-7 Engine electricals : (a) Fan belt tension adjustment (b) Replacement of fan belt ( c) Remove alternator, replace mounting bolt or check alternator at Lucas TVS Service Centre and refit (this does not comprise of overhaul of the alternator). (d) Dismount starter from the vehicle, checking, replacement of solenoid switch and refitting. EN-8 Intake and Exhaust systems : (a)removal of Intake Hose (b) Checking & replacement of Turbo Charger (b) Replacement of exhaust manifold/gasket (e) Replace EGR valve EN-9 Timing chain mechanism, valve mechanism and Cylinder head assembly. (a) Replacement of tappet cover gasket (b) Checking valve clearance and resetting ( c ) Checking and retightening cylinder head bolts and readjusting valve clearance. This comprises of removal and refitting of tappet cover. (d) Removal and reinstallation of rocker arms with rocker arm bearing bracket (this comprises of removal and refitting of tappet cover and resetting the valve clearance). (e) Minor valve mechanism overhaul such as replacement of valve stem oil seals, replacement of single valve spring etc. (this comprises of removal and refitting of the camshaft and tappet cover). (f) Removal and refitting of camshaft sprocket. This includes removal and refitting of tappet cover. (g) Replacement of cylinder head gasket (this comprises of removal and refitting of cylinder head assembly complete and resetting of valve clearance). (h) Dismount cylinder head, strip completely, decarburise and refit (this does not include outside charges for valve seat cutting). (I) Removal and refitting of automatic chain tensioner assembly (this does not comprise of disturbing the chain). (j) Removal and installation of chain idler gear (k) Removal and reinstallation of chain tensioner rail (this comprises of removal and refitting of radiator). (l) Removal and reinstallation of injection timing device/sliding rails lower ( or ). This comprises of removal and refitting of radiator and also resetting of the spill cut off timing. (m) Removal and reinstallation of intermediate sprocket shaft. This involves removal and refitting of radiator, removal and refitting of FI pump and resetting spill cut off timing. (n) Replacement of timing chain. This comprises of removal and refitting radiator, removal and refitting of tappet cover, camshaft sprocket, chain tension rail, slide rail upper, timer assembly, intermediate shaft and FI pump. Removal of these leads to chain dropping on the crankshaft sprocket, which is to be pulled by a puller and refitted. There is no need to dismantle the crankshaft. EN-10 Crankshaft Assembly : Note : (1) For jobs (a) through (d) mentioned below, there is no need to dismount the engine from the vehicle. Note : (2) For jobs (a) and (b), removal and refitting of radiator is involved. Note : (3) For jobs (c) and (d), removal and refitting of the gear box and clutch units are involved. (a) Removal and reinstallation of crankshaft pulley balancing disc. (b) Replacement of front crankshaft radial sealing ring / crankshaft sprocket. (c ) Removal and installation of crankshaft pilot bearing and cover ring.

3 (d) Removal for machining/replacement (including static balancing) of the flywheel and refitting. Machining charges extra. (e) Replacement of the crankshaft. This comprises of dismounting the engine from the vehicle, removing the crankshaft assembly, refitting connecting rod assembly and crankshaft, checking engine timing and remounting the engine on the vehicle. EN-11 Crankcase Assembly : (a) Removing piston assemblies, checking cylinder bore/replacement of piston rings / replacement of piston assembly / replacement of connecting rod assembly. (For this job, removal and refitting of the cylinder head, removal and refitting of the sump, removal and refitting of the connecting rod and piston assemblies, resetting cylinder head assembly, resetting valve clearance and FI pump timing resetting are involved). (b) Removal of connectiong rod big end bearing caps one by one, checking connecting rod bearings and refitting (This does not comprise of removal of crankshaft main bearings. This only comprises of removal and refitting of oil sump and oil pump). ( c) Renewing core plug of cylinder crankcase for plugs on side wall. For this it is necessary to remove and refit obstructions like the exhaust manifold, fuel injection pump, alternator etc., required. (d) Renewing core plugs on the rear wall of the crankcase. This comprises of dismounting and remounting of the gear box, clutch, flywheel and back plate. (e) Replacement of engine mounting rubbers. This comprises of removal of engine mounting bracket assemblies (both sides) and changing the rubbers with special tool. (IB) BS III (VP-37) ENGINES EXCLUSIVE LABOUR SCHDULE (a) Checking of Error code with diagnostics tool (b) Check & replacements of sensors ( c) Removal & replacement of turbo charger (d) Removal & replacement of Intake hoses & intercooler hoses. (e) ECU inespection & replacement TEMPO TRAX ENGINE TD2650FDI : Please refer to common TD2650 BS II Engine labour schedule. (II) CLUTCH : CL-1 Only gear box dismounting and refitting CL-2 Dismounting gear box, replacing clutch release bearing/ inspecting and refitting clutch plate and pressure plate & replacement of mainshaft oil seal. CL-3 Clutch master cylinder overhaul including bleeding of the system and resetting. CL-4 Slave cylinder overhaul including bleeding the system and resetting. (III) GEAR BOX TX 18/5 OD : GB-1 Minor jobs mentioned below, for which there is no need of dismounting of gear box. (a) Dismantling gear shifter lever mechanism components, checking, replacing and refitting. (b) Resetting the gear shifter lever mechanism adjustment. ( c) Replacement of speedo drive shaft/oil seal. (d) Replacement of gear box rear mounting rubber (e) Replacement of needle roller bearing / detent for gear box side cover. GB-2 Semi-major jobs mentioned below including dismantling & refitting of the gear box. (a) Replacement of rear transmission cover, replacement of oil seal/gasket. (b) Replacement of front transmission cover oil seal / replacement of shims, replacing direct drive gear bearing / gear.

4 GB-3 Major jobs mentioned below including dismantling & refitting of the gear box. (a) Replacement of synchromesh components of the 2nd / 4th gear. (b) Replacement of gears/bearing on the main shaft including regauging of the mainshaft. ( c) Replacement of the constant ratio gears on countershaft & resetting shims in the front cover. GB-4 Complete overhaul of the gear box including dismantling, inspection, gauging of mainshaft & countershaft, resetting plays & testing & remounting. (IV) FRONT SUSPENSION : The charges indicated are for one side suspension only - FS-1 Replacement of shock absorber FS-2 Replacement of shock absorber upper & lower bushes and refitting. FS-3 Replacement of single wheel joint - upper or lolwer FS-4 Replacement of solid torsion bar FS-5 Replacement of swing arm bushes FS-6 Replacement of control arm/silent block Note : For each of the above jobs, checking wheel alignment by floor gauge & resetting is a must, for which charges as under are allowed in addition to those mentioned above. (i) Checking wheel alignment by floor gauge only (when resetting is not found necessary). (ii) Checking wheel alignment by floor gauge and resetting by trial and error method. (V) REAR AXLE & SUSPENSION : RA-1 Replacement of helper spring only on one side (this can be done without the removal of the entire spring bundle from its mounting on the chassis). RA-2 Replacement of either or both 1st & 2nd spring, replacement of spring eye bushes/shackle bushes etc. (on one side only). Note : In case of any repairs done to the front & rear mounting brackets or the springs, the welding charges etc. only should be added to charges indicated under RS-2 above. RA-3 Check wheel bearing play with hub assembly on the vehicle only (without adjusting). RA-4 Check wheel bearing play and adjust by dismantling the hub (one side). RA-5 Regreasing hub (one side) (a) Replace shock absorber (single) (b) Replace shock absorber bushes (single shock absorber). RA-6 Remove drive flange, replace pinion oil seal & refit RA-7 Remove sump cover, check backlash & teeth contact pattern (without resetting) & refit the cover. RA-8 Dismantling rear axle, resetting crown wheel pinion backlash/mounting distance & refitting. RA-9 Dismantling rear axle, complete overhauling, replacing crown wheel pinion and other worn out parts like bearings, oil seals etc. & refitting. (VI) PROPELLER SHAFT : PR-1 Removal, inspection & replacement of propeller shaft (charges for truing at outside machine shop not included). PR-2 Removal and replacement of single UJ cross assembly (VII) BRAKES : BR-1 Brake pedal play setting by adjusting master cylinder push rod only. BR-2 Bleeding brakes and setting by cam adjustment (for all four wheels without removing drums). BR-3 Complete brake setting including bleeding, removing drums, polishing liners and cam setting (for all four wheels). BR-4 Master cylinder overhaul (only) BR-5 Wheel cylinder overhaul (single only) BR-6 Replacing liner and rivetting (for single shoe only) BR-7 Replace wheel cylinder dust caps (single cylinder only)

5 BR-8 Replace any single brake flexible hose or bundy tube and bleed the system. BR-9 Complete overhaul including overhaul of the master cylinder, all four wheel cylinders, replacement of liners and resetting of brakes. BR-10 Replacement of hand brake cable (single) and resetting BR-11 Setting of hand brake by cable adjustment (only) BR-12 Complete overhaul of the hand brakes including lever mechanism and cables and resetting. (VIII) STEERING : ST-1 Replace jacket bearing ST-2 Adjust worm & column play by adjusting screw (without dismantling from vehicle). ST-3 Remove steering box and adjust steering worm vertical play by adjusting shims and refit. ST-4 Dismantle, overhaul & refit steering box ST-5 Replace any of the steering linkages and reset wheel alignment. ST-6 Replace steering bolt and bearing bushes or replace steering bolt/bearing bolt and reset wheel alignment (both sides). ST-7 A complete overhaul of steering system including overhaul of the steering box, replacement, if necessary, of the steering linkages, replacement of guide bolt and bearing bolt/bushes and resetting wheel alignment. ST-8 Only check wheel alignment by Floor Gauge (without resetting). ST-9 Check wheel alignment by Floor Gauge and reset by trial and error. ST-10 Tyre rotation (IX) ELECTRICALS : EL-1 Minor jobs like : (a) Replacement of any one of the dashboard instruments like speedometer, temp.gauge. (b) Minor jobs on other body fittings like float unit, fuse box. ( C) Replacement of any single switch/wiper arm EL-2 For semi-major jobs like : (a) Dismantling wiper motor, getting it repaired from authorised service station and refitting. (b) Removal of starter/alternator, getting it repaired from authorised service station and refitting. (X) BODY : BD-1 Minor jobs like : (a) Replacing driver door handle / sliding glass fastener BD-2 Semi major jobs like : (a) Door remote control mechanism (b) Door inside lock mechanism. ( c) Repair driver seat sliding mechanism. BD-3 Major jobs like : FOLLOWING LAB OUR CHARGES ARE MADE BASED ON FIELD EXPERIENCE (a) A Post crack & windscreen frame crack. (Material +Metallic Paint + Labour)Pl refer Annexure A (g) Complete Painting to rectify paint fade & paint peeling (Mettalic) all passenger models. * The approval of paint complaint will be only from HQ Service on recommendation of Area Service Engineer. A detailied report with clear photographs of affected loactions is required for approval. CH-1 Replcement of old Chassis frame including stripping cabin & hold & other fitments on the chassis, transmission power unit & Wheels & complete fitment on the new chassis frame

6 I TEMPO TRAVELLER (I) ENGINE OM 616 : Please refer to common TD2650TCIC Engine labour schedule. (II) CLUTCH : CL-1 Replacement of clutch release bearing/clutch release fork, dismounting gear box, replacing clutch release bearing/clutch release shaft and remounting gear box. CL-2 Dismounting gear box, inspection/replacement of clutch plate/pressure plate and remounting. CL-3 Clutch master cylinder dismantling, over-hauling & refitting including bleeding & setting of play. CL-4 Dismounting, overhauling and replacing clutch slave cylinder. (III) GEAR BOX : GB-1 Minor jobs mentioned below, for which there is no need of dismounting of gear box. (a) Dismantling gear shifter lever mechanism components, checking, replacing and refitting. (b) Resetting the gear shifter lever mechanism adjustment. (c ) Replacement of speedo drive shaft/oil seal. (d) Replacement of gear box rear mounting rubber (e) Replacement of needle roller bearing/detent for gear box side cover. GB-2 Semi-major jobs mentioned below including dismantling and refitting of the gear box. (a) Replacement of rear transmission cover, replacement of oil seal/gasket. (b) Replacement of front transmission cover oil seal/ replacement of shims, replacing direct drive gear bearing / gear. GB-3 Major jobs mentioned below including dismantling & refitting of the gear box. (a) Replacement of synchromesh components of the 2nd/4th gear. (b) Replacement of gears / bearing on the main shaft including regauging of the mainshaft. ( c) Replacement of the constant ratio gears on countershaft & resetting shims in the front cover. GB-4 Complete overhaul of the gear box including dismantling, inspection, gauging of mainshaft & countershaft, resetting plays & testing & remounting. (IV) PROPELLER SHAFT : PR-1 Removal & inspection & replacement of front propeller shaft. PR-2 Removal and inspection and replacement of rear propeller shaft. PR-3 Removal & replacement of centre bearing PR-4 Removal & replacement of rubber boot on the rear propeller shaft. (V) FRONT AXLE : FA-1 For jobs mentioned below which does not involve removal of the axle complete from the vehicle (for one side only). (a) Checking and resetting TR bearing play (without dismantling). (b) Dismounting front hub, regreasing and refitting (without replacement of bearing). ( c) Dismounting front hub, replacing TR bearing/oil seal & refitting (Please note that the charges indicated above are inclusive of removing & refitting of the brake caliper). FA-2 Removing & replacing kingpin kit complete and refitting. (both sides). FA-3 Dismounting, stripping bare axle and checking trueness and refitting.

7 RA-1 (VI) REAR AXLE : Minor jobs mentioned below for which there is no need to dismount the rear axle from the vehicle. (a) Remove axle shaft, inspect the TR bearing/oil seal, replace & reset (play on the rear wheel TR bearing cannot be set without dismounting the axle) (one side only). (b) Remove drive flange, replace pinion oil seal and refit ( c) Remove sump cover, check backlash & teeth, contact pattern (without resetting) and refit the cover. RA-2 Dismantling rear axle, resetting crown wheel pinion backlash/mounting distance and refitting. RA-3 Dismantling rear axle, complete overhauling, replacing crown wheel pinion and other worn out parts like bearings, oil seals etc. and refitting. (VII) FRONT SUSPENSION : FS-1 Replacement of shock absorber complete FS-2 Replacement of shock absorber bushes (single shock absorber). FS-3 Replacement of antiroll bar bushes big and small (complete set). FS-4 Replacement of main leaf set/first spring/its bushes (including dismantling spring set & refitting (one side only). FS-5 Replacement of any of the spring leaves excepting main. FS-6 Replacement of spring buffer, part number (VIII) REAR SUSPENSION : RS-1 Replacement of rear shock absorber (single) RS-2 Replacement of shock absorber bushes (for single shock absorber). RS-3 Replacement of rubber mounting for anti-roll bar, P.No.B RS-4 Replacement of spring set/first spring/its bushes (including dismantling and refitting of the spring set). RS-5 Replacement of spring leaves other than first spring RS-6 Replacement of rear spring buffer, P. No (IX) BRAKES : Note : For all jobs mentioned below, charges for bleeding the system are included. BR-1 Bleeding of brake system complete in the front and rear and resetting the rear brakes (both). BR-2 Replacement of brake pads kit (both sides), polishing brake disc (without dismantling) and refitting. BR-3 Dismantling brake pads, replacing caliper piston seats and refitting (both sides). BR-4 Dismounting caliper, remove brake disc, re-machining/replacing & refitting (including removal & refitting of hubs) - both sides. BR-5 Removing Rear shoes, replacing liners, refitting & resetting (all four) BR-6 Removing, dismantling overhauling and resetting Rear wheel cylinder (one side). BR-7 Removing, dismantling, inspecting, overhauling and refitting master cylinder. BR-8 Removing brake booster, checking/replacing diaphragm kit and refitting. BR-9 Removing brake booster, replacing front minor kit and refitting. BR-10 Replacement of any single brake hose/bundy tube and resetting. BR-11 Replacing brake pedal spring/setting brake pedal play, master cylinder push rod play. BR-12 Replacing single hand brake cable and resetting ( ) BR-13 Replacing brake cable for hand brake lever ( ) BR-14 Repairing hand brake lever mechanism and refitting and resetting.

8 (X) STEERING : ST-1 Checking and resetting free play on steering wheel (this does not include dismounting of the steering assembly). ST-2 Pulling out and replacing steering wheel ST-3 Checking of wheel alignment with floor gauge (without resetting). ST-4 Checking and resetting of wheel alignment with floor gauge. ST-5 Removal of steering linkage (single) replacement of ball ends, refitting & resetting wheel alignment. ST-6 Checking steering geometry including caster camber and toe-in without resetting (with bubble gauge). ST-7 Dismantling, overhauling and refitting of the steering box ST-8 Complete overhaul of the steering system including overhauling of the steering box and linkages and resetting. (XI) ELECTRICALS : EL-1 Minor jobs like : (a) Replacement of any one of the dashboard instruments like speedometer, temp. gauge. (b) Minor jobs on other body fitting like float unit, fuse box. EL-2 For semi-major jobs like : (a) Removal and refitting combination switch (involving removal and refitting of steering wheel). (b) Dismantling wiper motor, getting it repaired from authorised service station and refitting. (XII) BODY : BD-1 Minor jobs like : (a) Replacing driver door crank hand/sliding glass fastener. BD-2 Semi-major jobs like : (a) Door window lock mechanism. (b) Door inside lock mechanism. ( c) Checking and resetting with shims rear door. (d) Repair driver seat sliding/tilting mechanism. BD-3 Major jobs like : (a) Replacement of windscreen glass/beeding. (b) Remove any single interior upholstery panel and refitting. BD-4 FOLLOWING LABOUR CHARGES ARE MADE BASED ON FIELD EXPERIENCE Scrubbing the old paint, giving a single coat of paint (cost of material & Labour included). (I )For 3050/3350 mm w.b ** 18750** 16000** (ii )For 3700 mm W.B ** 20000** 17000** ** The approval of paint complaint will be only from HQ Service on recommendation of Area Service Engineer. A detailied report with clear photographs of affected loactions is required for approval.

Copyright, 1941, Hudson Motor Car Co. I. Printed in U. S. A.

Copyright, 1941, Hudson Motor Car Co. I. Printed in U. S. A. INTRODUCTION Hudson Standard Flat Rate Manual covers a system of selling maintenance work at definite prices (see conversion table, page VI) and labor time allowances. Each individual operation is identified