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SAFARI STORME 		1
GENERAL INTRODUCTION 		2
INTRODUCTION 		4
TECHNICAL SPECIFICATIONS 		6
CHASSIS TYPE AND SALES DESIGNATION 		12
LUBRICANTS AND COOLANT RECOMMENDATIONS: 		13
SERVICE AND MAINTENANCE SCHEDULE 		15
ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS 		20
PRECAUTIONS 		22
1.1 GENERAL PRECAUTIONS 		26
1.2 SAFETY AGAINST PERSONAL INJURY 		27
A. WORKING WITH VEHICLES FITTED WITH AIRBAG 		27
B. WORKING WITH ENGINE 'ON' 		28
1.3 AVOIDING DAMAGE 		29
1.4 USED OIL HANDLING AND DISPOSAL 		29
1.5 FUEL HANDLING PRECAUTIONS 		30
1.6 HAZARDOUS MATERIAL 		31
ENGINE 		32
2.1.1 GENERAL INFORMATION 		40
2.1.1.1 SPECIFICATION 		40
2.1.1.2 TIGHTENING TORQUES 		41
2.1.1.3 SPECIAL TOOLS 		59
2.1.1.4 GENERAL SYMPTOMS DIAGNOSIS 		60
2.1.2 MAINTENANCE, INSPECTION AND TESTS 		63
2.1.2.1 PRELIMINARY INSPECTION 		63
2.1.2.2 REGULAR MAINTENANCE 		65
A. ENGINE OIL REPLACEMENT 		65
B. OIL FILTER REPLACEMENT 		66
C. AIR FILTER CLEANING 		66
D. FUEL FILTER REPLACEMENT 		67
E. DRAININGWATER FROM PREFILTER CUM SEDIMENTOR 		68
F. PREFILTER CUM SEDIMENTOR REPLACEMENT 		68
G. PREFILTER CARTIRDGE REPLACEMENT 		69
H. COOLANT REPLACEMENT 		73
2.1.2.3 ON VEHICLE PROCEDURES 		74
A. ENGINE REMOVAL 		74
B. AIR FILTER ASSEMBLY REMOVAL 		76
C. POWER STEERING PUMP BELT (STRETCH BELT) 		76
D. ALTERNATOR AND AC BELT 		77
E. INJECTOR REMOVAL 		78
F. TIMING BELT REMOVAL 		79
G. TIMING BELT FITMENT 		81
2.1.3 OVERHAULING 		84
2.1.3.1 ENGINE DISMANTLING:(ON STAND) 		84
2.1.3.2 CYLINDER HEAD 		91
2.1.3.3 TIMING SYSTEM 		103
2.1.3.4 ENGINE BLOCK 		106
2.1.3.5 ENGINE ASSEMBLY 		131
2.1.4 AIR INTAKE SYSTEM 		140
2.1.4.1 SYSTEM LAYOUT 		140
2.1.4.2 COMPONENTS 		141
2.1.4.3 EXPLODED VIEW 		142
2.1.4.4 ON VEHICLE REPAIRS 		143
2.1.4.5 BLOW-BY CIRCUIT 		144
2.1.4.5.1 BLOW BY CIRCUIT SCHEMATIC LAYOUT 		144
2.1.4.6 VACUUM MANAGEMENT SYSTEM 		146
2.1.4.6.1 VACUUM LINES SCHEMATIC LAYOUT 		146
2.1.4.6.2 COMPONENTS 		147
2.1.5 COOLING SYSTEM 		149
2.1.5.1 SYSTEM DESCRIPTION 		149
2.1.5.2 COMPONENTS 		150
2.1.5.3 EXPLODED VIEW 		152
2.1.5.4 MAINTENANCE 		153
2.1.5.4.1 ON VEHICLE REPAIRS 		153
2.1.6 LUBRICATION SYSTEM 		156
2.1.6.1. SYSTEM DESCRIPTION 		156
2.1.6.2 COMPONENTS 		157
2.1.6.3 EXPLODED VIEW 		160
2.1.7 FUEL SYSTEM 		162
2.1.7.1 INTRODUCTION TO VARICOR SYSTEM 		162
2.1.7.2 FUEL SYSTEM COMPONENTS 		166
2.1.7.3 MAINTENANCE 		171
2 .1.7.4. FUEL TANK PURGING PROCEDURE 		176
2.1.8 EXHAUST SYSTEM 		178
2.1.8.1 EXHUAST SYSTEM LAYOUT 		178
2.1.8.1.1 SYSTEM DESCRIPTION 		178
2 .1.8.1.2 COMPONENTS 		179
2 .1.8.1.3 CONSTRUCTIONAL DETAILS OF EXHAUST SYSTEM 		180
2 .1.8.1.4 MAINTENANCE 		181
2.1.8.2 EXHAUST GAS RECIRCULATION SYSTEM (EGR) 		184
2.1.8.2.1 SYSTEM DESCRIPTION 		184
2.1.8.2.2 SYSTEM COMPONENTS 		185
2.1.8.2.3 MAINTENANCE 		186
2.1.8.3 TURBOCHARGER 		187
2.1.8.3.1 DESCRIPTION 		187
2.1.8.3.2 MAINTENANCE 		188
2.1.9 ENGINE MANAGEMENT SYSTEM (EMS) 		196
2.1.10 DIAGNOSTIC USER MANUAL 		229
CLUTCH 		240
CLUTCH 320 NM 		240
3.1.1 GENERAL INFORMATION 		246
3.1.1.1 SPECIFICATIONS 		246
3.1.1.2 CLUTCH SYSTEM LAYOUT 		249
3.1.1.3 TIGHTENING TORQUES 		252
3.1.1.4 SPECIAL TOOLS 		255
3.1.1.5 GENERAL SYMPTOMS DIAGNOSIS 		256
3.1.2 MAINTENANCE, INSPECTION AND TESTS 		258
3.1.2.1 PRELIMINARY INSPECTION 		258
3.1.2.2. REGULAR MAINTENANCE 		259
3.1.2.3 REPAIRS 		261
3.1.2.3.1 CLUTCH PEDAL ASSEMBLY 		261
3.1.2.3.2 SELF ADJUSTING CLUTCH ASSEMBLY 		266
3.1.2.3.3 CLUTCH HYDRAULIC SYSTEM COMPONENTS 		271
3.1.2.3.5 SINGLE MASS FLYWHEEL (ON VEHICLE) 		276
CLUTCH 400 NM 		278
3.1.1 GENERAL INFORMATION 		284
3.1.1.1 SPECIFICATIONS 		284
3.1.1.2 CLUTCH SYSTEM LAYOUT 		287
3.1.1.3 TIGHTENING TORQUES 		290
3.1.1.4 SPECIAL TOOLS 		293
3.1.1.5 GENERAL SYMPTOMS DIAGNOSIS 		294
3.1.2 MAINTENANCE, INSPECTION AND TESTS 		296
3.1.2.1 PRELIMINARY INSPECTION 		296
3.1.2.2. REGULAR MAINTENANCE 		297
3.1.2.3 REPAIRS 		299
3.1.2.3.1 CLUTCH PEDAL ASSEMBLY 		299
3.1.2.3.2 SELF ADJUSTING CLUTCH ASSEMBLY 		304
3.1.2.3.3 CLUTCH HYDRAULIC SYSTEM COMPONENTS 		309
3.1.2.3.5 SINGLE MASS FLYWHEEL (ON VEHICLE) 		314
GEAR BOX 		316
4.2.1 GENERAL INFORMATION 		324
4.2.1.1 SPECIFICATIONS 		324
4.2.1.2 TIGHTENING TORQUES 		325
4.2.1.3 SPECIAL TOOLS 		329
4.2.1.4 GENERAL SYMPTOMS DIAGNOSIS 		333
4.2.2 MAINTENANCE, INSPECTION AND TEST 		334
4.2.2.1 PRELIMINARY INSPECTION 		334
4.2.2.2 REGULAR MAINTENANCE 		334
4.2.2.3 ON VEHICLE PROCEDURES 		335
4.2.3 OVERHAULING 		337
4.2.3.1 INFORMATION FOR OVERHAULING 		337
4.2.3.2 GEARBOX DISMANTLING (ON BENCH) 		344
4.2.3.3 DISMANTLING OF SUB-ASSEMBLIES 		351
4.2.3.4 GEAR BOX ASSEMBLY 		379
TRANSFER CASE 		388
4.3.1 GENERAL INFORMATION 		396
4.3.1.1 SPECIFICATIONS 		396
4.3.1.2 CONSTRUCTION 		397
4.3.1.3 COMPONENTS OF TRANSFER CASE 		399
4.3.1.4 WORKING OF TRANSFER CASE 		402
4.3.1.5 TIGHTENING TORQUES 		406
4.3.1.6 SPECIAL TOOLS 		409
4.3.1.7 GENERAL SYMPTOMS & DIAGNOSIS 		412
4.3.2 MAINTENANCE 		413
4.3.2.1 PRELIMINARY INSPECTION 		413
4.3.2.2 REGULAR MAINTENANCE 		413
4.3.2.3 ON VEHICLE REPAIRS 		414
4.3.3 OVERHAULING 		416
4.3.3.1 PRECAUTIONS 		416
4.3.3.2 DISMANTLING 		416
4.3.3.3 INSPECTION & CLEANING 		426
4.3.3.4 ASSEMBLY 		426
4.3.4 DIAGNOSTIC OF ECU 		437
SUSPENSION 		440
FRONT SUSPENSION 		444
5.1.1 GENERAL INFORMATION 		450
5.1.1.1 SPECIFICATIONS 		450
5.1.1.2 CONSTRUCTION 		451
5.1.1.3 TIGHTENING TORQUES 		452
5.1.1.4 SPECIAL TOOLS 		457
5.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 		460
5.1.2 MAINTENANCE 		461
5.1.2.1 PRELIMINARY INSPECTION 		461
5.1.2.2 REGULAR MAINTENANCE 		461
A. WHEEL ALIGNMENT 		461
B. ANTI ROLL BAR MOUNTING GREASING 		462
5.1.2.3 ON VEHICLE REPAIRS 		463
A. ANTI ROLL BAR (ARB) 		463
B. FRONT STRUT ASSEMBLY 		464
C. LOWER WISHBONE 		465
D. UPPER WISHBONE 		466
E. BUMP STOPPER 		468
5.1.3 OVERHAULING 		468
5.1.3.1 PRECAUTIONS 		468
5.1.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 		469
A. FRONT STRUT 		469
B. UPPER WISHBONE BUSH 		470
C. UPPER WISHBONE BALL JOINT 		472
D. LOWER WISHBONE BALL JOINT REMOVAL 		472
REAR SUSPENSION 		446
5.2 REAR SUSPENSION 		473
5.2.1 GENERAL INFORMATION 		473
5.2.1.1 SPECIFICATIONS 		473
5.2.1.2 CONSTRUCTION 		474
5.2.1.3 TIGHTENING TORQUES 		475
5.2.1.4 SPECIAL TOOLS 		478
5.2.2 MAINTENANCE 		481
5.2.2.1 ON VEHICLE REPAIRS 		481
A. ANTIROLL BAR 		481
B. UPPER LINK 		483
C. LOWER LINK 		484
D. PAN HARD ROD 		484
E. REAR SHOCK ABSORBER 		485
F. REAR COIL SPRING 		486
5.2.3 OVERHAULING 		487
5.2.3.1 PRECAUTIONS 		487
5.2.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 		487
A. UPPER LINK BUSH 		487
B. LOWER LINK BUSH 		488
C. PAN HARD ROD BUSH 		489
WHEEL AND TYRES 		448
5.3.1 GENERAL INFORMATION 		491
5.3.1.1 SPECIFICATIONS 		491
5.3.1.2 CONSTRUCTION 		492
5.3.1.3 TIGHTENING TORQUES 		493
5.3.1.4 GENERAL SYMPTOMS DIAGNOSIS 		494
A. DIAGNOSIS CHART 		494
B. TYRE WEAR PATTERN 		497
C. WEAR CAUSES 		499
D. TYRE VIBRATION DIAGNOSIS 		501
5.3.2 MAINTENANCE, INSPECTION AND TESTS 		502
5.3.2.1 PRELIMINARY INSPECTION 		502
A. VISUAL INSPECTION 		502
B. PRECAUTIONS 		502
5.3.2.2 REGULAR MAINTENANCE 		503
A. INFLATION 		503
B. WHEEL BALANCING 		503
C. TYRE ROTATION 		504
D WHEEL RUN OUT 		505
E. DO'S AND DON’TS 		506
5.3.2.3 WHEEL AND TYRE REPLACEMENT 		507
A. PRECAUTIONS DURING TYRE REPLACEMENT 		507
B. TYRE REPLACEMENT 		508
C. WHEEL ASSEMBLY REPLACEMENT 		508
FRONT AXLE 		509
FRONT AXLE (4X4) 		509
4.5.2 FRONT AXLE 4X4 		515
4.5.2.1 GENERAL INFORMATION 		515
4.5.2.1.1 SPECIFICATION 		515
4.5.2.1.2 SYSTEM LAYOUT 4X4 		516
4.5.2.1.3 TIGHTENING TORQUES 		517
4.5.2.1.4 SPECIAL TOOLS 		521
4.5.2.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 		526
4.5.2.2 MAINTENANCE 		527
4.5.2.2.1 PRELIMINARY INSPECTION 		527
4.5.2.2.2 REGULAR MAINTENANCE 		527
A. FRONT AXLE OIL REPLACEMENT 		527
B. FRONT AXLE DISCONNECT MECHANISM(FAD) CHECKING PROCEDURE 		527
4.5.2.2.3 ON VEHICLE REPAIRS 		528
A. FRONT AXLE ASSEMBLY 		528
B ELECTRICAL DISCONNECT ASSEMBLY 		532
C. TONER RING 		533
4.5.2.3 OVERHAULING 		534
4.5.2.3.1 PRECAUTIONS 		534
4.5.2.3.2 CONSTRUCTIONAL DETAILS 		534
4.5.2.3.3 DISMANTLING INSPECTION AND ASSEMBLY 		538
FRONT AXLE (4X2) 		569
4.5.1 FRONT AXLE 4X2 		575
4.5.1.1 GENERAL INFORMATION 		575
4.5.1.1.1 TECHNICAL SPECIFICATIONS 		575
4.5.1.1.2 CONSTRUCTION AND LAYOUT 		575
4.5.1.1.3 TIGHTENING TORQUE 		576
4.5.1.1.4 SPECIAL TOOLS 		577
4.5.1.2 MAINTENANCE 		579
4.5.1.2.1 ON VEHICLE PROCEUDRE 		579
4.5.1.3 OVERHAULING 		583
4.5.1.3.1 FRONT AXLE EXPLODED VIEW 		583
4.5.1.3.2 HUB REPLACEMENT 		584
4.5.1.3.3 TONER RING REPLACEMENT 		586
4.5.1.3.4 HUB BEARING REPLACEMENT 		587
REAR AXLE 		589
1. GENERAL INFORMATION 		592
1.1 AXLE SPECIFICATION & SERVICE DATA 		593
1.2 AXLE LUBRICATION 		594
1.3 AXLE IDENTIFICATION 		594
1.4 EXPLODED VIEW 		595
1.5 PARTS DESCRIPTIONS 		596
2. DIS-ASSEMBLY OF AXLE 		597
2.1 AXLE SHAFT DISASSEMBLY 		597
2.2 REMOVAL OF CARRIER SECTION FROM BANJO 		598
3. CARRIER SECTION: A-CARRIER DIS -ASSEMBLY 		598
3.1 DISASSEMBLY OF CARRIER SECTION &DIFFERENTIAL 		598
3.2 RING GEAR REMOVAL 		599
3.3 CASE DISASSEMBLY 		600
3.4 DRIVE PINION REMOVAL 		601
3.5 RING GEAR & PINION ASSEMBLYTHEORY: 		602
3.6 ESTABLISHING PINION & GEAR DEPTHUSING SERVICE TOOLS & GUAGES 		604
3.7 CASE REASSEMBLY 		606
3.8 ASSEMBLY OF DIFFERENTIAL IN CARRIER 		607
3.9 INTERPRETATION OF CONTACT PATTERN 		610
4. DIS-ASSEMBLY & REASSEMBLY OFLIMITED SLIP DIFFERENTIAL (TRAC-LOK) 		611
4.1 DIS-ASSEMBLY OF TRAC-LOKDIFFERENTIAL 		611
4.2 INSPECTION OF ALL THE PARTS FORWEAR, SCORE, ETC. 		613
4.3 REASSEMBLY 		613
5. AXLE SHAFT DIS-ASSEMBLY & REASSEMBLY 		615
5.1 DIS-ASSEMBLY OF AXLE SHAFTASSEMBLY 		615
5.2 ASSEMBLY OF AXLE SHAFT ASSEMBLY 		616
6. RE-ASSEMBLY OF AXLE & FIT TOVEHICLE 		617
6.1 INSTALL CARRIER SECTION ON BANJOBEAM 		617
6.2 INSTALL AXLE SHAFT ASSEMBLY ON BANJO BEAM 		617
7. TROUBLE SHOOTING 		619
PROPELLER SHAFT 		621
4.4.1 GENERAL INFORMATION 		627
4.4.1.1 ADJUSTMENT / REPAIR DATA 		627
4.4.1.2 SYSTEM LAYOUT 		628
A. FOR 4X2 DRIVE 		628
B. FOR 4X4 DRIVE 		629
4.4.1.3 TIGHTENING TORQUE 		630
4.4.1.4 SPECIAL TOOL 		631
4.4.1.5 GENERAL SYMPTOMS DIAGNOSIS 		632
4.4.2 MAINTENANCE, INSPECTION AND TESTS 		633
4.4.2.1 PRELIMINARY INSPECTION 		633
4.4.2.2 REGULAR MAINTENANCE 		633
4.4.2.3 ON VEHICLE REPAIRS 		634
A. PROPELLER SHAFT (4X2) 		635
B. PROPELLER SHAFT (4X4) 		636
C TVD (TORSIONAL VIBRATION DAMPERS)LOCATION 		637
4.4.3 OVERHAULING 		638
4.4.3.1 CONSTRUCTIONAL DETAILS 		638
A. PROPELLER SHAFT 4X2 DRIVE 		638
B. PROPELLER SHAFT 4X4 DRIVE 		639
4.4.3.2 UNIVERSAL JOINT 		640
4.4.3.3 CENTRE BEARING 		643
BRAKES 		647
6.1.1 GENERAL INFORMATION 		655
6.1.1.1 SPECIFICATION 		655
6.1.1.2 SYSTEM DETAILS 		656
A. SYSTEM SCHEMATIC FOR ABS VERSION 		656
B. SYSTEM LAYOUT FOR ABS VERSION 		657
C. SYSTEM SCHEMATIC FOR NON ABS VERSION 		658
D. SYSTEM LAYOUT FOR NON ABS VERSION 		659
6.1.1.3 TIGHTENING TORQUES 		660
6.1.1.4 GENERAL SYMPTOMS DIAGNOSIS 		664
6.1.2 MAINTENANCE, INSPECTION AND TEST 		666
6.1.2.1 PRELIMINARY INSPECTION 		666
A. FRONT BRAKE AND REAR BRAKE 		666
B. PARKING BRAKE 		666
C. BRAKE HOSES AND LINES 		666
D. ROAD TEST 		666
E REAR DRUM BRAKES 		667
F WHEEL CYLINDER SERVICING 		673
6.1.2.2 REGULAR MAINTENANCE 		675
A. BRAKE BLEEDING PROCEDURE 		675
B. ABS SECONDARY CIRCUIT BLEEDINGPROCEDURE (USING DIAGNOSTIC TOOL) 		676
C. CALIPER PAD REPLACEMENT 		681
D. PARKING BRAKE ADJUSTMENT 		682
E. BRAKE FLUID DRAINING PROCEDURE 		683
F. BRAKE LIGHT SWITCH ADJUSTMENT 		684
G. BOOSTER FILTER REPLACEMENT 		685
H. GREASING 		686
I. DISC RUN-OUT MEASUREMENTPROCEDURE 		687
6.1.2.3 ON VEHICLE REPAIRS 		687
A. CALIPER ASSEMBLY WITH CARRIER 		687
B. BRAKE DISC REMOVAL 		688
C. PARKING 		691
D. BRAKE PEDAL 		695
E. VACUUM LINES 		698
F. BOOSTER ASSEMBLY 		699
G.PARKING BRAKE (DRUM IN HAT) 		704
6.1.3 OVERHAULING 		706
6.1.3.1 PRECAUTIONS 		706
6.1.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 		707
A. FRONT CALIPER ASSEMBLY 		707
B. REAR CALIPER ASSEMBLY 		712
6.1.4 LOAD SENSING PROPORTIONATINGVALVE (LSPV) (FOR NON ABS VEHICLEONLY) 		716
ANTI-LOCK BRAKING SYSTEM (ABS) 		719
6.2.1 GENERAL INFORMATION 		725
6.2.1.1 NECESSITY OF ABS WITH EBD 		725
6.2.1.2 TECHNICAL SPECIFICATIONS 		726
6.2.1.3 TIGHTENING TORQUES 		727
6.2.1.4 SCHEMATIC OF HYDRAULIC CIRCUIT 		729
6.2.1.5 WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS) 		730
6.2.1.6 COMPONENTS 		734
A. ABS ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU) 		735
B. WHEEL SPEED SENSOR (WSS) 		738
C. ABS SYSTEM FAILURE WARNING LIGHT 		739
6.2.2 REPAIRS 		740
A. ABS ECU / HCU 		740
B. FRONT WHEEL SPEED SENSOR 		743
C. FRONT TONER RING 		744
D. REAR WHEEL SPEED SENSOR 		744
E. REAR TONER RING 		745
6.2.3 TROUBLE SHOOTING ANDDIAGNOSIS 		746
A. ROAD TEST 		746
B. TABLE OF ABS 8.1 - FALL-BACK LEVEL 		746
6.2.4 ABS DIAGNOSTIC USER MANUAL 		747
6.2.4.1 GENERAL 		747
6.2.4.2 OPERATING PROCEDURE 		748
STEERING 		759
7.1 GENERAL INFORMATION 		767
7.1.1 SPECIFICATIONS 		767
7.1.2 SYSTEM LAYOUT 		768
7.1.3 TIGHTENING TORQUES 		769
7.1.4 SPECIAL TOOLS 		775
7.1.5 GENERAL SYMPTOMS DIAGNOSIS 		776
7.2 MAINTENANCE, INSPECTION AND TEST 		783
7.2.1 PRELIMINARY INSPECTION 		783
7.2.2 REGULAR MAINTENANCE 		784
A. POWER STEERING OIL REPLACEMENT 		784
B. POWER STEERING RESERVOIR ASSY 		785
C. HYDRAULIC SYSTEM AIR BLEEDING 		786
E .STEERING WHEEL ALIGNMENT/ CENTRALISING 		787
F. STEERING WHEEL PLAY 		788
G. POWER STEERING OIL FLUSHING PROCEDURE 		788
7.2.3 REPAIRS 		789
7.2.3.1 STEERING WHEEL 		789
7.2.3.2 SYSTEM LAYOUT 		794
7.2.3.3 STEERING RESERVOIR & POWER STEERING PUMP 		799
A. STEERING RESERVOIR 		800
B. POWER STEERING PUMP 		800
7.2.3.4 RACK AND PINION ASSEMBLY 		801
7.3 RACK & PINION UNIT OVERHAULING 		802
7.3.1 General Instructions 		802
7.3.2 RACK AND PINION ASSEMBLY 		803
7.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 		804
7.3.3.1 OUTER BALL JOINT (OBJ) 		804
7.3.3.2 BELLOW KIT 		805
7.3.3.3 INNER BALL JOINT (IBJ) 		806
7.3.3.4 FEED PIPE 		807
7.3.3.5 DO’S & DON’TS 		808
ELECTRICAL 		811
8.1 TECHNICAL SPECIFICATIONS 		821
8.2 GENERAL ELECTRCIAL PRECAUTIONS 		824
8.3 STARTING AND CHARGING SYSTEM 		827
8.3.1 BATTERY 		827
8.3.2 ALTERNATOR 		833
8.3.3 STARTER MOTOR 		846
8.4 LIGHTING SYSTEM 		860
8.4.1 BULB SPECIFICATIONS 		860
8.4.2 TORQUE VALUE TABLE 		860
8.4.3 DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS 		861
8.4.4 HEAD LAMP 		864
8.4.5 FRONT FOG LAMP 		870
8.4.6 FRONT ROOF LAMP 		871
8.4.7 SECOND AND THIRD ROW ROOF LAMP 		872
8.4.8 REGISTRATION PLATE LAMP 		873
8.4.9 CENTER HIGH MOUNTED STOP LAMP 		873
8.4.10 PUDDLE LAMP 		875
8.4.11 GLOVE BOX LAMP 		876
8.4.12 TAIL LAMP 		876
8.4.13 REAR FOG LAMP (If fitted) 		877
8.5 HORN 		879
8.6 POWER SOCKET 		881
8.7 CIGAR LIGHTER 		883
8.8. BUZZER 		884
8.9 WIPER AND WASHER SYSTEM 		885
8.9.1 FRONT AND REAR WIPER AND WAHSER SYSTEM COMPONENT LOCATIONS 		885
8.9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 		886
8.9.3 FRONT AND REAR WIPER SYSTEMCOMPONENTS 		887
8.9.3.1 FRONT WIPER MOTOR 		887
8.9.3.2 FRONT WIPER ARM AND BLADE 		890
8.9.3.3 REAR WIPER ARM AND BLADE 		891
8.9.3.4 REAR WIPER MOTOR 		892
8.9.3.5 WIPER CARE 		894
8.9.4 WASHER SYSTEM COMPONENTS 		895
8.9.4.1 WASHER BOTTLE 		895
8.9.4.2 WASHER PUMP 		895
8.9.4.3 FRONT WAHSER NOZZLE 		896
8.9.4.4 REAR WASHER NOZZLE 		897
8.9.5 DIAGNOSTIC INFORMATION AND PROCEDURES 		898
8. 10 ELECTRICAL SWITCHES 		899
8.10.1 COMBINATION – SWITCH 		899
8.10.2 IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION 		906
8.10.3 MASTER LIGHT SWITCH 		909
8.10.4 ORVM SWITCH 		912
8.10.5 WINDOW WINDING SWITCHES 		915
8.10.6 BONNET SWITCH 		921
8.10.7 HAZARD WARNING SWITCH 		922
8.10.8 TRANSFER CASE SWITCH 		923
8.10.9 GLOVE BOX SWITCH 		924
8.10.10 REVERSE LIGHT SWITCH 		925
8.10.11 HAND BRAKE SWITCH 		927
8.10.12 INERTIA SWITCH 		928
8.11 WINDOW WINDING CONTROLLER 		930
8.12 BODY CONTROL MODULE (BCM) 		947
8.13 IMMOBILIZER SYSTEM 		990
8.14 INSTRUMENT CLUSTER 		1012
8.15 REVERSE PARKING SYSTEM WITH ULTRASONIC SENSOR (If equipped 		1025
8.16 ENTERTAINMENT SYSTEM 		1041
8.17. GENERAL ELECTRICAL INFORMATION 		1055
8.17.1 FUSE AND RELAY BOX DETAILS 		1055
ELECTRICAL CIRCUIT SCHEMATICS 		1063
SYMBOLS 		1069
WIRING HARNESS TOPOLOGY 		1070
POWER SUPPLY 		1071
STARTER AND CHARGING 		1076
EMS SYSTEM (DIESEL) 		1077
DIESEL FUEL SENDER 		1080
MANUAL HVAC 		1081
ROOF HVAC 		1082
RADIATOR FANS 		1083
POWER WINDOWS SYSTEM LX 		1084
POWER WINDOWS SYSTEM VX AND EX 		1086
CENTRAL DOOR LOCKING (WITH BCM) 		1088
INSTRUMENT CLUSTER 		1089
FRONT WIPER (BCM) 		1091
REAR WIPER 		1092
HEADLAMP LEVELING SYSTEM 		1093
EXTERIOR LIGHT (MASTER LIGHT SW AND COMBI) 		1094
CAN SYSTEM 		1097
IMMOBILISER 		1098
RESTRAINTS 		1099
HEATED REAR WINDOW 		1100
INTERIOR LAMPS 		1101
POWER MIRROR ADJUST 		1103
HORN (RELAY CONT)SHEET 		1105
POWER SOCKET AND CIGAR LIGHTER LX 		1106
POWER SOCKET AND CIGAR LIGHTER VX AND EX 		1107
REVERSE PARKING AID 		1108
4WD CONTROL 		1109
INFOTAINMENT SYSTEM 		1111
BCM 		1114
ABS 		1116
COMBI SW AND IGN SW PIN DIAGRAM 		1117
CONNECTOR VIEWS 		1118
DTC CODES 		1131
DTC 320 NM 		1131
DTC 400 NM 		1203
SUPPLEMENTARY RESTRAINT SYSTEM (SRS) 		1349
11.1.1 TIGHTENING TORQUES 		1355
11.1.2 WORKING OF RESTRAINTS 		1357
A. RESTRAINTS WITHOUT AIRBAGS 		1357
B. RESTRAINTS WITH AIRBAGS 		1357
11.1.3 SYSTEM LAYOUT 		1358
11.1.3.1 RESTRAINT WITHOUT AIRBAG 		1358
11.1.3.2 RESTRAINT WITH AIRBAG 		1358
11.1.4 SAFETY PRECAUTIONS 		1359
11.1.5 DISPOSAL OF FAULTY AIR BAG UNIT 		1361
11.1.6 COMPONENTS 		1362
11.1.6.1 RESTRAINT WITHOUT AIRBAGS 		1362
A. SEAT BELT 		1362
B. EMERGENCY LOCKING RETRACTOR (ELR) 		1362
C. MICROSWITCH AND SEAT BELT REMINDER(SBR) WARNING LAMP 		1362
11.1.6.2 RESTRAINT WITH AIRBAGS 		1363
11.1.6.2.1 ECU 		1363
11.1.6.2.2 SENSORS 		1368
11.1.6.2.3 AIR BAGS 		1370
11.1.6.2.4 CLOCK SPRING 		1372
11.1.6.2.5 RPLL BELTS 		1375
11.1.6.2.6 SRS WARNING LAMP 		1377
11.1 7 DIAGNOSTIC USER MANUAL 		1378
BODY 		1386
9.1 GENERAL INFORMATION 		1396
9.1.1 SPECIFICATIONS 		1396
9.1.2 LAYOUT 		1400
9.1.3 TIGHTENING TORQUES 		1401
9.1.4 SPECIAL TOOL 		1404
9.2 ON VEHICLE REPAIRS 		1405
9.2.1 BONNET 		1405
9.2.2 FLOOR CONSOLE 		1409
9.2.3 DASHBOARD 		1411
9.2.4 TOP UTILITY BIN 		1415
9.2.5 GLOVE BOX 		1415
9.2.6 SIDE AIR VENTS 		1416
9.2.7 CENTRAL FINISHER 		1418
9.2.8 FRONT BUMPER 		1419
9.2.9 REAR BUMPER 		1422
9.2.10 DOOR TRIMS 		1425
9.2.11 FRONT DOOR 		1428
9.2.12 DOOR LOCK HANDLE AND DOOR LATCH 		1431
9.2.13 FRONT OUTER DOOR LOCK BARRELAND HANDLE 		1432
9.2.14 FRONT DOOR LATCH 		1433
9.2.15 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 		1435
9.2.16 REAR DOOR 		1437
9.2.17 REAR OUTER DOOR LOCK 		1439
9.2.18 DOOR LATCH REAR 		1441
9.2.19 TAILGATE TRIM 		1442
9.2.20 TAIL GATE 		1445
9.2.21 ORVM 		1450
9.2.22 INNER REAR VIEW MIRROR 		1451
9.2.23 FRONT ROW SEAT 		1451
9.2.24 SECOND ROW SEAT 		1452
9.2.25 THIRD ROW SEAT 		1453
9.2.26 SEAT BELTS 		1454
9.2.27 SECOND ROW SEAT BELT 		1456
9.2.28 “A” PILLAR TRIM 		1457
9.2.29 “B” PILLAR TRIMS 		1458
9.2.30 “C” PILLAR TRIM 		1459
9.2.31 “D” PILLAR TRIM 		1460
9.2.32 REAR QUARTER TRIM 		1461
9.2.33 GRAB HANDLES 		1461
9.2.34 SUNVISOR 		1462
9.2.35 PLENUM COVER ASSEMBLY 		1463
9.2.36 STONE GUARD 		1463
9.2.37 FRONT WHEEL ARCH LINER 		1463
9.2.38 GEAR LEVER BOOT 		1464
9.2.39 BONNET INSULATION 		1464
9.2.40 FUEL FILLER ASSEMBLY 		1465
9.2.41 GLASS 		1467
9.2.42 ROOF LINER ASSEMBLY 		1472
9.2.43 FRONT FENDER 		1473
9.2.44 FRONT WHEEL ARCH COVER 		1474
9.2.45 SILL FINISHER 		1474
9.2.46 REAR WHEEL ARCH LINER 		1475
9.2.47 SIDE FOOT STEP 		1476
9.2.48 SPOILER 		1477
9.3 BODY REPAIR 		1478
HVAC 		1490
10.1 GENERAL INFORMATION 		1498
10.1.1 SPECIFICATIONS 		1498
10.1.2 TIGHTENING TORQUES 		1500
10.1.3 PRECAUTIONS 		1505
10.1.4 HVAC SYSTEM LAYOUT AND WORKING 		1507
10.1.5 COMPONENTS OF HVAC 		1511
10.1.5.1 CONTROL PANEL 		1512
10.1.5.2 FRONT HVAC UNIT 		1515
10.1.5.3 ROOF AC UNIT (if fitted 		1517
10.1.5.4 COMPRESSOR 		1519
10.1.5.5 CONDENSER 		1520
10.1.5.6 THERMISTER OR THERMO SENSOR 		1521
10.1.5.7 TRINARY PRESSURE SWITCH 		1523
10.1.5.8 ACTUATOR 		1524
10.1.5.9 AIR INLET ACTUATOR 		1528
10.1.5.10 REAR BLOWER SWITCH 		1528
10.1.6 TROUBLESHOOTING 		1530
10.2 MAINTENANCE 		1543
10.2.1 PRELIMINARY INSPECTION 		1543
A. AC SYSTEM PERFORMANCE TEST 		1543
B. LEAK DETECTION 		1545
10.2.2 REGULAR MAINTENANCE 		1545
A. REFRIGERANT RECOVERY, RECYCLINGAND RECHARGING 		1545
B. FLUSHING OF AC SYSTEM 		1547
C. REPLENISHING COMPRESSOR OIL 		1548
D. PRESSURE TEST USING MANIFOLD GAUGES 		1549
10.3 ON VEHICLE REPAIRS 		1551
10.3.1 CONTROL PANEL ASSEMBLY 		1551
10.3.2 COMPRESSOR 		1551
10.3.3 FRONT HVAC UNIT 		1552
10.3.4 ROOF AC UNIT 		1553
10.3.5 HEATER HOSE 		1554
10.3.6 BLOWER (FRONT HVAC UNIT 		1555
10.3.7 BLOWER CONTROL MODULE 		1555
10.3.8 PRESSURE SWITCH 		1556
10.3.9 CONDENSER 		1556
10.3.10 REFRIGERANT HOSES/PIPES 		1557
10.3.11 FRONT AC DUCTING 		1558
10.3.12 CONDENSER SEALING DUCT 		1559
10.3.13. RECEIVER DRIER BOTTLE 		1559
10.4 OVERHAULING 		1560
10.4.1 BLOWER 		1560
10.4.2 FRONT HVAC UNIT 		1562
10.4.3 ROOF AC 		1569
10.4.4 COMPRESSOR 		1571
10.4.5 DO’S AND DONT’S FOR A/C SYSTEM 		1574
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