NANO
|
NANO |
1 |
|
NANO MY13 |
1 |
|
1. GENERAL |
7 |
|
1.1 AN OVERVIEW - NANO |
15 |
|
1.2 ABBREVIATIONS |
16 |
|
1.3 LIFTING, JACKING, TOWING POINTS |
19 |
|
1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
22 |
|
1.5 AGGREGATE NUMBERING SYSTEM |
23 |
|
1.6 TECHNICAL SPECIFICATIONS |
26 |
|
1.7 VEHICLE DIMENSIONS |
28 |
|
1.8 FUEL, LUBRICANTS & COOLANTS |
29 |
|
1.9 SERVICE SCHEDULE |
32 |
|
2. PRECAUTIONS |
35 |
|
2.1 GENERAL SAFETY PRECAUTIONS |
41 |
|
2.2 GENERAL SERVICE PRECAUTIONS |
45 |
|
3. ENGINE |
47 |
|
3.1 GENERAL INFORMATION |
55 |
|
TECHNICAL SPECIFICATIONS |
57 |
|
FEATURES OF 273 MPFI ENGINE |
58 |
|
TIGHTENING TORQUE |
59 |
|
SPECIAL TOOLS & EQUIPMENTS |
61 |
|
GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
|
3.2 ON VEHICLE PROCEDURES |
69 |
|
IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
|
ENGINE OIL REPLACEMENT |
73 |
|
OIL FILTER REPLACEMENT |
74 |
|
AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
|
FUEL FILTER REPLACEMENT |
76 |
|
TAPPET SETTING |
77 |
|
ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
|
COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
|
TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
|
CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
|
COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
|
3.3 ENGINE MECHANICAL |
91 |
|
PRELIMINARY INSPECTION OF ENGINE |
93 |
|
REMOVAL OF ENGINE FROM VEHICLE |
95 |
|
3.3.1 CYLINDER HEAD |
99 |
|
GENERAL DESCRIPTION |
101 |
|
EXPLODED VIEW |
102 |
|
CYLINDER HEAD OVERHAUL |
104 |
|
CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
|
DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
|
INSPECTION & REPAIR DATA |
111 |
|
ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
|
3.3.2 ENGINE BLOCK |
123 |
|
GENERAL DESCRIPTION |
125 |
|
EXPLODED VIEW |
126 |
|
ENGINE BLOCK OVERHAUL |
128 |
|
DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
|
INSPECTION & REPAIR DATA |
133 |
|
ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
|
REFITMENT OF ENGINE ACCESSORIES |
156 |
|
ENGINE TESTING |
158 |
|
INSTALLATION OF ENGINE ON VEHICLE |
158 |
|
3.4 ACCELERATOR |
159 |
|
EXPLODED VIEWS & CABLE ROUTING |
161 |
|
SYSTEM MAINTENANCE |
163 |
|
3.5 COOLING SYSTEM |
167 |
|
GENERAL DESCRIPTION |
169 |
|
SYSTEM SCHEMATICS |
169 |
|
EXPLODED VIEWS |
170 |
|
SPECIFICATIONS |
172 |
|
SYSTEM COMPONENTS |
173 |
|
SYSTEM MAINTENANCE |
174 |
|
3.6 LUBRICATION SYSTEM |
183 |
|
GENERAL DESCRIPTION |
185 |
|
SYSTEM SCHEMATICS |
185 |
|
SPECIFICATIONS |
186 |
|
SYSTEM MAINTENANCE |
187 |
|
3.7 FUEL SYSTEM |
199 |
|
GENERAL DESCRIPTION |
201 |
|
SYSTEM SCHEMATICS |
201 |
|
EXPLODED VIEWS |
202 |
|
PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
|
SYSTEM COMPONENTS |
204 |
|
SYSTEM MAINTENANCE |
208 |
|
EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
|
3.8 INTAKE SYSTEM |
221 |
|
GENERAL DESCRIPTION |
223 |
|
EXPLODED VIEWS |
224 |
|
SYSTEM MAINTENANCE |
225 |
|
3.9 EXHAUST SYSTEM |
231 |
|
GENERAL DESCRIPTION |
233 |
|
EXPLODED VIEWS |
234 |
|
TIGHTENING TORQUE |
235 |
|
SYSTEM COMPONENTS |
236 |
|
SYSTEM MAINTENANCE |
238 |
|
3.10 IGNITION SYSTEM |
243 |
|
GENERAL DESCRIPTION |
245 |
|
SYSTEM SCHEMATICS |
245 |
|
SYSTEM MAINTENANCE |
246 |
|
3.11 ENGINE MANAGEMENT SYSTEM |
251 |
|
ABBREVIATIONS |
253 |
|
AN OVERVIEW |
254 |
|
3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
|
ECU BLOCK DIAGRAM |
256 |
|
ECU PIN ASSIGNMENT DETAILS |
257 |
|
ECU HANDLING AND CARE |
258 |
|
ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
|
3.11.2 SENSORS |
260 |
|
CRANK SHAFT POSITION SENSOR |
260 |
|
COOLANT TEMPERATURE SENSOR |
261 |
|
T-MAP SENSOR |
263 |
|
KNOCK SENSOR |
264 |
|
THROTTLE POSITION SENSOR |
265 |
|
LAMBDA (OXYGEN) SENSOR |
268 |
|
VEHICLE SPEED SENSOR |
269 |
|
3.11.3 ACTUATORS |
271 |
|
CANISTER PURGE VALVE |
271 |
|
FUEL INJECTOR |
272 |
|
IGNITION COIL |
274 |
|
INTAKE AIR CONTROL VALVE (IACV) |
277 |
|
COMPONENT FITMENT DATA |
279 |
|
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
|
DTC LIST |
283 |
|
LAPTOP BASED DIAGNOSTIC TESTER |
293 |
|
BLINK CODE |
308 |
|
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
|
REPAIRING STEPS |
310 |
|
VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
|
SENSOR AND ACTUATOR TESTING |
312 |
|
EMERGENCY SERVICE TIPS |
314 |
|
4. DRIVETRAIN |
315 |
|
4.1 CLUTCH |
321 |
|
4.1.1 GENERAL INFORMATION |
323 |
|
TECHNICAL SPECIFICATIONS |
323 |
|
CONSTRUCTION |
326 |
|
PRECAUTIONS |
328 |
|
TIGHTENING TORQUES |
329 |
|
SPECIAL TOOLS |
330 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
|
TROUBLE SHOOTING |
334 |
|
MAINTENANCE AND REPAIR |
335 |
|
A. PRELIMINARY INSPECTION |
335 |
|
B. CLUTCH SLIPPAGE TEST |
335 |
|
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
|
D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
|
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
|
4.1.2 OVERHAUL |
337 |
|
EXPLODED VIEWS |
337 |
|
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
|
B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
|
C. CLUTCH CABLE REPLACEMENT |
344 |
|
4.2 TRANSAXLE TA-59 |
347 |
|
4.2.1 GENERAL INFORMATION |
349 |
|
TECHNICAL SPECIFICATION |
349 |
|
CONSTRUCTION |
349 |
|
PRECAUTIONS |
350 |
|
TIGHTENING TORQUES |
351 |
|
SPECIAL TOOLS |
354 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
358 |
|
TRANSAXLE OIL REPLACEMENT |
359 |
|
4.2.2 OVERHAUL |
360 |
|
EXPLODED VIEWS |
360 |
|
COMPONENT IDENTIFICATION |
367 |
|
PRECAUTIONS |
369 |
|
REMOVAL OF TRANSAXLE FROM VEHICLE |
369 |
|
TRANSAXLE DISMANTLING |
372 |
|
INPUT SHAFT ASSEMBLY |
376 |
|
LAY SHAFT ASSEMBLY |
381 |
|
SHIFTER SHAFT AND SHIFTER FORK |
387 |
|
DIFFERENTIAL ASSEMBLY |
390 |
|
REAR HALF HOUSING TOP COVER ASSEMBLY |
394 |
|
REAR HALF HOUSING ASSEMBLY |
400 |
|
FRONT HALF HOUSING |
402 |
|
TRANSAXLE ASSEMBLY |
404 |
|
A. SHIM SELECTION |
404 |
|
B. ASSEMBLING THE TRANSAXLE |
405 |
|
GEAR SHIFTER LINKAGE |
409 |
|
A. GEAR SHIFTER CABLE REPLACEMENT |
409 |
|
B. GEAR SHIFTER ADJUSTMENT |
410 |
|
4.3 DRIVESHAFT |
411 |
|
4.3.1 GENERAL INFORMATION |
413 |
|
TIGHTENING TORQUE |
413 |
|
SPECIAL TOOL |
414 |
|
CONSTRUCTIONAL DETAILS |
415 |
|
EXPLODED VIEW - DRIVESHAFT |
415 |
|
COMPONENT DESCRIPTION |
416 |
|
TROUBLESHOOTING AND DIAGNOSIS |
417 |
|
4.3.2 ON VEHICLE REPAIRS |
418 |
|
PRECAUTIONS |
418 |
|
REMOVAL FROM VEHICLE |
420 |
|
DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
|
5. SUSPENSION SYSTEM |
429 |
|
5.1 GENERAL INFORMATION |
435 |
|
TECHNICAL SPECIFICATIONS |
435 |
|
TIGHTENING TORQUES |
436 |
|
SPECIAL TOOLS |
439 |
|
LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
|
LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
|
MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
|
TROUBLESHOOTING AND DIAGNOSIS |
446 |
|
5.2 ON VEHICLE REPAIRS |
449 |
|
FRONT SUSPENSION COMPONENTS |
449 |
|
STRUT |
449 |
|
ANTI-ROLL BAR |
455 |
|
LOWER ARM |
456 |
|
WHEEL BEARING |
458 |
|
REAR SUSPENSION COMPONENTS |
461 |
|
SHOCK ABSORBER |
462 |
|
COIL SPRING |
463 |
|
BUMP STOPPER AND SPRING UPPER SEAT |
464 |
|
SEMI TRAILING ARM |
465 |
|
WHEEL HUB AND WHEEL BEARING |
468 |
|
5.3 WHEELS AND TYRES |
473 |
|
5.3.1 GENERAL INFORMATION |
473 |
|
TECHNICAL SPECIFICATIONS |
473 |
|
TIGHTENING TORQUE |
474 |
|
EXPLODED VIEW |
475 |
|
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
|
5.3.2 ON VEHICLE REPAIRS |
477 |
|
WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
|
WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
|
WHEEL BALANCING |
480 |
|
WHEEL RUNOUT |
481 |
|
TYRE REPLACEMENT |
482 |
|
WHEEL ASSEMBLY REPLACEMENT |
483 |
|
REPAIRING TUBELESS TYRE PUNCTURE |
483 |
|
TYRE DIAGNOSIS |
484 |
|
6. BRAKE SYSTEM |
493 |
|
6.1 GENERAL INFORMATION |
499 |
|
TECHNICAL SPECIFICATIONS |
499 |
|
TIGHTENING TORQUES |
500 |
|
SPECIAL TOOLS |
504 |
|
SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
|
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
|
FRONT DRUM BRAKES |
507 |
|
REAR DRUM BRAKES |
508 |
|
AUTO INCREMENTAL BRAKE |
509 |
|
TANDEM MASTER CYLINDER (TMC) |
510 |
|
TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
|
WHEEL CYLINDER |
514 |
|
PARKING BRAKES |
515 |
|
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
|
BLEEDING OF HYDRAULIC SYSTEM |
521 |
|
TROUBLESHOOTING AND DIAGNOSIS |
523 |
|
6.4 ON VEHICLE REPAIRS |
530 |
|
FRONT BRAKE COMPONENTS |
531 |
|
FRONT BRAKE DRUM |
532 |
|
FRONT BRAKE SHOES |
534 |
|
FRONT BRAKE BACK PLATE |
539 |
|
REAR BRAKE COMPONENTS |
540 |
|
REAR BRAKE DRUM |
541 |
|
REAR BRAKE SHOES |
542 |
|
REAR BRAKE BACK PLATE |
544 |
|
TMC |
546 |
|
WHEEL CYLINDER |
555 |
|
PARKING BRAKES |
561 |
|
VACUUM BRAKE BOOSTER |
564 |
|
BRAKE HOSES/PIPES SCHEMATIC |
565 |
|
VACUUM LINES |
567 |
|
7. STEERING |
569 |
|
7.1 GENERAL INFORMATION |
575 |
|
TECHNICAL SPECIFICATIONS |
575 |
|
TIGHTENING TORQUES |
576 |
|
SPECIAL TOOLS |
578 |
|
EXPLODED VIEWS |
579 |
|
SCHEMATIC OF STEERING SYSTEM |
581 |
|
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
|
7.3 ON VEHICLE REPAIRS |
584 |
|
STEERING WHEEL |
586 |
|
STEERING COLUMN ASSEMBLY |
587 |
|
STEERING UPPER COLUMN |
589 |
|
INTERMEDIATE SHAFT |
589 |
|
STEERING RACK AND PINION ASSEMBLY |
590 |
|
OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
|
WHEEL ALIGNMENT |
601 |
|
TROUBLESHOOTING AND DIAGNOSIS |
603 |
|
8. ELECTRICAL |
607 |
|
8.1 TECHNICAL SPECIFICATION |
613 |
|
8.2 GENERAL PRECAUTIONS |
614 |
|
8.3 BATTERY |
617 |
|
8.4 ALTERNATOR |
620 |
|
8.5 STARTER MOTOR |
641 |
|
8.6 LIGHTING SYSTEM |
659 |
|
8.7 HORN |
675 |
|
8.8 WIPER SYSTEM |
677 |
|
8.9 FLASHER |
686 |
|
8.10 FOG LAMP CONTROLLER |
687 |
|
8.11 BRAKE LAMP CHECK |
689 |
|
8.12 POWER SOCKET |
689 |
|
8.13 CIGARETTE LIGHTER (IF EQUIPPED) |
690 |
|
8.14 CENTRAL DOOR LOCKING |
691 |
|
8.15 POWER WINDOW SYSTEM |
694 |
|
8.16 INSTRUMENT CLUSTER |
697 |
|
8.17 ELECTRICAL SWITCHES |
700 |
|
8.18 ACCESSORY CONNECTORS |
710 |
|
8.19 FUSE BOX/RELAY LOCATION & DETAILS |
715 |
|
8.20 ELECTRIC WIRING AND FITMENT SCHEMATICS |
716 |
|
8.20.1 HARNESS & CONNECTOR DESCRIPTION |
716 |
|
8.20.2 UNDERSTANDING THE CIRCUIT SCHEMATIC |
718 |
|
8.20.3 CONNECTOR CODE/PIN NO./CONNECTOR LAYOUT |
719 |
|
8.20.4 ELECTRICAL SYMBOLS |
720 |
|
CIRCUIT SCHEMATICS |
722-723 |
|
1. TOPOLOGY / GROUND POINT LOCATION |
726-727 |
|
2. POWER DISTRIBUTION |
728-729 |
|
3. EARTH |
742-743 |
|
4. STARTER AND CHARGING |
744-745 |
|
5. EMS ECU |
746-747 |
|
6. FUEL PUMP |
750-751 |
|
7. HVAC |
752-753 |
|
8. RADIATOR FAN |
756-757 |
|
9. POWER WINDOW |
758-759 |
|
10. CENTRAL DOOR LOCKING |
762-763 |
|
11. INSTRUMENT CLUSTER |
766-767 |
|
12. FRONT WIPER |
772-773 |
|
13. EXTERIOR LIGHTING |
774-775 |
|
14. CAN CIRCUIT |
788-789 |
|
15. IMMOBILISER |
790-791 |
|
16. INTERIOR LAMPS |
792-793 |
|
17. HORN AND ROOF LAMP |
794-795 |
|
18. POWER SHOCKET AND CIGAR LIGHTER |
796-797 |
|
19. REVERSE PARKING AID |
798-799 |
|
20. MUSIC SYSTEM |
800-801 |
|
21. FUSE BOX DETAILS |
802-803 |
|
9. BODY |
804 |
|
9.1 GENERAL INFORMATION |
810 |
|
TECHNICAL SPECIFICATIONS |
810 |
|
TIGHTENING TORQUE |
811 |
|
9.2 ON VEHICLE REPAIRS |
815 |
|
EXPLODED VIEW - BUMPERS & HOOD |
815 |
|
FRONT BUMPER |
816 |
|
FENDER (SIDE BONNET) |
817 |
|
HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
818 |
|
FRONT DOOR |
822 |
|
REAR DOOR |
833 |
|
REAR SHELF |
842 |
|
TAILGATE |
842 |
|
REAR BUMPER |
843 |
|
DASHBOARD |
845 |
|
CENTER CONSOLE |
848 |
|
SEATS & BELTS |
849 |
|
OUTER REAR VIEW MIRROR (ORVM) |
859 |
|
SUN VISOR |
859 |
|
TRIMS |
860 |
|
FLOOR CARPET |
861 |
|
WINDSHIELD |
864 |
|
9.3 PAINT CARE |
866 |
|
9.4 BODY REPAIR DATA |
869 |
|
9.5 TROUBLESHOOTING AND DIAGNOSIS |
874 |
|
10. HVAC |
876 |
|
10.1 GENERAL INFORMATION |
882 |
|
TECHNICAL SPECIFICATIONS |
882 |
|
TIGHTENING TORQUES |
883 |
|
GENERAL PRECAUTIONS |
885 |
|
COMPONENT DESCRIPTION |
891 |
|
10.2 MAINTENANCE OF AC/HVAC SYSTEM |
894 |
|
TROUBLESHOOTING AND DIAGNOSIS |
895 |
|
PRESSURE TEST USING MANIFOLD GAUGES |
908 |
|
FLUSHING OF AC SYSTEM |
913 |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
915 |
|
A/C SYSTEM PERFORMANCE TEST |
917 |
|
LEAK TEST SYSTEM |
917 |
|
10.3 ON VEHICLE REPAIRS |
918 |
|
CONTROL PANEL ASSEMBLY |
919 |
|
A/C COMPRESSOR |
920 |
|
HVAC UNIT |
931 |
|
BLOWER UNIT |
935 |
|
BLOWER RESISTER |
935 |
|
FILTER |
936 |
|
EVAPORATOR AND EXPANSION VALVE |
937 |
|
HEATER ASSEMBLY |
939 |
|
KINEMATICS |
940 |
|
PRESSURE SWITCH |
940 |
|
CONDENSER ASSEMBLY |
941 |
|
DRIER CARTRIDGE/R.D. BOTTLE |
943 |
|
CONDENSER FAN AND CONDENSER MOTOR |
945 |
|
REFRIGERANT LINES |
946 |
|
HEATER LINES |
948 |
|
NANO AMT |
950 |
|
1. GENERAL |
7 |
|
1.1 AN OVERVIEW - NANO |
15 |
|
1.2 ABBREVIATIONS |
16 |
|
1.3 LIFTING, JACKING, TOWING POINTS |
19 |
|
1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
22 |
|
1.5 AGGREGATE NUMBERING SYSTEM |
23 |
|
1.6 TECHNICAL SPECIFICATIONS |
26 |
|
1.7 VEHICLE DIMENSIONS |
28 |
|
1.8 FUEL, LUBRICANTS & COOLANTS |
29 |
|
1.9 SERVICE SCHEDULE |
32 |
|
2. PRECAUTIONS |
35 |
|
2.1 GENERAL SAFETY PRECAUTIONS |
41 |
|
2.2 GENERAL SERVICE PRECAUTIONS |
45 |
|
3. ENGINE |
47 |
|
3.1 GENERAL INFORMATION |
55 |
|
TECHNICAL SPECIFICATIONS |
57 |
|
FEATURES OF 273 MPFI ENGINE |
58 |
|
TIGHTENING TORQUE |
59 |
|
SPECIAL TOOLS & EQUIPMENTS |
61 |
|
GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
|
3.2 ON VEHICLE PROCEDURES |
69 |
|
IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
|
ENGINE OIL REPLACEMENT |
73 |
|
OIL FILTER REPLACEMENT |
74 |
|
AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
|
FUEL FILTER REPLACEMENT |
76 |
|
TAPPET SETTING |
77 |
|
ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
|
COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
|
TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
|
CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
|
COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
|
3.3 ENGINE MECHANICAL |
91 |
|
PRELIMINARY INSPECTION OF ENGINE |
93 |
|
REMOVAL OF ENGINE FROM VEHICLE |
95 |
|
3.3.1 CYLINDER HEAD |
99 |
|
GENERAL DESCRIPTION |
101 |
|
EXPLODED VIEW |
102 |
|
CYLINDER HEAD OVERHAUL |
104 |
|
CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
|
DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
|
INSPECTION & REPAIR DATA |
111 |
|
ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
|
3.3.2 ENGINE BLOCK |
123 |
|
GENERAL DESCRIPTION |
125 |
|
EXPLODED VIEW |
126 |
|
ENGINE BLOCK OVERHAUL |
128 |
|
DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
|
INSPECTION & REPAIR DATA |
133 |
|
ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
|
REFITMENT OF ENGINE ACCESSORIES |
156 |
|
ENGINE TESTING |
158 |
|
INSTALLATION OF ENGINE ON VEHICLE |
158 |
|
3.4 ACCELERATOR |
159 |
|
EXPLODED VIEWS & CABLE ROUTING |
161 |
|
SYSTEM MAINTENANCE |
163 |
|
ENGINE COOLING COMPONENTS_NANO AMT |
952 |
|
1.0 RADIATOR LOCATION ON VEHICLE |
956 |
|
2.0 TECHNICAL SPECIFICATIONS |
957 |
|
3.0 RADIATOR REMOVAL AND REFITMENTON VEHICLE |
958 |
|
4.0 RADIATOR FAN REMOVAL AND REFITMENTPROCEDURE |
967 |
|
5.0 COOLANT TANK REMOVAL AND REFITMENTON VEHICLE |
971 |
|
6.0 OIL FILTER REMOVAL AND REFITMENTPROCEDURES ON VEHICLE |
973 |
|
3.6 LUBRICATION SYSTEM |
183 |
|
GENERAL DESCRIPTION |
185 |
|
SYSTEM SCHEMATICS |
185 |
|
SPECIFICATIONS |
186 |
|
SYSTEM MAINTENANCE |
187 |
|
3.7 FUEL SYSTEM |
199 |
|
GENERAL DESCRIPTION |
201 |
|
SYSTEM SCHEMATICS |
201 |
|
EXPLODED VIEWS |
202 |
|
PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
|
SYSTEM COMPONENTS |
204 |
|
SYSTEM MAINTENANCE |
208 |
|
EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
|
3.8 INTAKE SYSTEM |
221 |
|
GENERAL DESCRIPTION |
223 |
|
EXPLODED VIEWS |
224 |
|
SYSTEM MAINTENANCE |
225 |
|
3.9 EXHAUST SYSTEM |
231 |
|
GENERAL DESCRIPTION |
233 |
|
EXPLODED VIEWS |
234 |
|
TIGHTENING TORQUE |
235 |
|
SYSTEM COMPONENTS |
236 |
|
SYSTEM MAINTENANCE |
238 |
|
3.10 IGNITION SYSTEM |
243 |
|
GENERAL DESCRIPTION |
245 |
|
SYSTEM SCHEMATICS |
245 |
|
SYSTEM MAINTENANCE |
246 |
|
3.11 ENGINE MANAGEMENT SYSTEM |
251 |
|
ABBREVIATIONS |
253 |
|
AN OVERVIEW |
254 |
|
3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
|
ECU BLOCK DIAGRAM |
256 |
|
ECU PIN ASSIGNMENT DETAILS |
257 |
|
ECU HANDLING AND CARE |
258 |
|
ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
|
3.11.2 SENSORS |
260 |
|
CRANK SHAFT POSITION SENSOR |
260 |
|
COOLANT TEMPERATURE SENSOR |
261 |
|
T-MAP SENSOR |
263 |
|
KNOCK SENSOR |
264 |
|
THROTTLE POSITION SENSOR |
265 |
|
LAMBDA (OXYGEN) SENSOR |
268 |
|
VEHICLE SPEED SENSOR |
269 |
|
3.11.3 ACTUATORS |
271 |
|
CANISTER PURGE VALVE |
271 |
|
FUEL INJECTOR |
272 |
|
IGNITION COIL |
274 |
|
INTAKE AIR CONTROL VALVE (IACV) |
277 |
|
COMPONENT FITMENT DATA |
279 |
|
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
|
DTC LIST |
283 |
|
LAPTOP BASED DIAGNOSTIC TESTER |
293 |
|
BLINK CODE |
308 |
|
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
|
REPAIRING STEPS |
310 |
|
VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
|
SENSOR AND ACTUATOR TESTING |
312 |
|
EMERGENCY SERVICE TIPS |
314 |
|
4. DRIVETRAIN |
315 |
|
4.1 CLUTCH |
321 |
|
4.1.1 GENERAL INFORMATION |
323 |
|
TECHNICAL SPECIFICATIONS |
323 |
|
CONSTRUCTION |
326 |
|
PRECAUTIONS |
328 |
|
TIGHTENING TORQUES |
329 |
|
SPECIAL TOOLS |
330 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
|
TROUBLE SHOOTING |
334 |
|
MAINTENANCE AND REPAIR |
335 |
|
A. PRELIMINARY INSPECTION |
335 |
|
B. CLUTCH SLIPPAGE TEST |
335 |
|
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
|
D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
|
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
|
4.1.2 OVERHAUL |
337 |
|
EXPLODED VIEWS |
337 |
|
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
|
B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
|
C. CLUTCH CABLE REPLACEMENT |
344 |
|
TRANSAXLE-AMT |
978 |
|
1.0 AMT-KIT LOCATION ON VEHICLE |
982 |
|
2.0 PRECAUTIONS (DO’S AND DON’TS):-DO’S |
983 |
|
3.0 TECHNICAL SPECIFICATIONS |
985 |
|
4.0 TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS |
986 |
|
5.0 SPECIAL TOOLS |
988 |
|
6.0 AMT UNIT REMOVAL ANDINSTALLATION PROCEDURES ONVEHICLE |
990 |
|
7.0 MECHATRONIC GEAR ACTUATORUNIT (MGA) REMOVAL AND RE-FITMENTON BENCH |
996 |
|
8.0 TRANSMISSION CONTROL UNIT (TCU)REMOVAL AND RE-FITMENT ON BENCH |
998 |
|
9.0 OIL TANK REMOVAL AND REFITMENTON BENCH |
1001 |
|
10.0 DC MOTOR REMOVAL AND REFITMENTON BENCH |
1003 |
|
11.0 CLUTCH POSITION SENSORREMOVAL AND RE-FITMENT ON BENCH |
1004 |
|
12.0 HYDRAULIC OIL ACCUMLATORREMOVAL AND RE-FITMENT ON BENCH |
1004 |
|
13.0 POWER UNIT (PWU) BASE PLATEREMOVAL AND RE-FITMENT ON BENCH |
1005 |
|
4.3 DRIVESHAFT |
411 |
|
4.3.1 GENERAL INFORMATION |
413 |
|
TIGHTENING TORQUE |
413 |
|
SPECIAL TOOL |
414 |
|
CONSTRUCTIONAL DETAILS |
415 |
|
EXPLODED VIEW - DRIVESHAFT |
415 |
|
COMPONENT DESCRIPTION |
416 |
|
TROUBLESHOOTING AND DIAGNOSIS |
417 |
|
4.3.2 ON VEHICLE REPAIRS |
418 |
|
PRECAUTIONS |
418 |
|
REMOVAL FROM VEHICLE |
420 |
|
DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
|
GEAR SHIFTER CONSOLE |
1006 |
|
1.0 AUTOMATED MANUAL TRANSMISSION(AMT) GEARBOX SHIFTER AND SHIFTINGMECHANISM |
1009 |
|
2.0 GEAR SHIFTER CENTER CONSOLEREMOVAL AND RE-FITMENT ONVEHICLE |
1011 |
|
5. SUSPENSION SYSTEM |
429 |
|
5.1 GENERAL INFORMATION |
435 |
|
TECHNICAL SPECIFICATIONS |
435 |
|
TIGHTENING TORQUES |
436 |
|
SPECIAL TOOLS |
439 |
|
LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
|
LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
|
MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
|
TROUBLESHOOTING AND DIAGNOSIS |
446 |
|
5.2 ON VEHICLE REPAIRS |
449 |
|
FRONT SUSPENSION COMPONENTS |
449 |
|
STRUT |
449 |
|
ANTI-ROLL BAR |
455 |
|
LOWER ARM |
456 |
|
WHEEL BEARING |
458 |
|
REAR SUSPENSION COMPONENTS |
461 |
|
SHOCK ABSORBER |
462 |
|
COIL SPRING |
463 |
|
BUMP STOPPER AND SPRING UPPER SEAT |
464 |
|
SEMI TRAILING ARM |
465 |
|
WHEEL HUB AND WHEEL BEARING |
468 |
|
5.3 WHEELS AND TYRES |
473 |
|
5.3.1 GENERAL INFORMATION |
473 |
|
TECHNICAL SPECIFICATIONS |
473 |
|
TIGHTENING TORQUE |
474 |
|
EXPLODED VIEW |
475 |
|
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
|
5.3.2 ON VEHICLE REPAIRS |
477 |
|
WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
|
WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
|
WHEEL BALANCING |
480 |
|
WHEEL RUNOUT |
481 |
|
TYRE REPLACEMENT |
482 |
|
WHEEL ASSEMBLY REPLACEMENT |
483 |
|
REPAIRING TUBELESS TYRE PUNCTURE |
483 |
|
TYRE DIAGNOSIS |
484 |
|
6. BRAKE SYSTEM |
493 |
|
6.1 GENERAL INFORMATION |
499 |
|
TECHNICAL SPECIFICATIONS |
499 |
|
TIGHTENING TORQUES |
500 |
|
SPECIAL TOOLS |
504 |
|
SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
|
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
|
FRONT DRUM BRAKES |
507 |
|
REAR DRUM BRAKES |
508 |
|
AUTO INCREMENTAL BRAKE |
509 |
|
TANDEM MASTER CYLINDER (TMC) |
510 |
|
TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
|
WHEEL CYLINDER |
514 |
|
PARKING BRAKES |
515 |
|
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
|
BLEEDING OF HYDRAULIC SYSTEM |
521 |
|
TROUBLESHOOTING AND DIAGNOSIS |
523 |
|
6.4 ON VEHICLE REPAIRS |
530 |
|
FRONT BRAKE COMPONENTS |
531 |
|
FRONT BRAKE DRUM |
532 |
|
FRONT BRAKE SHOES |
542 |
|
FRONT BRAKE BACK PLATE |
539 |
|
REAR BRAKE COMPONENTS |
540 |
|
REAR BRAKE DRUM |
541 |
|
REAR BRAKE SHOES |
542 |
|
REAR BRAKE BACK PLATE |
544 |
|
TMC |
546 |
|
WHEEL CYLINDER |
555 |
|
PARKING BRAKES |
561 |
|
VACUUM BRAKE BOOSTER |
564 |
|
BRAKE HOSES/PIPES SCHEMATIC |
565 |
|
VACUUM LINES |
567 |
|
7. STEERING |
569 |
|
7.1 GENERAL INFORMATION |
575 |
|
TECHNICAL SPECIFICATIONS |
575 |
|
TIGHTENING TORQUES |
576 |
|
SPECIAL TOOLS |
578 |
|
EXPLODED VIEWS |
579 |
|
SCHEMATIC OF STEERING SYSTEM |
581 |
|
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
|
7.3 ON VEHICLE REPAIRS |
584 |
|
STEERING WHEEL |
586 |
|
STEERING COLUMN ASSEMBLY |
587 |
|
STEERING UPPER COLUMN |
589 |
|
INTERMEDIATE SHAFT |
589 |
|
STEERING RACK AND PINION ASSEMBLY |
590 |
|
OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
|
WHEEL ALIGNMENT |
601 |
|
TROUBLESHOOTING AND DIAGNOSIS |
603 |
|
8. ELECTRICALS |
1016 |
|
1.0 EMS ECU AND AMT TCU CONNECTOR’S REMOVAL AND RE-FITMENT ON VEHICLE |
1019 |
|
1.1 PARTS LIST |
1019 |
|
1.2 EMS ECU CONNECTOR REMOVALAND RE-FITMENT ON VEHICLE |
1021 |
|
1.3 AMT TCU UNIT CONNECTOR’SREMOVAL AND RE-FIMENT ON VEHICLE |
1026 |
|
2.0 FOG LAMP REMOVAL AND REFITMENTON VEHICLE |
1030 |
|
3.0 HORN REMOVAL AND RE-FITMENT ONVEHICLE |
1033 |
|
4.0 AMBIENT TEMPERATURE SENSORREMOVAL AND RE-FITMENT ONVEHICLE |
1036 |
|
5.0 TRANSMISSION INPUT SPEEDSENSOR REMOVAL AND RE-FITMENT ONVEHICLE |
1040 |
|
6.0 EXHAUST FAN REMOVAL AND REFITMENTON VEHICLE |
1042 |
|
7.0 DIAGNOSTIC TROUBLE CODES FOR ELECTRONIC POWER ASSISTED STEERING |
1045 |
|
8.0 DIAGNOSTIC TROUBLE CODES FOR ENGINE MANAGEMENT SYSTEM |
1046 |
|
CIRCUIT SCHEMATICS |
1076-1077 |
|
INDEX AND COLOUR CODES |
1078-1079 |
|
SYMBOLS |
1080-1081 |
|
CONNECTOR DETAILS |
1082-1083 |
|
WIRING HARNESS TOPOLOGY |
1084-1085 |
|
POWER SUPPLY - 1 |
1086-1087 |
|
POWER SUPPLY - 2 |
1088-1089 |
|
POWER SUPPLY - 3 |
1090-1091 |
|
POWER SUPPLY - 4 |
1092-1093 |
|
POWER SUPPLY - 5 |
1094-1095 |
|
POWER SUPPLY - 6 |
1096-1097 |
|
POWER SUPPLY - 7 |
1098-1099 |
|
POWER SUPPLY - 8 |
1100-1101 |
|
POWER SUPPLY - 9 |
1102-1103 |
|
CIRCUIT SCHEMATIC - EARTH 1 |
1104-1105 |
|
CIRCUIT SCHEMATIC - EARTH 2 |
1106-1107 |
|
CIRCUIT SCHEMATIC - EARTH 3 |
1108-1109 |
|
CIRCUIT SCHEMATIC - EARTH 4 |
1110-1111 |
|
STARTING AND CHARGING |
1112-1113 |
|
ENGINE CONTROL (PETROL) - 1 |
1114-1115 |
|
ENGINE CONTROL (PETROL) - 2 |
1116-1117 |
|
ENGINE CONTROL (PETROL) - 3 |
1118-1119 |
|
ENGINE CONTROL (PETROL) - 4 |
1120-1121 |
|
FUEL PUMP |
1122-1123 |
|
HVAC (MANUAL) |
1124-1125 |
|
RADIATOR FAN |
1126-1127 |
|
POWER WINDOWS - 1 |
1128-1129 |
|
POWER WINDOWS - 2 |
1130-1131 |
|
REMOTE KEYLESS ENTRY - 1 |
1132-1133 |
|
REMOTE KEYLESS ENTRY - 2 |
1134-1135 |
|
CENTRAL DOOR LOCKING |
1136-1137 |
|
CLUSTER |
1138-1139 |
|
CLUSTER - 2 |
1140-1141 |
|
FRONT WIPER (PASSIVE) |
1142-1143 |
|
EXTERIOR LIGHTING - 1 |
1144-1145 |
|
EXTERIOR LIGHTING - 2 |
1146-1147 |
|
EXTERIOR LIGHTING - 3 |
1148-1149 |
|
EXTERIOR LIGHTING - 4 |
1150-1151 |
|
EXTERIOR LIGHTING - 5 |
1152-1153 |
|
CAN |
1154-1155 |
|
INTERIOR LAMPS |
1156-1157 |
|
EPAS |
1158-1159 |
|
HORN |
1160-1161 |
|
POWER SOCKET AND CIGAR LIGHTER |
1162-1163 |
|
REAR PARKING AIS |
1164-1165 |
|
AUTO TRANSMISSION (AMT) |
1166-1167 |
|
AUDIO SYSTEM |
1168-1169 |
|
AUDIO SYSTEM - 2 |
1170-1171 |
|
9. BODY |
804 |
|
9.1 GENERAL INFORMATION |
810 |
|
TECHNICAL SPECIFICATIONS |
810 |
|
TIGHTENING TORQUE |
811 |
|
9.2 ON VEHICLE REPAIRS |
815 |
|
EXPLODED VIEW - BUMPERS & HOOD |
815 |
|
FRONT BUMPER |
816 |
|
FENDER (SIDE BONNET) |
817 |
|
HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
818 |
|
FRONT DOOR |
822 |
|
REAR DOOR |
833 |
|
REAR SHELF |
842 |
|
TAILGATE |
842 |
|
REAR BUMPER |
843 |
|
DASHBOARD |
845 |
|
CENTER CONSOLE |
848 |
|
SEATS & BELTS |
849 |
|
OUTER REAR VIEW MIRROR (ORVM) |
859 |
|
SUN VISOR |
859 |
|
TRIMS |
860 |
|
FLOOR CARPET |
861 |
|
WINDSHIELD |
864 |
|
9.3 PAINT CARE |
866 |
|
9.4 BODY REPAIR DATA |
869 |
|
9.5 TROUBLESHOOTING AND DIAGNOSIS |
874 |
|
10. HVAC |
876 |
|
10.1 GENERAL INFORMATION |
882 |
|
TECHNICAL SPECIFICATIONS |
882 |
|
TIGHTENING TORQUES |
883 |
|
GENERAL PRECAUTIONS |
885 |
|
COMPONENT DESCRIPTION |
891 |
|
10.2 MAINTENANCE OF AC/HVAC SYSTEM |
894 |
|
TROUBLESHOOTING AND DIAGNOSIS |
895 |
|
PRESSURE TEST USING MANIFOLD GAUGES |
908 |
|
FLUSHING OF AC SYSTEM |
913 |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
915 |
|
A/C SYSTEM PERFORMANCE TEST |
917 |
|
LEAK TEST SYSTEM |
917 |
|
10.3 ON VEHICLE REPAIRS |
918 |
|
CONTROL PANEL ASSEMBLY |
919 |
|
AC COMPRESSOR |
1172 |
|
1.0 AC COMPRESSOR LOCATION ON VEHICLE |
1176 |
|
2.0 TECHNICAL SPECIFICATIONS |
1177 |
|
3.0 TIGHTENING TORQUES |
1178 |
|
4.0 PRECAUTIONS |
1179 |
|
5.0 EXPLODED VIEW AND PART LIST |
1182 |
|
6.0 AC COMPRESSOR REMOVAL ANDRE-FITMENT ON VEHICLE |
1183 |
|
HVAC UNIT |
931 |
|
BLOWER UNIT |
935 |
|
BLOWER RESISTER |
935 |
|
FILTER |
936 |
|
EVAPORATOR AND EXPANSION VALVE |
937 |
|
HEATER ASSEMBLY |
939 |
|
KINEMATICS |
940 |
|
PRESSURE SWITCH |
940 |
|
CONDENSER ASSEMBLY |
941 |
|
DRIER CARTRIDGE/R.D. BOTTLE |
943 |
|
CONDENSER FAN AND CONDENSER MOTOR |
945 |
|
REFRIGERANT LINES |
946 |
|
HEATER LINES |
948 |
|
NANO CNG |
1190 |
|
GENERAL |
1196 |
|
1. INTRODUCTION TO CNG SYSTEM |
1200 |
|
2. BENEFITS OF CNG |
1200 |
|
3. FEATURES OF CNG BI-FUEL SYSTEM |
1200 |
|
4. GENERAL INSTRUCTION / PRECAUTIONSWHILE WORKING ON CNG VEHICLE |
1201 |
|
5. IN CASE OF LEAKAGE |
1203 |
|
6. TECHNICAL SPECIFICATIONS |
1205 |
|
7. TIGHTENING TORQUE |
1209 |
|
8. SPECIAL TOOLS |
1214 |
|
9. LIST OF APPROVED CNG CYLINDER TESTING STATION |
1215 |
|
10. SERVICE SCHEDULE |
1216 |
|
11. LUBRICANTS AND COOLANTS |
1220 |
|
2. PRECAUTIONS |
35 |
|
2.1 GENERAL SAFETY PRECAUTIONS |
41 |
|
2.2 GENERAL SERVICE PRECAUTIONS |
45 |
|
ENGINE |
1222 |
|
1. TECHNICAL SPECIFICATION |
1226 |
|
2. REPAIR DATA |
1227 |
|
A. BELT TENSION VALUES |
1227 |
|
3. ENGINE CONTRUCTIONAL DETAIL |
1228 |
|
A. ENGINE |
1228 |
|
B. INTAKE MANIFOLD |
1228 |
|
4. GENERAL SYSTEM OVERVIEW OF Bi-FUEL ENGINE MANAGEMENT SYSTEM |
1230-1231 |
|
5. REMOVAL AND REFITMENT OF ENGINEACCESS WINDOW AND ENGINE COVER |
1234 |
|
6. GAS INJECTOR |
1237 |
|
7. GAS RAIL |
1239 |
|
8. PRESSURE AND TEMPERATURE (P&T)SENSOR |
1241 |
|
9. DIAGNOSTIC USER MANUAL |
1243 |
|
4. DRIVETRAIN |
315 |
|
4.1 CLUTCH |
321 |
|
4.1.1 GENERAL INFORMATION |
321 |
|
TECHNICAL SPECIFICATIONS |
321 |
|
CONSTRUCTION |
326 |
|
PRECAUTIONS |
328 |
|
TIGHTENING TORQUES |
329 |
|
SPECIAL TOOLS |
330 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
|
TROUBLE SHOOTING |
334 |
|
MAINTENANCE AND REPAIR |
335 |
|
A. PRELIMINARY INSPECTION |
335 |
|
B. CLUTCH SLIPPAGE TEST |
335 |
|
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
|
D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
|
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
|
4.1.2 OVERHAUL |
337 |
|
EXPLODED VIEWS |
337 |
|
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
|
B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
|
C. CLUTCH CABLE REPLACEMENT |
344 |
|
TRANSAXLE |
1264 |
|
1 GENERAL INFORMATION |
1270 |
|
A. TECHNICAL SPECIFICATIONS |
1270 |
|
B. PRECAUTIONS |
1271 |
|
C. TIGHTENING TORQUES |
1272 |
|
D. SPECIAL TOOLS |
1275 |
|
E. GENERAL SYMPTOMS AND DIAGNOSIS |
1279 |
|
F. TRANSAXLE OIL REPLACEMENT |
1280 |
|
2. OVERHAULING (EXPLODED VIEWS) |
1281 |
|
A. TRANSAXLE HOUSING |
1281 |
|
B. INPUT SHAFT AND LAY SHAFT |
1282 |
|
C. SHIFTER SHAFT AND SHIFTER SLEEVE |
1283 |
|
D. DIFFERENTIAL |
1284 |
|
E. TOP COVER ASSEMBLY |
1285 |
|
F. SHIFTER LINKAGE |
1286 |
|
3. COMPONENT IDENTIFICATION |
1288 |
|
A. SHIFTER SHAFTS |
1288 |
|
B. SHIFTER FORKS (DOGS) |
1288 |
|
C. SHIFTER SLEEVE |
1289 |
|
4. REMOVAL OF TRANSAXLE FROM VEHICLE |
1290 |
|
5. TRANSAXLE DISMANTLING |
1293 |
|
6. INPUT SHAFT ASSEMBLY |
1297 |
|
7. LAYSHAFT ASSEMBLY |
1302 |
|
8. SHIFTER SHAFT AND SHIFTER FORK |
1308 |
|
9. REVERSE GEAR SHIFTER BRACKET - ASSEMBLY |
1309 |
|
10. DIFFERENTIAL ASSEMBLY |
1311 |
|
11. REAR HALF HOUSING TOP COVER ASSEMBLY |
1315 |
|
12. REAR HALF HOUSING ASSEMBLY |
1322 |
|
13. FRONT HALF HOUSING |
1324 |
|
14. TRANSAXLE ASSEMBLY |
1326 |
|
A. SHIM SELECTION |
1326 |
|
B. ASSEMBLING THE TRANSAXLE |
1327 |
|
15. GEAR SHIFTER LINKAGE |
1332 |
|
A. GEAR SHIFTER CABLE REPLACEMENT |
1332 |
|
B. GEAR SHIFTER ADJUSTMENT |
1334 |
|
4.3 DRIVESHAFT |
411 |
|
4.3.1 GENERAL INFORMATION |
413 |
|
TIGHTENING TORQUE |
413 |
|
SPECIAL TOOL |
414 |
|
CONSTRUCTIONAL DETAILS |
415 |
|
EXPLODED VIEW - DRIVESHAFT |
415 |
|
COMPONENT DESCRIPTION |
416 |
|
TROUBLESHOOTING AND DIAGNOSIS |
417 |
|
4.3.2 ON VEHICLE REPAIRS |
418 |
|
PRECAUTIONS |
418 |
|
REMOVAL FROM VEHICLE |
420 |
|
DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
|
5. SUSPENSION SYSTEM |
429 |
|
5.1 GENERAL INFORMATION |
435 |
|
TECHNICAL SPECIFICATIONS |
435 |
|
TIGHTENING TORQUES |
436 |
|
SPECIAL TOOLS |
439 |
|
LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
|
LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
|
MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
|
TROUBLESHOOTING AND DIAGNOSIS |
446 |
|
5.2 ON VEHICLE REPAIRS |
449 |
|
FRONT SUSPENSION COMPONENTS |
449 |
|
STRUT |
449 |
|
ANTI-ROLL BAR |
455 |
|
LOWER ARM |
456 |
|
WHEEL BEARING |
458 |
|
REAR SUSPENSION COMPONENTS |
461 |
|
SHOCK ABSORBER |
462 |
|
COIL SPRING |
463 |
|
BUMP STOPPER AND SPRING UPPER SEAT |
464 |
|
SEMI TRAILING ARM |
465 |
|
WHEEL HUB AND WHEEL BEARING |
468 |
|
5.3 WHEELS AND TYRES |
473 |
|
5.3.1 GENERAL INFORMATION |
473 |
|
TECHNICAL SPECIFICATIONS |
473 |
|
TIGHTENING TORQUE |
474 |
|
EXPLODED VIEW |
475 |
|
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
|
5.3.2 ON VEHICLE REPAIRS |
477 |
|
WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
|
WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
|
WHEEL BALANCING |
480 |
|
WHEEL RUNOUT |
481 |
|
TYRE REPLACEMENT |
482 |
|
WHEEL ASSEMBLY REPLACEMENT |
483 |
|
REPAIRING TUBELESS TYRE PUNCTURE |
483 |
|
TYRE DIAGNOSIS |
484 |
|
6. BRAKE SYSTEM |
493 |
|
6.1 GENERAL INFORMATION |
499 |
|
TECHNICAL SPECIFICATIONS |
499 |
|
TIGHTENING TORQUES |
500 |
|
SPECIAL TOOLS |
504 |
|
SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
|
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
|
FRONT DRUM BRAKES |
507 |
|
REAR DRUM BRAKES |
508 |
|
AUTO INCREMENTAL BRAKE |
509 |
|
TANDEM MASTER CYLINDER (TMC) |
510 |
|
TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
|
WHEEL CYLINDER |
514 |
|
PARKING BRAKES |
515 |
|
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
|
BLEEDING OF HYDRAULIC SYSTEM |
521 |
|
TROUBLESHOOTING AND DIAGNOSIS |
523 |
|
6.4 ON VEHICLE REPAIRS |
530 |
|
FRONT BRAKE COMPONENTS |
531 |
|
FRONT BRAKE DRUM |
532 |
|
FRONT BRAKE SHOES |
534 |
|
FRONT BRAKE BACK PLATE |
539 |
|
REAR BRAKE COMPONENTS |
540 |
|
REAR BRAKE DRUM |
541 |
|
REAR BRAKE SHOES |
542 |
|
REAR BRAKE BACK PLATE |
544 |
|
TMC |
546 |
|
WHEEL CYLINDER |
555 |
|
PARKING BRAKES |
561 |
|
VACUUM BRAKE BOOSTER |
564 |
|
BRAKE HOSES/PIPES SCHEMATIC |
565 |
|
VACUUM LINES |
567 |
|
FUEL SYSTEM |
1336 |
|
1 INTRODUCTION |
1340 |
|
A. CNG LAYOUT (ON VEHICLE) |
1341 |
|
2. CNG FUEL SYSTEM COMPONENTS |
1342 |
|
A. CNG CYLINDER |
1342 |
|
B. CYLINDER VALVE |
1344 |
|
C. LOW PRESSURE CNG FILTER |
1349 |
|
D. PRESSURE GAUGE |
1352 |
|
E. PRESSURE REGULATOR |
1353 |
|
F. HIGH PRESSURE (H.P) SENSOR |
1358 |
|
G. CNG RECEPTACLE VALVE |
1360 |
|
3. CNG TUBE FITTINGS / JOINTS TIGHTENING INSTRUCTIONS |
1363 |
|
A. SWAGING PROCEDURE |
1363 |
|
B. PROCEDURE FOR NPT THREAD ASSEMBLY |
1365 |
|
4. CNG LEAK DETECTION TESTING |
1367 |
|
5. TROUBLE SHOOTING |
1368 |
|
ELECTRICAL |
1370 |
|
1 TECHNICAL SPECIFICATION |
1374 |
|
2. LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE |
1375 |
|
3. INSTRUMENT CLUSTER |
1376 |
|
4. FUEL GAUGE |
1377 |
|
5. REMOVAL AND REFITTMENT OF BATTERY |
1378 |
|
6. STARTER MOTOR |
1379 |
|
A. EXPLODED VIEW |
1379 |
|
B. ON VEHICLE REMOVAL AND REFITTMENT OF STARTER MOTOR |
1379 |
|
C. STARTER MOTOR OVER HAULING |
1380 |
|
CIRCUIT SCHEMATICS |
1386-1387 |
|
FUSE BOX AND RELAY ( CABIN ) |
1390-1391 |
|
FUSE BOX AND RELAY ( BATTERY MOUNTED ) |
1392-1393 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 1 OF 5 ) |
1394-1395 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 2 OF 5 |
1396-1397 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 3 OF 5 ) |
1398-1399 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 4 OF 5) |
1400-1401 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 5 OF 5) |
1402-1403 |
|
FUSE DISTRIBUTION (SHEET 1 OF 6) |
1404-1405 |
|
FUSE DISTRIBUTION (SHEET 2 OF 6) |
1406-1407 |
|
FUSE DISTRIBUTION (SHEET 3 OF 6) |
1408-1409 |
|
FUSE DISTRIBUTION (SHEET 4 OF 6) |
1410-1411 |
|
FUSE DISTRIBUTION (SHEET 5 OF 6) |
1412-1413 |
|
FUSE DISTRIBUTION (SHEET 6 OF 6) |
1414-1415 |
|
DTC CODES |
1418-1419 |
|
NANO ePAS |
1456 |
|
STEERING |
1462 |
|
1.1 GENERAL INFORMATION |
1467 |
|
1.1.1 SPECIFICATIONS |
1467 |
|
1.1.2 SYSTEM LAYOUT |
1467 |
|
1.1.3 GENERAL DESCRIPTION |
1468 |
|
1.1.4 TIGHTENING TORQUES |
1469 |
|
1.1.5 SPECIAL TOOLS |
1471 |
|
1.2. MAINTENANCE, INSPECTION AND TEST |
1472 |
|
1.2.1 PRELIMINARY INSPECTION |
1472 |
|
1.2.2 REGULAR MAINTENANCE |
1473 |
|
1.2.3 ON VEHICLE REPAIRS |
1475 |
|
1.2.3.1 STEERING WHEEL REMOVAL |
1475 |
|
1.2.3.2 STEERING COLUMN REMOVAL |
1476 |
|
1.2.3.3 INTERMEDIATE SHAFT REMOVAL |
1477 |
|
1.2.3.4 ECU REMOVAL |
1478 |
|
1.2.3.5 RACK & PINION ASSEMBLY REMOVAL |
1479 |
|
1.3. OVERHAULING |
1481 |
|
1.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
1481 |
|
1.3.2 PRECAUTIONS |
1482 |
|
1.3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
1482 |
|
1.3.3.1 DISASSEMBLY OF RACK & PINON |
1482 |
|
1.3.3.2 INSPECTION OF DISMANTLED PARTS |
1483 |
|
1.3.3.3 ASSEMBLY OF RACK & PINON |
1484 |
|
1.3.3.4 OBJ ON-VEHICLE REMOVAL |
1485 |
|
1.3.3.5 DO’S & DON’TS |
1486 |
|
1.3.3.6 WHEEL ALIGNMENT |
1486 |
|
1.4. TROUBLESHOOTING AND DIAGNOSIS |
1488 |
|
ELECTRICAL |
1494 |
|
2.1. TECHNICAL SPECIFICATION |
1500 |
|
2.2. INSTRUMENT CLUSTER |
1502 |
|
2.2.1. ART WORK |
1502 |
|
2.2.2. TELL TALES |
1502 |
|
2.2.3. SPECIFICATION |
1503 |
|
2.2.4. CONNECTION DETAILS |
1503 |
|
2.2.5. CONNECTOR DETAILS |
1503 |
|
2.2.6. PINOUT DETAILS |
1503 |
|
2.2.7 FREQUENTLY ASKED QUESTIONSDistance to Empty (DTE) |
1504 |
|
2.2.8 SEASON ODOMETER WRITING /UPDATING PROCEDURE |
1506 |
|
2.3. EPAS ECU |
1507 |
|
2.3.1. SPECIFICATION |
1507 |
|
2.3.2. LOCATION |
1507 |
|
2.3.3. CONNECTION DETAILS |
1508 |
|
2.3.4. PINOUT DETAILS |
1508 |
|
2.4. FUSEBOX & RELAY DETAILS |
1509 |
|
2.4.1 LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE |
1509 |
|
2.4.2. BATTERY MOUNTED FUSE BOX DETAILS (FOR NANO CNG AND MY13) |
1509 |
|
2.4.3. CABIN FUSE BOX DETAILS(NANO MY13 EPAS) |
1510 |
|
2.4.4. RELAY BOX DETAILS (FOR NANO CNG AND MY13) |
1512 |
|
2.4.5. DIAGNOSTIC CONNECTOR LOCATION |
1512 |
|
2.4.6 ECU AND STEERING COLUMN PAIRING PROCESS |
1513 |
|
2.5 DIAGNOSTIC USER MANUAL |
1514 |
|
2.6 DIAGNOSTIC TROUBLE CODES - EPAS |
1524 |
|
2.7 DIAGNOSTIC TROUBLE CODES – EMS ECU |
1531 |
|
2.8 DIAGNOSTIC TROUBLE CODES – INSTRUMENT CLUSTER |
1532-1533 |
|
CIRCUIT SCHEMATICS NANO MY13 EPAS |
1554-1555 |
|
1. SYMBOLS & COLOUR CODES |
1562-1563 |
|
2. FUSE & RELAY BOX |
1564-1565 |
|
3. GROUND TOPOLOGY |
1566-1567 |
|
4. POWER SUPPLY |
1568-1569 |
|
5. EARTH |
1584-1585 |
|
6. STARTER & CHARGING |
1590-1591 |
|
7. ENGINE CONTROL (PETROL) |
1592-1593 |
|
8. FUEL PUMP |
1600-1601 |
|
9. MANUAL HVAC |
1602-1603 |
|
10. RADIATOR FAN |
1604-1605 |
|
11. POWER WINDOWS |
1606-1607 |
|
12. CENTRAL DOOR LOCKING |
1610-1611 |
|
13. INSTRUMENT CLUSTER |
1616-1617 |
|
14. FRONT WIPER |
1620-1621 |
|
15. EXTERIOR LIGHTS |
1622-1623 |
|
16. CAN |
1632-1633 |
|
17. IMMOBILISER |
1634-1635 |
|
18. INTERIOR LAMPS |
1636-1637 |
|
19. EPAS |
1638-1639 |
|
20. HORN |
1640-1641 |
|
21. POWER SOCKET & CIGAR LIGHTER |
1642-1643 |
|
22. REVERSE PARKING |
1644-1645 |
|
23. AUDIO SYSTEM |
1646-1647 |
|
CIRCUIT SCHEMATICS NANAO CNG EPAS |
1650-1651 |
|
SYMBOLS & SCHEMATIC CODES |
1658-1659 |
|
FUSE & RELAY BOX |
1660-1661 |
|
GROUND TOPOLOGY |
1662-1663 |
|
POWER SUPPLY |
1664-1665 |
|
EARTH |
1680-1681 |
|
STARTER & CHARGING |
1686-1687 |
|
ENGINE CONTROL (PETROL) |
1688-1689 |
|
FUEL PUMP |
1698-1699 |
|
MANUAL HVAC |
1700-1701 |
|
RADIATOR FAN |
1702-1703 |
|
POWER WINDOWS |
1704-1705 |
|
CENTRAL DOOR LOCKING |
1708-1709 |
|
INSTRUMENT CLUSTER |
1712-1713 |
|
FRONT WIPER |
1718-1719 |
|
EXTERIOR LIGHT |
1720-1721 |
|
CAN |
1728-1729 |
|
IMMOBILISER |
1732-1733 |
|
INTERIOR LAMPS |
1734-1735 |
|
HORN |
1736-1737 |
|
POWER SOCKET & CIGAR LIGHTER |
1738-1739 |
|
REVERSE PARKING |
1740-1741 |
|
AUDIO SYSTEM |
1742-1743 |
|
EPAS |
1744-1745 |
|
NANO OTG |
1746 |
|
GENERAL |
1750 |
|
1.1 TECHNICAL SPECIFICATION |
1754 |
|
1.2 FUEL, LUBRICANTS AND COOLANTS |
1756 |
|
1.3 SERVICE SCHEDULE |
1757 |
|
2. PRECAUTIONS |
35 |
|
2.1 GENERAL SAFETY PRECAUTIONS |
41 |
|
2.2 GENERAL SERVICE PRECAUTIONS |
45 |
|
3. ENGINE |
47 |
|
3.1 GENERAL INFORMATION |
55 |
|
TECHNICAL SPECIFICATIONS |
57 |
|
FEATURES OF 273 MPFI ENGINE |
58 |
|
TIGHTENING TORQUE |
59 |
|
SPECIAL TOOLS & EQUIPMENTS |
61 |
|
GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
|
3.2 ON VEHICLE PROCEDURES |
69 |
|
IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
|
ENGINE OIL REPLACEMENT |
73 |
|
OIL FILTER REPLACEMENT |
74 |
|
AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
|
FUEL FILTER REPLACEMENT |
76 |
|
TAPPET SETTING |
77 |
|
ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
|
COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
|
TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
|
CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
|
COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
|
3.3 ENGINE MECHANICAL |
91 |
|
PRELIMINARY INSPECTION OF ENGINE |
93 |
|
REMOVAL OF ENGINE FROM VEHICLE |
95 |
|
3.3.1 CYLINDER HEAD |
99 |
|
GENERAL DESCRIPTION |
101 |
|
EXPLODED VIEW |
102 |
|
CYLINDER HEAD OVERHAUL |
104 |
|
CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
|
DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
|
INSPECTION & REPAIR DATA |
111 |
|
ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
|
3.3.2 ENGINE BLOCK |
123 |
|
GENERAL DESCRIPTION |
125 |
|
EXPLODED VIEW |
126 |
|
ENGINE BLOCK OVERHAUL |
128 |
|
DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
|
INSPECTION & REPAIR DATA |
133 |
|
ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
|
REFITMENT OF ENGINE ACCESSORIES |
156 |
|
ENGINE TESTING |
158 |
|
INSTALLATION OF ENGINE ON VEHICLE |
158 |
|
3.4 ACCELERATOR |
159 |
|
EXPLODED VIEWS & CABLE ROUTING |
161 |
|
SYSTEM MAINTENANCE |
163 |
|
3.5 COOLING SYSTEM |
167 |
|
GENERAL DESCRIPTION |
169 |
|
SYSTEM SCHEMATICS |
169 |
|
EXPLODED VIEWS |
170 |
|
SPECIFICATIONS |
172 |
|
SYSTEM COMPONENTS |
173 |
|
SYSTEM MAINTENANCE |
174 |
|
3.6 LUBRICATION SYSTEM |
183 |
|
GENERAL DESCRIPTION |
185 |
|
SYSTEM SCHEMATICS |
185 |
|
SPECIFICATIONS |
186 |
|
SYSTEM MAINTENANCE |
187 |
|
3.7 FUEL SYSTEM |
199 |
|
GENERAL DESCRIPTION |
201 |
|
SYSTEM SCHEMATICS |
201 |
|
EXPLODED VIEWS |
202 |
|
PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
|
SYSTEM COMPONENTS |
204 |
|
SYSTEM MAINTENANCE |
208 |
|
EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
|
3.8 INTAKE SYSTEM |
221 |
|
GENERAL DESCRIPTION |
223 |
|
EXPLODED VIEWS |
224 |
|
SYSTEM MAINTENANCE |
225 |
|
3.9 EXHAUST SYSTEM |
231 |
|
GENERAL DESCRIPTION |
233 |
|
EXPLODED VIEWS |
234 |
|
TIGHTENING TORQUE |
235 |
|
SYSTEM COMPONENTS |
236 |
|
SYSTEM MAINTENANCE |
238 |
|
3.10 IGNITION SYSTEM |
243 |
|
GENERAL DESCRIPTION |
245 |
|
SYSTEM SCHEMATICS |
245 |
|
SYSTEM MAINTENANCE |
246 |
|
3.11 ENGINE MANAGEMENT SYSTEM |
251 |
|
ABBREVIATIONS |
253 |
|
AN OVERVIEW |
254 |
|
3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
|
ECU BLOCK DIAGRAM |
256 |
|
ECU PIN ASSIGNMENT DETAILS |
257 |
|
ECU HANDLING AND CARE |
258 |
|
ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
|
3.11.2 SENSORS |
260 |
|
CRANK SHAFT POSITION SENSOR |
260 |
|
COOLANT TEMPERATURE SENSOR |
261 |
|
TMAP SENSOR |
263 |
|
KNOCK SENSOR |
264 |
|
THROTTLE POSITION SENSOR |
265 |
|
LAMBDA (OXYGEN) SENSOR |
268 |
|
VEHICLE SPEED SENSOR |
269 |
|
3.11.3 ACTUATORS |
271 |
|
CANISTER PURGE VALVE |
271 |
|
FUEL INJECTOR |
272 |
|
IGNITION COIL |
274 |
|
INTAKE AIR CONTROL VALVE (IACV) |
277 |
|
COMPONENT FITMENT DATA |
279 |
|
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
|
DTC LIST |
283 |
|
LAPTOP BASED DIAGNOSTIC TESTER |
293 |
|
BLINK CODE |
308 |
|
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
|
REPAIRING STEPS |
310 |
|
VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
|
SENSOR AND ACTUATOR TESTING |
312 |
|
EMERGENCY SERVICE TIPS |
314 |
|
4. DRIVETRAIN |
315 |
|
4.1 CLUTCH |
321 |
|
4.1.1 GENERAL INFORMATION |
323 |
|
TECHNICAL SPECIFICATIONS |
323 |
|
CONSTRUCTION |
326 |
|
PRECAUTIONS |
328 |
|
TIGHTENING TORQUES |
329 |
|
SPECIAL TOOLS |
330 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
|
TROUBLE SHOOTING |
334 |
|
MAINTENANCE AND REPAIR |
335 |
|
A. PRELIMINARY INSPECTION |
335 |
|
B. CLUTCH SLIPPAGE TEST |
335 |
|
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
|
D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
|
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
|
4.1.2 OVERHAUL |
337 |
|
EXPLODED VIEWS |
337 |
|
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
|
B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
|
C. CLUTCH CABLE REPLACEMENT |
344 |
|
4.2 TRANSAXLE TA-59 |
347 |
|
4.2.1 GENERAL INFORMATION |
349 |
|
TECHNICAL SPECIFICATION |
349 |
|
CONSTRUCTION |
349 |
|
PRECAUTIONS |
350 |
|
TIGHTENING TORQUES |
351 |
|
SPECIAL TOOLS |
354 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
358 |
|
TRANSAXLE OIL REPLACEMENT |
359 |
|
4.2.2 OVERHAUL |
360 |
|
EXPLODED VIEWS |
360 |
|
COMPONENT IDENTIFICATION |
367 |
|
PRECAUTIONS |
369 |
|
REMOVAL OF TRANSAXLE FROM VEHICLE |
369 |
|
TRANSAXLE DISMANTLING |
372 |
|
INPUT SHAFT ASSEMBLY |
376 |
|
LAY SHAFT ASSEMBLY |
381 |
|
SHIFTER SHAFT AND SHIFTER FORK |
387 |
|
DIFFERENTIAL ASSEMBLY |
390 |
|
REAR HALF HOUSING TOP COVER ASSEMBLY |
394 |
|
REAR HALF HOUSING ASSEMBLY |
400 |
|
FRONT HALF HOUSING |
402 |
|
TRANSAXLE ASSEMBLY |
404 |
|
A. SHIM SELECTION |
404 |
|
B. ASSEMBLING THE TRANSAXLE |
405 |
|
GEAR SHIFTER LINKAGE |
409 |
|
A. GEAR SHIFTER CABLE REPLACEMENT |
409 |
|
B. GEAR SHIFTER ADJUSTMENT |
410 |
|
4.3 DRIVESHAFT |
411 |
|
4.3.1 GENERAL INFORMATION |
413 |
|
TIGHTENING TORQUE |
413 |
|
SPECIAL TOOL |
414 |
|
CONSTRUCTIONAL DETAILS |
415 |
|
EXPLODED VIEW - DRIVESHAFT |
415 |
|
COMPONENT DESCRIPTION |
416 |
|
TROUBLESHOOTING AND DIAGNOSIS |
417 |
|
4.3.2 ON VEHICLE REPAIRS |
418 |
|
PRECAUTIONS |
418 |
|
REMOVAL FROM VEHICLE |
420 |
|
DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
|
5. SUSPENSION SYSTEM |
429 |
|
5.1 GENERAL INFORMATION |
435 |
|
TECHNICAL SPECIFICATIONS |
435 |
|
TIGHTENING TORQUES |
436 |
|
SPECIAL TOOLS |
439 |
|
LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
|
LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
|
MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
|
TROUBLESHOOTING AND DIAGNOSIS |
446 |
|
5.2 ON VEHICLE REPAIRS |
449 |
|
FRONT SUSPENSION COMPONENTS |
449 |
|
STRUT |
449 |
|
ANTI-ROLL BAR |
455 |
|
LOWER ARM |
456 |
|
WHEEL BEARING |
458 |
|
REAR SUSPENSION COMPONENTS |
461 |
|
SHOCK ABSORBER |
462 |
|
COIL SPRING |
463 |
|
BUMP STOPPER AND SPRING UPPER SEAT |
464 |
|
SEMI TRAILING ARM |
465 |
|
WHEEL HUB AND WHEEL BEARING |
468 |
|
5.3 WHEELS AND TYRES |
473 |
|
5.3.1 GENERAL INFORMATION |
473 |
|
TECHNICAL SPECIFICATIONS |
473 |
|
TIGHTENING TORQUE |
474 |
|
EXPLODED VIEW |
475 |
|
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
|
5.3.2 ON VEHICLE REPAIRS |
477 |
|
WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
|
WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
|
WHEEL BALANCING |
480 |
|
WHEEL RUNOUT |
481 |
|
TYRE REPLACEMENT |
482 |
|
WHEEL ASSEMBLY REPLACEMENT |
483 |
|
REPAIRING TUBELESS TYRE PUNCTURE |
483 |
|
TYRE DIAGNOSIS |
484 |
|
BRAKE |
493 |
|
6.1 GENERAL INFORMATION |
499 |
|
TECHNICAL SPECIFICATIONS |
499 |
|
TIGHTENING TORQUES |
500 |
|
SPECIAL TOOLS |
504 |
|
BRAKE CIRCUIT |
1790 |
|
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
|
FRONT DRUM BRAKES |
507 |
|
REAR DRUM BRAKES |
508 |
|
AUTO INCREMENTAL BRAKE |
509 |
|
TANDEM MASTER CYLINDER (TMC) |
510 |
|
TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
|
WHEEL CYLINDER |
514 |
|
PARKING BRAKES |
515 |
|
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
|
BLEEDING OF HYDRAULIC SYSTEM |
521 |
|
TROUBLESHOOTING AND DIAGNOSIS |
523 |
|
6.4 ON VEHICLE REPAIRS |
530 |
|
FRONT BRAKE COMPONENTS |
531 |
|
FRONT BRAKE DRUM |
532 |
|
FRONT BRAKE SHOES |
534 |
|
FRONT BRAKE BACK PLATE |
539 |
|
REAR BRAKE COMPONENTS |
540 |
|
REAR BRAKE DRUM |
541 |
|
REAR BRAKE SHOES |
542 |
|
REAR BRAKE BACK PLATE |
544 |
|
TMC |
546 |
|
WHEEL CYLINDER |
555 |
|
PARKING BRAKES |
561 |
|
VACUUM BRAKE BOOSTER |
564 |
|
BRAKE HOSES/PIPES SCHEMATIC |
565 |
|
VACUUM LINES |
567 |
|
7. STEERING |
569 |
|
7.1 GENERAL INFORMATION |
575 |
|
TECHNICAL SPECIFICATIONS |
575 |
|
TIGHTENING TORQUES |
576 |
|
SPECIAL TOOLS |
578 |
|
EXPLODED VIEWS |
579 |
|
SCHEMATIC OF STEERING SYSTEM |
581 |
|
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
|
7.3 ON VEHICLE REPAIRS |
584 |
|
STEERING WHEEL |
586 |
|
STEERING COLUMN ASSEMBLY |
587 |
|
STEERING UPPER COLUMN |
589 |
|
INTERMEDIATE SHAFT |
589 |
|
STEERING RACK AND PINION ASSEMBLY |
590 |
|
OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
|
WHEEL ALIGNMENT |
601 |
|
TROUBLESHOOTING AND DIAGNOSIS |
603 |
|
FUEL SYSTEM |
1778 |
|
1.1 INTRODUCTION |
1782 |
|
1.2 PRECAUTIONS |
1782 |
|
1.3 SPECIFICATIONS |
1782 |
|
1.4 TIGHTENING TORQUE |
1783 |
|
1.5 FUEL TANK UNIT REMOVAL AND REFITMENT |
1784 |
|
1.6 FUEL TANK REMOVAL AND REFITMENT |
1785 |
|
8. ELECTRICAL |
607 |
|
8.1 TECHNICAL SPECIFICATION |
613 |
|
8.2 GENERAL PRECAUTIONS |
614 |
|
8.3 BATTERY |
617 |
|
8.4 ALTERNATOR |
620 |
|
8.5 STARTER MOTOR |
641 |
|
8.6 LIGHTING SYSTEM |
659 |
|
8.7 HORN |
675 |
|
8.8 WIPER SYSTEM |
677 |
|
8.9 FLASHER |
686 |
|
8.10 FOG LAMP CONTROLLER |
687 |
|
8.11 BRAKE LAMP CHECK |
689 |
|
8.12 POWER SOCKET |
689 |
|
8.13 CIGARETTE LIGHTER (IF EQUIPPED) |
690 |
|
8.14 CENTRAL DOOR LOCKING |
691 |
|
8.15 POWER WINDOW SYSTEM |
694 |
|
8.16 INSTRUMENT CLUSTER |
697 |
|
8.17 ELECTRICAL SWITCHES |
700 |
|
8.18 ACCESSORY CONNECTORS |
710 |
|
8.19 FUSE BOX/RELAY LOCATION & DETAILS |
715 |
|
8.20 ELECTRIC WIRING AND FITMENT SCHEMATICS |
716 |
|
8.20.1 HARNESS & CONNECTOR DESCRIPTION |
716 |
|
8.20.2 UNDERSTANDING THE CIRCUIT SCHEMATIC |
718 |
|
8.20.3 CONNECTOR CODE/PIN NO./CONNECTOR LAYOUT |
719 |
|
8.20.4 ELECTRICAL SYMBOLS |
720 |
|
CIRCUIT SCHEMATICS NANO MY14 |
1792-1793 |
|
INDEX |
1794-1795 |
|
FUSE AND RELAY DETAILS |
1796-1797 |
|
TOPOLOGY |
1798-1799 |
|
POWER SUPPLY |
1800-1801 |
|
EARTH |
1818-1819 |
|
STARTER AND CHARGING |
1824-1825 |
|
ENGINE CONTROL (PETROL) |
1826-1827 |
|
FUEL PUMP |
1834-1835 |
|
HVAC (MANUAL) |
1836-1837 |
|
RADIATOR FANS |
1838-1839 |
|
POWER WINDOWS |
1840-1841 |
|
CENTRAL DOOR LOCKING |
1844-1845 |
|
CLUSTER |
1850-1851 |
|
FRONT WIPER PASSIVE |
1854-1855 |
|
EXTERIOR LIGHTING |
1856-1857 |
|
DATA COMMUNICATION (CAN) |
1866-1867 |
|
INTERIOR LAMPS |
1870-1871 |
|
EPAS |
1872-1873 |
|
HORN |
1874-1875 |
|
POWER SOCKET AND CIGAR LIGHTER |
1876-1877 |
|
REAR PARKING AIS |
1878-1879 |
|
AUDIO SYSTEM |
1880-1881 |
|
CONNECTOR DETAILS |
1884-1885 |
|
BODY |
1760 |
|
1.1 TIGHTENING TORQUES |
1764 |
|
1.2 FRONT BUMPER REMOVAL AND REFITMENT |
1765 |
|
1.3 REAR BUMPER REMOVAL AND REFITMENT |
1766 |
|
1.4 TAILGATE REMOVAL AND REFITMENT |
1767 |
|
1.5 TAIL LAMP ASSEMBLY REMOVAL ANDREFITMENT |
1770 |
|
1.6 FRONT FOG LAMP REMOVAL AND REFITMENT |
1771 |
|
1.7 LIGHT STALK REMOVAL AND REFITMENT |
1772 |
|
1.8 COMBINATION SWITCH REMOVAL AND REFITMENT |
1774 |
|
10. HVAC |
876 |
|
10.1 GENERAL INFORMATION |
882 |
|
TECHNICAL SPECIFICATIONS |
882 |
|
TIGHTENING TORQUES |
883 |
|
GENERAL PRECAUTIONS |
885 |
|
COMPONENT DESCRIPTION |
891 |
|
10.2 MAINTENANCE OF AC/HVAC SYSTEM |
894 |
|
TROUBLESHOOTING AND DIAGNOSIS |
895 |
|
PRESSURE TEST USING MANIFOLD GAUGES |
908 |
|
FLUSHING OF AC SYSTEM |
913 |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
915 |
|
A/C SYSTEM PERFORMANCE TEST |
917 |
|
LEAK TEST SYSTEM |
917 |
|
10.3 ON VEHICLE REPAIRS |
918 |
|
CONTROL PANEL ASSEMBLY |
919 |
|
A/C COMPRESSOR |
920 |
|
HVAC UNIT |
931 |
|
BLOWER UNIT |
935 |
|
BLOWER RESISTER |
935 |
|
FILTER |
936 |
|
EVAPORATOR AND EXPANSION VALVE |
937 |
|
HEATER ASSEMBLY |
939 |
|
KINEMATICS |
940 |
|
PRESSURE SWITCH |
940 |
|
CONDENSER ASSEMBLY |
941 |
|
DRIER CARTRIDGE/R.D. BOTTLE |
943 |
|
CONDENSER FAN AND CONDENSER MOTOR |
945 |
|
REFRIGERANT LINES |
946 |
|
HEATER LINES |
948 |