NANO ePAS
|
NANO ePAS |
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 |
|
STEERING |
575 |
|
1.1 GENERAL INFORMATION |
580 |
|
1.1.1 SPECIFICATIONS |
580 |
|
1.1.2 SYSTEM LAYOUT |
580 |
|
1.1.3 GENERAL DESCRIPTION |
581 |
|
1.1.4 TIGHTENING TORQUES |
582 |
|
1.1.5 SPECIAL TOOLS |
584 |
|
1.2. MAINTENANCE, INSPECTION AND TEST |
585 |
|
1.2.1 PRELIMINARY INSPECTION |
585 |
|
1.2.2 REGULAR MAINTENANCE |
586 |
|
1.2.3 ON VEHICLE REPAIRS |
588 |
|
1.2.3.1 STEERING WHEEL REMOVAL |
588 |
|
1.2.3.2 STEERING COLUMN REMOVAL |
589 |
|
1.2.3.3 INTERMEDIATE SHAFT REMOVAL |
590 |
|
1.2.3.4 ECU REMOVAL |
591 |
|
1.2.3.5 RACK & PINION ASSEMBLY REMOVAL |
592 |
|
1.3. OVERHAULING |
594 |
|
1.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
594 |
|
1.3.2 PRECAUTIONS |
595 |
|
1.3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
595 |
|
1.3.3.1 DISASSEMBLY OF RACK & PINON |
595 |
|
1.3.3.2 INSPECTION OF DISMANTLED PARTS |
596 |
|
1.3.3.3 ASSEMBLY OF RACK & PINON |
597 |
|
1.3.3.4 OBJ ON-VEHICLE REMOVAL |
598 |
|
1.3.3.5 DO’S & DON’TS |
599 |
|
1.3.3.6 WHEEL ALIGNMENT |
599 |
|
1.4. TROUBLESHOOTING AND DIAGNOSIS |
601 |
|
ELECTRICAL |
607 |
|
2.1. TECHNICAL SPECIFICATION |
613 |
|
2.2. INSTRUMENT CLUSTER |
615 |
|
2.2.1. ART WORK |
615 |
|
2.2.2. TELL TALES |
615 |
|
2.2.3. SPECIFICATION |
616 |
|
2.2.4. CONNECTION DETAILS |
616 |
|
2.2.5. CONNECTOR DETAILS |
616 |
|
2.2.6. PINOUT DETAILS |
616 |
|
2.2.7 FREQUENTLY ASKED QUESTIONSDistance to Empty (DTE) |
617 |
|
2.2.8 SEASON ODOMETER WRITING /UPDATING PROCEDURE |
619 |
|
2.3. EPAS ECU |
620 |
|
2.3.1. SPECIFICATION |
620 |
|
2.3.2. LOCATION |
620 |
|
2.3.3. CONNECTION DETAILS |
621 |
|
2.3.4. PINOUT DETAILS |
621 |
|
2.4. FUSEBOX & RELAY DETAILS |
622 |
|
2.4.1 LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE |
622 |
|
2.4.2. BATTERY MOUNTED FUSE BOX DETAILS (FOR NANO CNG AND MY13) |
622 |
|
2.4.3. CABIN FUSE BOX DETAILS(NANO MY13 EPAS) |
623 |
|
2.4.4. RELAY BOX DETAILS (FOR NANO CNG AND MY13) |
625 |
|
2.4.5. DIAGNOSTIC CONNECTOR LOCATION |
625 |
|
2.4.6 ECU AND STEERING COLUMN PAIRING PROCESS |
626 |
|
2.5 DIAGNOSTIC USER MANUAL |
627 |
|
2.6 DIAGNOSTIC TROUBLE CODES - EPAS |
637 |
|
2.7 DIAGNOSTIC TROUBLE CODES – EMS ECU |
644 |
|
2.8 DIAGNOSTIC TROUBLE CODES – INSTRUMENT CLUSTER |
646-647 |
|
CIRCUIT SCHEMATICS NANO MY13 EPAS |
668-669 |
|
1. SYMBOLS & COLOUR CODES |
676-677 |
|
2. FUSE & RELAY BOX |
678-679 |
|
3. GROUND TOPOLOGY |
680-681 |
|
4. POWER SUPPLY |
682-683 |
|
5. EARTH |
698-699 |
|
6. STARTER & CHARGING |
704-705 |
|
7. ENGINE CONTROL (PETROL) |
706-707 |
|
8. FUEL PUMP |
714-715 |
|
9. MANUAL HVAC |
716-717 |
|
10. RADIATOR FAN |
718-719 |
|
11. POWER WINDOWS |
720-721 |
|
12. CENTRAL DOOR LOCKING |
724-725 |
|
13. INSTRUMENT CLUSTER |
730-731 |
|
14. FRONT WIPER |
734-735 |
|
15. EXTERIOR LIGHTS |
736-737 |
|
16. CAN |
746-747 |
|
17. IMMOBILISER |
748-749 |
|
18. INTERIOR LAMPS |
750-751 |
|
19. EPAS |
752-753 |
|
20. HORN |
754-755 |
|
21. POWER SOCKET & CIGAR LIGHTER |
756-757 |
|
22. REVERSE PARKING |
758-759 |
|
23. AUDIO SYSTEM |
760-761 |
|
CIRCUIT SCHEMATICS NANAO CNG EPAS |
764-765 |
|
SYMBOLS & SCHEMATIC CODES |
772-773 |
|
FUSE & RELAY BOX |
774-775 |
|
GROUND TOPOLOGY |
776-777 |
|
POWER SUPPLY |
778-779 |
|
EARTH |
794-795 |
|
STARTER & CHARGING |
800-801 |
|
ENGINE CONTROL (PETROL) |
802-803 |
|
FUEL PUMP |
812-813 |
|
MANUAL HVAC |
814-815 |
|
RADIATOR FAN |
816-817 |
|
POWER WINDOWS |
818-819 |
|
CENTRAL DOOR LOCKING |
822-823 |
|
INSTRUMENT CLUSTER |
826-827 |
|
FRONT WIPER |
832-833 |
|
EXTERIOR LIGHT |
834-835 |
|
CAN |
842-843 |
|
IMMOBILISER |
846-847 |
|
INTERIOR LAMPS |
848-849 |
|
HORN |
850-851 |
|
POWER SOCKET & CIGAR LIGHTER |
852-853 |
|
REVERSE PARKING |
854-855 |
|
AUDIO SYSTEM |
856-857 |
|
EPAS |
858-859 |
|
9. BODY |
860 |
|
9.1 GENERAL INFORMATION |
866 |
|
TECHNICAL SPECIFICATIONS |
866 |
|
TIGHTENING TORQUE |
867 |
|
9.2 ON VEHICLE REPAIRS |
871 |
|
EXPLODED VIEW - BUMPERS & HOOD |
871 |
|
FRONT BUMPER |
872 |
|
FENDER (SIDE BONNET) |
873 |
|
HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
874 |
|
FRONT DOOR |
878 |
|
REAR DOOR |
889 |
|
REAR SHELF |
898 |
|
TAILGATE |
898 |
|
REAR BUMPER |
899 |
|
DASHBOARD |
901 |
|
CENTER CONSOLE |
904 |
|
SEATS & BELTS |
905 |
|
OUTER REAR VIEW MIRROR (ORVM) |
915 |
|
SUN VISOR |
915 |
|
TRIMS |
916 |
|
FLOOR CARPET |
917 |
|
WINDSHIELD |
920 |
|
9.3 PAINT CARE |
922 |
|
9.4 BODY REPAIR DATA |
925 |
|
9.5 TROUBLESHOOTING AND DIAGNOSIS |
930 |
|
10. HVAC |
932 |
|
10.1 GENERAL INFORMATION |
938 |
|
TECHNICAL SPECIFICATIONS |
938 |
|
TIGHTENING TORQUES |
939 |
|
GENERAL PRECAUTIONS |
941 |
|
COMPONENT DESCRIPTION |
947 |
|
10.2 MAINTENANCE OF AC/HVAC SYSTEM |
950 |
|
TROUBLESHOOTING AND DIAGNOSIS |
951 |
|
PRESSURE TEST USING MANIFOLD GAUGES |
964 |
|
FLUSHING OF AC SYSTEM |
969 |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
971 |
|
A/C SYSTEM PERFORMANCE TEST |
973 |
|
LEAK TEST SYSTEM |
973 |
|
10.3 ON VEHICLE REPAIRS |
974 |
|
CONTROL PANEL ASSEMBLY |
975 |
|
A/C COMPRESSOR |
976 |
|
HVAC UNIT |
987 |
|
BLOWER UNIT |
991 |
|
BLOWER RESISTER |
991 |
|
FILTER |
992 |
|
EVAPORATOR AND EXPANSION VALVE |
993 |
|
HEATER ASSEMBLY |
995 |
|
KINEMATICS |
996 |
|
PRESSURE SWITCH |
996 |
|
CONDENSER ASSEMBLY |
997 |
|
DRIER CARTRIDGE/R.D. BOTTLE |
999 |
|
CONDENSER FAN AND CONDENSER MOTOR |
1001 |
|
REFRIGERANT LINES |
1002 |
|
HEATER LINES |
1004 |