NANO CNG
|
NANO CNG |
1 |
|
GENERAL |
8 |
|
1. INTRODUCTION TO CNG SYSTEM |
12 |
|
2. BENEFITS OF CNG |
12 |
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3. FEATURES OF CNG BI-FUEL SYSTEM |
12 |
|
4. GENERAL INSTRUCTION / PRECAUTIONSWHILE WORKING ON CNG VEHICLE |
13 |
|
5. IN CASE OF LEAKAGE |
15 |
|
6. TECHNICAL SPECIFICATIONS |
17 |
|
7. TIGHTENING TORQUE |
21 |
|
8. SPECIAL TOOLS |
26 |
|
9. LIST OF APPROVED CNG CYLINDER TESTING STATION |
27 |
|
10. SERVICE SCHEDULE |
28 |
|
11. LUBRICANTS AND COOLANTS |
32 |
|
2. PRECAUTIONS |
34 |
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2.1 GENERAL SAFETY PRECAUTIONS |
40 |
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2.2 GENERAL SERVICE PRECAUTIONS |
44 |
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ENGINE |
46 |
|
1. TECHNICAL SPECIFICATION |
50 |
|
2. REPAIR DATA |
51 |
|
A. BELT TENSION VALUES |
51 |
|
3. ENGINE CONTRUCTIONAL DETAIL |
52 |
|
A. ENGINE |
52 |
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B. INTAKE MANIFOLD |
52 |
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4. GENERAL SYSTEM OVERVIEW OF Bi-FUEL ENGINE MANAGEMENT SYSTEM |
54-55 |
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5. REMOVAL AND REFITMENT OF ENGINEACCESS WINDOW AND ENGINE COVER |
58 |
|
6. GAS INJECTOR |
61 |
|
7. GAS RAIL |
63 |
|
8. PRESSURE AND TEMPERATURE (P&T)SENSOR |
65 |
|
9. DIAGNOSTIC USER MANUAL |
67 |
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4. DRIVETRAIN |
88 |
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4.1 CLUTCH |
94 |
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4.1.1 GENERAL INFORMATION |
96 |
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TECHNICAL SPECIFICATIONS |
96 |
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CONSTRUCTION |
99 |
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PRECAUTIONS |
101 |
|
TIGHTENING TORQUES |
102 |
|
SPECIAL TOOLS |
103 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
104 |
|
TROUBLE SHOOTING |
107 |
|
MAINTENANCE AND REPAIR |
108 |
|
A. PRELIMINARY INSPECTION |
108 |
|
B. CLUTCH SLIPPAGE TEST |
108 |
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C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
108 |
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D. CLUTCH PEDAL PLAY ADJUSTMENT |
108 |
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E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
109 |
|
4.1.2 OVERHAUL |
110 |
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EXPLODED VIEWS |
110 |
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A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
113 |
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B. CLUTCH ACTUATION MECHANISM OVERHAUL |
114 |
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C. CLUTCH CABLE REPLACEMENT |
117 |
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TRANSAXLE |
120 |
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1 GENERAL INFORMATION |
126 |
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A. TECHNICAL SPECIFICATIONS |
126 |
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B. PRECAUTIONS |
127 |
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C. TIGHTENING TORQUES |
128 |
|
D. SPECIAL TOOLS |
131 |
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E. GENERAL SYMPTOMS AND DIAGNOSIS |
135 |
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F. TRANSAXLE OIL REPLACEMENT |
136 |
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2. OVERHAULING (EXPLODED VIEWS) |
137 |
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A. TRANSAXLE HOUSING |
137 |
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B. INPUT SHAFT AND LAY SHAFT |
138 |
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C. SHIFTER SHAFT AND SHIFTER SLEEVE |
139 |
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D. DIFFERENTIAL |
140 |
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E. TOP COVER ASSEMBLY |
141 |
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F. SHIFTER LINKAGE |
142 |
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3. COMPONENT IDENTIFICATION |
144 |
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A. SHIFTER SHAFTS |
144 |
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B. SHIFTER FORKS (DOGS) |
144 |
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C. SHIFTER SLEEVE |
145 |
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4. REMOVAL OF TRANSAXLE FROM VEHICLE |
146 |
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5. TRANSAXLE DISMANTLING |
149 |
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6. INPUT SHAFT ASSEMBLY |
153 |
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7. LAYSHAFT ASSEMBLY |
158 |
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8. SHIFTER SHAFT AND SHIFTER FORK |
164 |
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9. REVERSE GEAR SHIFTER BRACKET - ASSEMBLY |
165 |
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10. DIFFERENTIAL ASSEMBLY |
167 |
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11. REAR HALF HOUSING TOP COVER ASSEMBLY |
171 |
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12. REAR HALF HOUSING ASSEMBLY |
178 |
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13. FRONT HALF HOUSING |
180 |
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14. TRANSAXLE ASSEMBLY |
182 |
|
A. SHIM SELECTION |
182 |
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B. ASSEMBLING THE TRANSAXLE |
183 |
|
15. GEAR SHIFTER LINKAGE |
188 |
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A. GEAR SHIFTER CABLE REPLACEMENT |
188 |
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B. GEAR SHIFTER ADJUSTMENT |
190 |
|
4.3 DRIVESHAFT |
192 |
|
4.3.1 GENERAL INFORMATION |
194 |
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TIGHTENING TORQUE |
194 |
|
SPECIAL TOOL |
195 |
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CONSTRUCTIONAL DETAILS |
196 |
|
EXPLODED VIEW - DRIVESHAFT |
196 |
|
COMPONENT DESCRIPTION |
197 |
|
TROUBLESHOOTING AND DIAGNOSIS |
198 |
|
4.3.2 ON VEHICLE REPAIRS |
199 |
|
PRECAUTIONS |
199 |
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REMOVAL FROM VEHICLE |
201 |
|
DRIVESHAFT DISMANTLING / ASSEMBLY |
204 |
|
5. SUSPENSION SYSTEM |
210 |
|
5.1 GENERAL INFORMATION |
216 |
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TECHNICAL SPECIFICATIONS |
216 |
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TIGHTENING TORQUES |
217 |
|
SPECIAL TOOLS |
220 |
|
LAY OUT OF FRONT SUSPENSION SYSTEM |
222 |
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LAY OUT OF REAR SUSPENSION SYSTEM |
223 |
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MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
224 |
|
TROUBLESHOOTING AND DIAGNOSIS |
227 |
|
5.2 ON VEHICLE REPAIRS |
230 |
|
FRONT SUSPENSION COMPONENTS |
230 |
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STRUT |
230 |
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ANTI-ROLL BAR |
236 |
|
LOWER ARM |
237 |
|
WHEEL BEARING |
239 |
|
REAR SUSPENSION COMPONENTS |
242 |
|
SHOCK ABSORBER |
243 |
|
COIL SPRING |
244 |
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BUMP STOPPER AND SPRING UPPER SEAT |
245 |
|
SEMI TRAILING ARM |
246 |
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WHEEL HUB AND WHEEL BEARING |
249 |
|
5.3 WHEELS AND TYRES |
254 |
|
5.3.1 GENERAL INFORMATION |
254 |
|
TECHNICAL SPECIFICATIONS |
254 |
|
TIGHTENING TORQUE |
255 |
|
EXPLODED VIEW |
256 |
|
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
257 |
|
5.3.2 ON VEHICLE REPAIRS |
258 |
|
WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
259 |
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WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
260 |
|
WHEEL BALANCING |
261 |
|
WHEEL RUNOUT |
262 |
|
TYRE REPLACEMENT |
263 |
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WHEEL ASSEMBLY REPLACEMENT |
264 |
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REPAIRING TUBELESS TYRE PUNCTURE |
264 |
|
TYRE DIAGNOSIS |
265 |
|
6. BRAKE SYSTEM |
274 |
|
6.1 GENERAL INFORMATION |
280 |
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TECHNICAL SPECIFICATIONS |
280 |
|
TIGHTENING TORQUES |
281 |
|
SPECIAL TOOLS |
285 |
|
SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
286 |
|
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
288 |
|
FRONT DRUM BRAKES |
288 |
|
REAR DRUM BRAKES |
289 |
|
AUTO INCREMENTAL BRAKE |
290 |
|
TANDEM MASTER CYLINDER (TMC) |
291 |
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TMC WITH VACUUM BOOSTER ASSEMBLY |
292 |
|
WHEEL CYLINDER |
295 |
|
PARKING BRAKES |
296 |
|
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
297 |
|
BLEEDING OF HYDRAULIC SYSTEM |
302 |
|
TROUBLESHOOTING AND DIAGNOSIS |
304 |
|
6.4 ON VEHICLE REPAIRS |
311 |
|
FRONT BRAKE COMPONENTS |
312 |
|
FRONT BRAKE DRUM |
313 |
|
FRONT BRAKE SHOES |
315 |
|
FRONT BRAKE BACK PLATE |
320 |
|
REAR BRAKE COMPONENTS |
321 |
|
REAR BRAKE DRUM |
322 |
|
REAR BRAKE SHOES |
323 |
|
REAR BRAKE BACK PLATE |
325 |
|
TMC |
327 |
|
WHEEL CYLINDER |
336 |
|
PARKING BRAKES |
342 |
|
VACUUM BRAKE BOOSTER |
345 |
|
BRAKE HOSES/PIPES SCHEMATIC |
346 |
|
VACUUM LINES |
348 |
|
7. STEERING |
350 |
|
7.1 GENERAL INFORMATION |
356 |
|
TECHNICAL SPECIFICATIONS |
356 |
|
TIGHTENING TORQUES |
357 |
|
SPECIAL TOOLS |
359 |
|
EXPLODED VIEWS |
360 |
|
SCHEMATIC OF STEERING SYSTEM |
362 |
|
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
364 |
|
7.3 ON VEHICLE REPAIRS |
365 |
|
STEERING WHEEL |
367 |
|
STEERING COLUMN ASSEMBLY |
368 |
|
STEERING UPPER COLUMN |
370 |
|
INTERMEDIATE SHAFT |
370 |
|
STEERING RACK AND PINION ASSEMBLY |
371 |
|
OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
373 |
|
WHEEL ALIGNMENT |
382 |
|
TROUBLESHOOTING AND DIAGNOSIS |
384 |
|
FUEL SYSTEM |
388 |
|
1 INTRODUCTION |
392 |
|
A. CNG LAYOUT (ON VEHICLE) |
393 |
|
2. CNG FUEL SYSTEM COMPONENTS |
394 |
|
A. CNG CYLINDER |
394 |
|
B. CYLINDER VALVE |
396 |
|
C. LOW PRESSURE CNG FILTER |
401 |
|
D. PRESSURE GAUGE |
404 |
|
E. PRESSURE REGULATOR |
405 |
|
F. HIGH PRESSURE (H.P) SENSOR |
410 |
|
G. CNG RECEPTACLE VALVE |
412 |
|
3. CNG TUBE FITTINGS / JOINTS TIGHTENING INSTRUCTIONS |
415 |
|
A. SWAGING PROCEDURE |
415 |
|
B. PROCEDURE FOR NPT THREAD ASSEMBLY |
417 |
|
4. CNG LEAK DETECTION TESTING |
419 |
|
5. TROUBLE SHOOTING |
420 |
|
ELECTRICAL |
422 |
|
1 TECHNICAL SPECIFICATION |
426 |
|
2. LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE |
427 |
|
3. INSTRUMENT CLUSTER |
428 |
|
4. FUEL GAUGE |
429 |
|
5. REMOVAL AND REFITTMENT OF BATTERY |
430 |
|
6. STARTER MOTOR |
431 |
|
A. EXPLODED VIEW |
431 |
|
B. ON VEHICLE REMOVAL AND REFITTMENT OF STARTER MOTOR |
431 |
|
C. STARTER MOTOR OVER HAULING |
432 |
|
CIRCUIT SCHEMATICS |
438-439 |
|
FUSE BOX AND RELAY ( CABIN ) |
442-443 |
|
FUSE BOX AND RELAY ( BATTERY MOUNTED ) |
444-445 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 1 OF 5 ) |
446-447 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 2 OF 5 |
448-449 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 3 OF 5 ) |
450-451 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 4 OF 5) |
452-453 |
|
CIRCUIT SCHEMATIC OF EMS ECU (SHEET 5 OF 5) |
454-455 |
|
FUSE DISTRIBUTION (SHEET 1 OF 6) |
456-457 |
|
FUSE DISTRIBUTION (SHEET 2 OF 6) |
458-459 |
|
FUSE DISTRIBUTION (SHEET 3 OF 6) |
460-461 |
|
FUSE DISTRIBUTION (SHEET 4 OF 6) |
462-463 |
|
FUSE DISTRIBUTION (SHEET 5 OF 6) |
464-465 |
|
FUSE DISTRIBUTION (SHEET 6 OF 6) |
466-467 |
|
DTC CODES |
470-471 |
|
9. BODY |
508 |
|
9.1 GENERAL INFORMATION |
514 |
|
TECHNICAL SPECIFICATIONS |
514 |
|
TIGHTENING TORQUE |
515 |
|
9.2 ON VEHICLE REPAIRS |
519 |
|
EXPLODED VIEW - BUMPERS & HOOD |
519 |
|
FRONT BUMPER |
520 |
|
FENDER (SIDE BONNET) |
521 |
|
HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
522 |
|
FRONT DOOR |
526 |
|
REAR DOOR |
537 |
|
REAR SHELF |
546 |
|
TAILGATE |
546 |
|
REAR BUMPER |
547 |
|
DASHBOARD |
549 |
|
CENTER CONSOLE |
552 |
|
SEATS & BELTS |
553 |
|
OUTER REAR VIEW MIRROR (ORVM) |
563 |
|
SUN VISOR |
563 |
|
TRIMS |
564 |
|
FLOOR CARPET |
565 |
|
WINDSHIELD |
568 |
|
9.3 PAINT CARE |
570 |
|
9.4 BODY REPAIR DATA |
573 |
|
9.5 TROUBLESHOOTING AND DIAGNOSIS |
578 |
|
10. HVAC |
580 |
|
10.1 GENERAL INFORMATION |
586 |
|
TECHNICAL SPECIFICATIONS |
586 |
|
TIGHTENING TORQUES |
587 |
|
GENERAL PRECAUTIONS |
589 |
|
COMPONENT DESCRIPTION |
595 |
|
10.2 MAINTENANCE OF AC/HVAC SYSTEM |
598 |
|
TROUBLESHOOTING AND DIAGNOSIS |
599 |
|
PRESSURE TEST USING MANIFOLD GAUGES |
612 |
|
FLUSHING OF AC SYSTEM |
617 |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
619 |
|
A/C SYSTEM PERFORMANCE TEST |
621 |
|
LEAK TEST SYSTEM |
621 |
|
10.3 ON VEHICLE REPAIRS |
622 |
|
CONTROL PANEL ASSEMBLY |
623 |
|
A/C COMPRESSOR |
624 |
|
HVAC UNIT |
635 |
|
BLOWER UNIT |
639 |
|
BLOWER RESISTER |
639 |
|
FILTER |
640 |
|
EVAPORATOR AND EXPANSION VALVE |
641 |
|
HEATER ASSEMBLY |
643 |
|
KINEMATICS |
644 |
|
PRESSURE SWITCH |
644 |
|
CONDENSER ASSEMBLY |
645 |
|
DRIER CARTRIDGE/R.D. BOTTLE |
647 |
|
CONDENSER FAN AND CONDENSER MOTOR |
649 |
|
REFRIGERANT LINES |
650 |
|
HEATER LINES |
652 |