NANO AMT
|
NANO AMT |
1 |
|
1. GENERAL |
5 |
|
1.1 AN OVERVIEW - NANO |
13 |
|
1.2 ABBREVIATIONS |
14 |
|
1.3 LIFTING, JACKING, TOWING POINTS |
17 |
|
1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
20 |
|
1.5 AGGREGATE NUMBERING SYSTEM |
21 |
|
1.6 TECHNICAL SPECIFICATIONS |
24 |
|
1.7 VEHICLE DIMENSIONS |
26 |
|
1.8 FUEL, LUBRICANTS & COOLANTS |
27 |
|
1.9 SERVICE SCHEDULE |
30 |
|
2. PRECAUTIONS |
33 |
|
2.1 GENERAL SAFETY PRECAUTIONS |
39 |
|
2.2 GENERAL SERVICE PRECAUTIONS |
43 |
|
3. ENGINE |
45 |
|
3.1 GENERAL INFORMATION |
53 |
|
TECHNICAL SPECIFICATIONS |
55 |
|
FEATURES OF 273 MPFI ENGINE |
56 |
|
TIGHTENING TORQUE |
57 |
|
SPECIAL TOOLS & EQUIPMENTS |
59 |
|
GENERAL SYMPTOMS & DIAGNOSTICS |
63 |
|
3.2 ON VEHICLE PROCEDURES |
67 |
|
IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
69 |
|
ENGINE OIL REPLACEMENT |
71 |
|
OIL FILTER REPLACEMENT |
72 |
|
AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
73 |
|
FUEL FILTER REPLACEMENT |
74 |
|
TAPPET SETTING |
75 |
|
ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
76 |
|
COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
77 |
|
TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
|
CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
84 |
|
COMPRESSION PRESSURE CHECKING PROCEDURE |
87 |
|
3.3 ENGINE MECHANICAL |
89 |
|
PRELIMINARY INSPECTION OF ENGINE |
91 |
|
REMOVAL OF ENGINE FROM VEHICLE |
93 |
|
3.3.1 CYLINDER HEAD |
97 |
|
GENERAL DESCRIPTION |
99 |
|
EXPLODED VIEW |
100 |
|
CYLINDER HEAD OVERHAUL |
102 |
|
CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
102 |
|
DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
106 |
|
INSPECTION & REPAIR DATA |
109 |
|
ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
116 |
|
3.3.2 ENGINE BLOCK |
121 |
|
GENERAL DESCRIPTION |
123 |
|
EXPLODED VIEW |
124 |
|
ENGINE BLOCK OVERHAUL |
126 |
|
DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
126 |
|
INSPECTION & REPAIR DATA |
131 |
|
ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
141 |
|
REFITMENT OF ENGINE ACCESSORIES |
154 |
|
ENGINE TESTING |
156 |
|
INSTALLATION OF ENGINE ON VEHICLE |
156 |
|
ENGINE COOLING COMPONENTS_NANO AMT |
157 |
|
1.0 RADIATOR LOCATION ON VEHICLE |
161 |
|
2.0 TECHNICAL SPECIFICATIONS |
162 |
|
3.0 RADIATOR REMOVAL AND REFITMENTON VEHICLE |
163 |
|
4.0 RADIATOR FAN REMOVAL AND REFITMENTPROCEDURE |
172 |
|
5.0 COOLANT TANK REMOVAL AND REFITMENTON VEHICLE |
176 |
|
6.0 OIL FILTER REMOVAL AND REFITMENTPROCEDURES ON VEHICLE |
178 |
|
3.4 ACCELERATOR |
183 |
|
EXPLODED VIEWS & CABLE ROUTING |
185 |
|
SYSTEM MAINTENANCE |
187 |
|
3.6 LUBRICATION SYSTEM |
191 |
|
GENERAL DESCRIPTION |
193 |
|
SYSTEM SCHEMATICS |
193 |
|
SPECIFICATIONS |
194 |
|
SYSTEM MAINTENANCE |
195 |
|
3.7 FUEL SYSTEM |
207 |
|
GENERAL DESCRIPTION |
209 |
|
SYSTEM SCHEMATICS |
209 |
|
EXPLODED VIEWS |
210 |
|
PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
211 |
|
SYSTEM COMPONENTS |
212 |
|
SYSTEM MAINTENANCE |
216 |
|
EVAPORATIVE EMISSION CONTROL SYSTEM |
226 |
|
3.8 INTAKE SYSTEM |
229 |
|
GENERAL DESCRIPTION |
231 |
|
EXPLODED VIEWS |
232 |
|
SYSTEM MAINTENANCE |
233 |
|
3.9 EXHAUST SYSTEM |
239 |
|
GENERAL DESCRIPTION |
241 |
|
EXPLODED VIEWS |
242 |
|
TIGHTENING TORQUE |
243 |
|
SYSTEM COMPONENTS |
244 |
|
SYSTEM MAINTENANCE |
246 |
|
3.10 IGNITION SYSTEM |
251 |
|
GENERAL DESCRIPTION |
253 |
|
SYSTEM SCHEMATICS |
253 |
|
SYSTEM MAINTENANCE |
254 |
|
3.11 ENGINE MANAGEMENT SYSTEM |
259 |
|
ABBREVIATIONS |
261 |
|
AN OVERVIEW |
262 |
|
3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
263 |
|
ECU BLOCK DIAGRAM |
264 |
|
ECU PIN ASSIGNMENT DETAILS |
265 |
|
ECU HANDLING AND CARE |
266 |
|
ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
267 |
|
3.11.2 SENSORS |
268 |
|
CRANK SHAFT POSITION SENSOR |
268 |
|
COOLANT TEMPERATURE SENSOR |
269 |
|
T-MAP SENSOR |
271 |
|
KNOCK SENSOR |
272 |
|
THROTTLE POSITION SENSOR |
273 |
|
LAMBDA (OXYGEN) SENSOR |
276 |
|
VEHICLE SPEED SENSOR |
277 |
|
3.11.3 ACTUATORS |
279 |
|
CANISTER PURGE VALVE |
279 |
|
FUEL INJECTOR |
280 |
|
IGNITION COIL |
282 |
|
INTAKE AIR CONTROL VALVE (IACV) |
285 |
|
COMPONENT FITMENT DATA |
287 |
|
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
291 |
|
DTC LIST |
291 |
|
LAPTOP BASED DIAGNOSTIC TESTER |
301 |
|
BLINK CODE |
316 |
|
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
318 |
|
REPAIRING STEPS |
318 |
|
VEHICLE TROUBLE SHOOTING FLOW CHART |
319 |
|
SENSOR AND ACTUATOR TESTING |
320 |
|
EMERGENCY SERVICE TIPS |
322 |
|
4. DRIVETRAIN |
323 |
|
4.1 CLUTCH |
329 |
|
4.1.1 GENERAL INFORMATION |
331 |
|
TECHNICAL SPECIFICATIONS |
331 |
|
CONSTRUCTION |
334 |
|
PRECAUTIONS |
336 |
|
TIGHTENING TORQUES |
337 |
|
SPECIAL TOOLS |
338 |
|
GENERAL SYMPTOMS AND DIAGNOSIS |
339 |
|
TROUBLE SHOOTING |
342 |
|
MAINTENANCE AND REPAIR |
343 |
|
A. PRELIMINARY INSPECTION |
343 |
|
B. CLUTCH SLIPPAGE TEST |
343 |
|
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
343 |
|
D. CLUTCH PEDAL PLAY ADJUSTMENT |
343 |
|
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
344 |
|
4.1.2 OVERHAUL |
345 |
|
EXPLODED VIEWS |
345 |
|
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
348 |
|
B. CLUTCH ACTUATION MECHANISM OVERHAUL |
349 |
|
C. CLUTCH CABLE REPLACEMENT |
352 |
|
TRANSAXLE-AMT |
355 |
|
1.0 AMT-KIT LOCATION ON VEHICLE |
359 |
|
2.0 PRECAUTIONS (DO’S AND DON’TS):-DO’S |
360 |
|
3.0 TECHNICAL SPECIFICATIONS |
362 |
|
4.0 TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS |
363 |
|
5.0 SPECIAL TOOLS |
365 |
|
6.0 AMT UNIT REMOVAL ANDINSTALLATION PROCEDURES ONVEHICLE |
367 |
|
7.0 MECHATRONIC GEAR ACTUATORUNIT (MGA) REMOVAL AND RE-FITMENTON BENCH |
373 |
|
8.0 TRANSMISSION CONTROL UNIT (TCU)REMOVAL AND RE-FITMENT ON BENCH |
375 |
|
9.0 OIL TANK REMOVAL AND REFITMENTON BENCH |
378 |
|
10.0 DC MOTOR REMOVAL AND REFITMENTON BENCH |
380 |
|
11.0 CLUTCH POSITION SENSORREMOVAL AND RE-FITMENT ON BENCH |
381 |
|
12.0 HYDRAULIC OIL ACCUMLATORREMOVAL AND RE-FITMENT ON BENCH |
381 |
|
13.0 POWER UNIT (PWU) BASE PLATEREMOVAL AND RE-FITMENT ON BENCH |
382 |
|
4.3 DRIVESHAFT |
383 |
|
4.3.1 GENERAL INFORMATION |
385 |
|
TIGHTENING TORQUE |
385 |
|
SPECIAL TOOL |
386 |
|
CONSTRUCTIONAL DETAILS |
387 |
|
EXPLODED VIEW - DRIVESHAFT |
387 |
|
COMPONENT DESCRIPTION |
388 |
|
TROUBLESHOOTING AND DIAGNOSIS |
389 |
|
4.3.2 ON VEHICLE REPAIRS |
390 |
|
PRECAUTIONS |
390 |
|
REMOVAL FROM VEHICLE |
392 |
|
DRIVESHAFT DISMANTLING / ASSEMBLY |
395 |
|
GEAR SHIFTER CONSOLE |
401 |
|
1.0 AUTOMATED MANUAL TRANSMISSION(AMT) GEARBOX SHIFTER AND SHIFTINGMECHANISM |
404 |
|
2.0 GEAR SHIFTER CENTER CONSOLEREMOVAL AND RE-FITMENT ONVEHICLE |
406 |
|
5. SUSPENSION SYSTEM |
411 |
|
5.1 GENERAL INFORMATION |
417 |
|
TECHNICAL SPECIFICATIONS |
417 |
|
TIGHTENING TORQUES |
418 |
|
SPECIAL TOOLS |
421 |
|
LAY OUT OF FRONT SUSPENSION SYSTEM |
423 |
|
LAY OUT OF REAR SUSPENSION SYSTEM |
424 |
|
MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
425 |
|
TROUBLESHOOTING AND DIAGNOSIS |
428 |
|
5.2 ON VEHICLE REPAIRS |
431 |
|
FRONT SUSPENSION COMPONENTS |
431 |
|
STRUT |
431 |
|
ANTI-ROLL BAR |
437 |
|
LOWER ARM |
438 |
|
WHEEL BEARING |
440 |
|
REAR SUSPENSION COMPONENTS |
443 |
|
SHOCK ABSORBER |
444 |
|
COIL SPRING |
445 |
|
BUMP STOPPER AND SPRING UPPER SEAT |
446 |
|
SEMI TRAILING ARM |
447 |
|
WHEEL HUB AND WHEEL BEARING |
450 |
|
5.3 WHEELS AND TYRES |
455 |
|
5.3.1 GENERAL INFORMATION |
455 |
|
TECHNICAL SPECIFICATIONS |
455 |
|
TIGHTENING TORQUE |
456 |
|
EXPLODED VIEW |
457 |
|
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
458 |
|
5.3.2 ON VEHICLE REPAIRS |
459 |
|
WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
460 |
|
WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
461 |
|
WHEEL BALANCING |
462 |
|
WHEEL RUNOUT |
463 |
|
TYRE REPLACEMENT |
464 |
|
WHEEL ASSEMBLY REPLACEMENT |
465 |
|
REPAIRING TUBELESS TYRE PUNCTURE |
465 |
|
TYRE DIAGNOSIS |
466 |
|
6. BRAKE SYSTEM |
473 |
|
6.1 GENERAL INFORMATION |
479 |
|
TECHNICAL SPECIFICATIONS |
479 |
|
TIGHTENING TORQUES |
480 |
|
SPECIAL TOOLS |
484 |
|
SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
485 |
|
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
487 |
|
FRONT DRUM BRAKES |
487 |
|
REAR DRUM BRAKES |
488 |
|
AUTO INCREMENTAL BRAKE |
489 |
|
TANDEM MASTER CYLINDER (TMC) |
490 |
|
TMC WITH VACUUM BOOSTER ASSEMBLY |
491 |
|
WHEEL CYLINDER |
494 |
|
PARKING BRAKES |
495 |
|
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
496 |
|
BLEEDING OF HYDRAULIC SYSTEM |
501 |
|
TROUBLESHOOTING AND DIAGNOSIS |
503 |
|
6.4 ON VEHICLE REPAIRS |
510 |
|
FRONT BRAKE COMPONENTS |
511 |
|
FRONT BRAKE DRUM |
512 |
|
FRONT BRAKE SHOES |
514 |
|
FRONT BRAKE BACK PLATE |
519 |
|
REAR BRAKE COMPONENTS |
520 |
|
REAR BRAKE DRUM |
521 |
|
REAR BRAKE SHOES |
522 |
|
REAR BRAKE BACK PLATE |
524 |
|
TMC |
526 |
|
WHEEL CYLINDER |
535 |
|
PARKING BRAKES |
541 |
|
VACUUM BRAKE BOOSTER |
544 |
|
BRAKE HOSES/PIPES SCHEMATIC |
545 |
|
VACUUM LINES |
547 |
|
7. STEERING |
549 |
|
7.1 GENERAL INFORMATION |
555 |
|
TECHNICAL SPECIFICATIONS |
555 |
|
TIGHTENING TORQUES |
556 |
|
SPECIAL TOOLS |
558 |
|
EXPLODED VIEWS |
559 |
|
SCHEMATIC OF STEERING SYSTEM |
561 |
|
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
563 |
|
7.3 ON VEHICLE REPAIRS |
564 |
|
STEERING WHEEL |
566 |
|
STEERING COLUMN ASSEMBLY |
567 |
|
STEERING UPPER COLUMN |
569 |
|
INTERMEDIATE SHAFT |
569 |
|
STEERING RACK AND PINION ASSEMBLY |
570 |
|
OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
572 |
|
WHEEL ALIGNMENT |
581 |
|
TROUBLESHOOTING AND DIAGNOSIS |
583 |
|
8. ELECTRICALS |
587 |
|
1.0 EMS ECU AND AMT TCU CONNECTOR’S REMOVAL AND RE-FITMENT ON VEHICLE |
590 |
|
1.1 PARTS LIST |
590 |
|
1.2 EMS ECU CONNECTOR REMOVALAND RE-FITMENT ON VEHICLE |
592 |
|
1.3 AMT TCU UNIT CONNECTOR’SREMOVAL AND RE-FIMENT ON VEHICLE |
597 |
|
2.0 FOG LAMP REMOVAL AND REFITMENTON VEHICLE |
601 |
|
3.0 HORN REMOVAL AND RE-FITMENT ONVEHICLE |
604 |
|
4.0 AMBIENT TEMPERATURE SENSORREMOVAL AND RE-FITMENT ONVEHICLE |
607 |
|
5.0 TRANSMISSION INPUT SPEEDSENSOR REMOVAL AND RE-FITMENT ONVEHICLE |
611 |
|
6.0 EXHAUST FAN REMOVAL AND REFITMENTON VEHICLE |
613 |
|
7.0 DIAGNOSTIC TROUBLE CODES FOR ELECTRONIC POWER ASSISTED STEERING |
616 |
|
8.0 DIAGNOSTIC TROUBLE CODES FOR ENGINE MANAGEMENT SYSTEM |
617 |
|
CIRCUIT SCHEMATICS |
648-649 |
|
INDEX AND COLOUR CODES |
650-651 |
|
SYMBOLS |
652-653 |
|
CONNECTOR DETAILS |
654-655 |
|
WIRING HARNESS TOPOLOGY |
656-657 |
|
POWER SUPPLY - 1 |
658-659 |
|
POWER SUPPLY - 2 |
660-661 |
|
POWER SUPPLY - 3 |
662-663 |
|
POWER SUPPLY - 4 |
664-665 |
|
POWER SUPPLY - 5 |
666-667 |
|
POWER SUPPLY - 6 |
668-669 |
|
POWER SUPPLY - 7 |
670-671 |
|
POWER SUPPLY - 8 |
672-673 |
|
POWER SUPPLY - 9 |
674-675 |
|
CIRCUIT SCHEMATIC - EARTH 1 |
676-677 |
|
CIRCUIT SCHEMATIC - EARTH 2 |
678-679 |
|
CIRCUIT SCHEMATIC - EARTH 3 |
680-681 |
|
CIRCUIT SCHEMATIC - EARTH 4 |
682-683 |
|
STARTING AND CHARGING |
684-685 |
|
ENGINE CONTROL (PETROL) - 1 |
686-687 |
|
ENGINE CONTROL (PETROL) - 2 |
688-689 |
|
ENGINE CONTROL (PETROL) - 3 |
690-691 |
|
ENGINE CONTROL (PETROL) - 4 |
692-693 |
|
FUEL PUMP |
694-695 |
|
HVAC (MANUAL) |
696-697 |
|
RADIATOR FAN |
698-699 |
|
POWER WINDOWS - 1 |
700-701 |
|
POWER WINDOWS - 2 |
702-703 |
|
REMOTE KEYLESS ENTRY - 1 |
704-705 |
|
REMOTE KEYLESS ENTRY - 2 |
706-707 |
|
CENTRAL DOOR LOCKING |
708-709 |
|
CLUSTER |
710-711 |
|
CLUSTER - 2 |
712-713 |
|
FRONT WIPER (PASSIVE) |
714-715 |
|
EXTERIOR LIGHTING - 1 |
716-717 |
|
EXTERIOR LIGHTING - 2 |
718-719 |
|
EXTERIOR LIGHTING - 3 |
720-721 |
|
EXTERIOR LIGHTING - 4 |
722-723 |
|
EXTERIOR LIGHTING - 5 |
724-725 |
|
CAN |
726-727 |
|
INTERIOR LAMPS |
728-729 |
|
EPAS |
730-731 |
|
HORN |
732-733 |
|
POWER SOCKET AND CIGAR LIGHTER |
734-735 |
|
REAR PARKING AIS |
736-737 |
|
AUTO TRANSMISSION (AMT) |
738-739 |
|
AUDIO SYSTEM |
740-741 |
|
AUDIO SYSTEM - 2 |
742-743 |
|
9. BODY |
744 |
|
9.1 GENERAL INFORMATION |
750 |
|
TECHNICAL SPECIFICATIONS |
750 |
|
TIGHTENING TORQUE |
751 |
|
9.2 ON VEHICLE REPAIRS |
755 |
|
EXPLODED VIEW - BUMPERS & HOOD |
755 |
|
FRONT BUMPER |
756 |
|
FENDER (SIDE BONNET) |
757 |
|
HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
758 |
|
FRONT DOOR |
762 |
|
REAR DOOR |
773 |
|
REAR SHELF |
782 |
|
TAILGATE |
782 |
|
REAR BUMPER |
783 |
|
DASHBOARD |
785 |
|
CENTER CONSOLE |
788 |
|
SEATS & BELTS |
789 |
|
OUTER REAR VIEW MIRROR (ORVM) |
799 |
|
SUN VISOR |
799 |
|
TRIMS |
800 |
|
FLOOR CARPET |
801 |
|
WINDSHIELD |
804 |
|
9.3 PAINT CARE |
806 |
|
9.4 BODY REPAIR DATA |
809 |
|
9.5 TROUBLESHOOTING AND DIAGNOSIS |
814 |
|
10. HVAC |
816 |
|
10.1 GENERAL INFORMATION |
822 |
|
TECHNICAL SPECIFICATIONS |
822 |
|
TIGHTENING TORQUES |
823 |
|
GENERAL PRECAUTIONS |
825 |
|
COMPONENT DESCRIPTION |
831 |
|
10.2 MAINTENANCE OF AC/HVAC SYSTEM |
834 |
|
TROUBLESHOOTING AND DIAGNOSIS |
835 |
|
PRESSURE TEST USING MANIFOLD GAUGES |
848 |
|
FLUSHING OF AC SYSTEM |
853 |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
855 |
|
A/C SYSTEM PERFORMANCE TEST |
857 |
|
LEAK TEST SYSTEM |
857 |
|
10.3 ON VEHICLE REPAIRS |
858 |
|
CONTROL PANEL ASSEMBLY |
859 |
|
AC COMPRESSOR |
860 |
|
1.0 AC COMPRESSOR LOCATION ON VEHICLE |
864 |
|
2.0 TECHNICAL SPECIFICATIONS |
865 |
|
3.0 TIGHTENING TORQUES |
866 |
|
4.0 PRECAUTIONS |
867 |
|
5.0 EXPLODED VIEW AND PART LIST |
870 |
|
6.0 AC COMPRESSOR REMOVAL ANDRE-FITMENT ON VEHICLE |
871 |
|
HVAC UNIT |
878 |
|
BLOWER UNIT |
882 |
|
BLOWER RESISTER |
882 |
|
FILTER |
883 |
|
EVAPORATOR AND EXPANSION VALVE |
884 |
|
HEATER ASSEMBLY |
886 |
|
KINEMATICS |
887 |
|
PRESSURE SWITCH |
887 |
|
CONDENSER ASSEMBLY |
888 |
|
DRIER CARTRIDGE/R.D. BOTTLE |
890 |
|
CONDENSER FAN AND CONDENSER MOTOR |
892 |
|
REFRIGERANT LINES |
893 |
|
HEATER LINES |
895 |