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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
3.1.1 TECHNICAL SPECIFICATIONS 		57
3.1.2 FEATURES OF 273 MPFI ENGINE 		58
3.1.3 TIGHTENING TORQUE 		59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 		61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 		65
3.2 ON VEHICLE PROCEDURES 		69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 		71
3.2.2 ENGINE OIL REPLACEMENT 		73
3.2.3 OIL FILTER REPLACEMENT 		74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		75
3.2.5 FUEL FILTER REPLACEMENT 		76
3.2.6 TAPPET SETTING 		77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 		78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 		79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 		81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 		86
3.2.11 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
3.3.1.1 GENERAL DESCRIPTION 		101
3.3.1.2 EXPLODED VIEW 		102
3.3.1.3 CYLINDER HEAD OVERHAUL 		104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 		104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 		108
3.3.1.6 INSPECTION & REPAIR DATA 		111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 		118
3.3.2 ENGINE BLOCK 		123
3.3.2.1 GENERAL DESCRIPTION 		125
3.3.2.2 EXPLODED VIEW 		126
3.3.2.3 ENGINE BLOCK OVERHAUL 		128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 		128
3.3.2.5 INSPECTION & REPAIR DATA 		133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 		143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 		156
3.3.2.8 ENGINE TESTING 		158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 		158
3.4 ACCELERATOR 		159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 		161
3.4.2 SYSTEM MAINTENANCE 		163
3.5 COOLING SYSTEM 		167
3.5.1 GENERAL DESCRIPTION 		169
3.5.2 SYSTEM SCHEMATICS 		169
3.5.3 EXPLODED VIEWS 		170
3.5.4 SPECIFICATIONS 		172
3.5.5 SYSTEM COMPONENTS 		173
3.5.6 SYSTEM MAINTENANCE 		174
3.6 LUBRICATION SYSTEM 		183
3.6.1 GENERAL DESCRIPTION 		185
3.6.2 SYSTEM SCHEMATICS 		185
3.6.3 SPECIFICATIONS 		186
3.6.4 SYSTEM MAINTENANCE 		187
3.7 FUEL SYSTEM 		199
3.7.1 GENERAL DESCRIPTION 		201
3.7.2 SYSTEM SCHEMATICS 		201
3.7.3 EXPLODED VIEWS 		202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 		203
3.7.5 SYSTEM COMPONENTS 		204
3.7.6 SYSTEM MAINTENANCE 		208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 		218
3.8 INTAKE SYSTEM 		221
3.8.1 GENERAL DESCRIPTION 		223
3.8.2 EXPLODED VIEWS 		224
3.8.3 SYSTEM MAINTENANCE 		225
3.9 EXHAUST SYSTEM 		231
3.9.1 GENERAL DESCRIPTION 		233
3.9.2 EXPLODED VIEWS 		234
3.9.3 TIGHTENING TORQUE 		235
3.9.4 SYSTEM COMPONENTS 		236
3.9.5 SYSTEM MAINTENANCE 		238
3.10 IGNITION SYSTEM 		243
3.10.1 GENERAL DESCRIPTION 		245
3.10.2 SYSTEM SCHEMATICS 		245
3.10.3 SYSTEM MAINTENANCE 		246
3.11 ENGINE MANAGEMENT SYSTEM 		251
ABBREVIATIONS 		251
AN OVERVIEW 		254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 		255
3.11.1.1 ECU BLOCK DIAGRAM 		256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 		257
3.11.1.3 ECU HANDLING AND CARE 		258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 		259
3.11.2 SENSORS 		260
3.11.2.1 CRANK SHAFT POSITION SENSOR 		260
3.11.2.2 COOLANT TEMPERATURE SENSOR 		261
3.11.2.3 T-MAP SENSOR 		263
3.11.2.4 KNOCK SENSOR 		264
3.11.2.5 THROTTLE POSITION SENSOR 		265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 		268
3.11.2.7 VEHICLE SPEED SENSOR 		269
3.11.3 ACTUATORS 		271
3.11.3.1 CANISTER PURGE VALVE 		271
3.11.3.2 FUEL INJECTOR 		272
3.11.3.3 IGNITION COIL 		274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 		277
3.11.3.5 COMPONENT FITMENT DATA 		279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 		283
3.11.4.1 DTC LIST 		283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 		293
3.11.4.3 BLINK CODE 		308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 		310
3.11.5.1 REPAIRING STEPS 		310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 		311
3.11.5.3 SENSOR AND ACTUATOR TESTING 		312
3.11.5.4 EMERGENCY SERVICE TIPS 		314
4. DRIVETRAIN 		315
4.1 CLUTCH 		321
4.1.1 GENERAL INFORMATION 		323
4.1.1.1 TECHNICAL SPECIFICATIONS 		323
4.1.1.2 CONSTRUCTION 		326
4.1.1.3 PRECAUTIONS 		328
4.1.1.4 TIGHTENING TORQUES 		329
4.1.1.5 SPECIAL TOOLS 		330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		331
4.1.1.7 TROUBLE SHOOTING 		334
4.1.1.8 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
4.2.1.1 TECHNICAL SPECIFICATION 		349
4.2.1.2 CONSTRUCTION 		349
4.2.1.3 PRECAUTIONS 		350
4.2.1.4 TIGHTENING TORQUES 		351
4.2.1.5 SPECIAL TOOLS 		354
4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		358
4.2.1.7 TRANSAXLE OIL REPLACEMENT 		359
4.2.2 OVERHAUL 		360
4.2.2.1 EXPLODED VIEWS 		360
4.2.2.2 COMPONENT IDENTIFICATION 		367
4.2.2.3 PRECAUTIONS 		369
4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE 		369
4.2.2.5 TRANSAXLE DISMANTLING 		372
4.2.2.6 INPUT SHAFT ASSEMBLY 		376
4.2.2.7 LAY SHAFT ASSEMBLY 		381
4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK 		387
4.2.2.9 DIFFERENTIAL ASSEMBLY 		390
4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY 		394
4.2.2.11 REAR HALF HOUSING ASSEMBLY 		400
4.2.2.12 FRONT HALF HOUSING 		402
4.2.2.13 TRANSAXLE ASSEMBLY 		404
A. SHIM SELECTION 		404
B. ASSEMBLING THE TRANSAXLE 		405
4.2.2.14 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
4.3.1.1 TIGHTENING TORQUE 		413
4.3.1.2 SPECIAL TOOL 		414
4.3.1.3 CONSTRUCTIONAL DETAILS 		415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 		415
4.3.1.5 COMPONENT DESCRIPTION 		416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 		417
4.3.2 ON VEHICLE REPAIRS 		418
4.3.2.1 PRECAUTIONS 		418
4.3.2.2 REMOVAL FROM VEHICLE 		420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 		423
5. SUSPENSION SYSTEM 		429
5.1 GENERAL INFORMATION 		435
5.1.1 TECHNICAL SPECIFICATIONS 		435
5.1.2 TIGHTENING TORQUES 		436
5.1.3 SPECIAL TOOLS 		439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 		441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 		442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 		443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 		446
5.2 ON VEHICLE REPAIRS 		449
5.2.1 FRONT SUSPENSION COMPONENTS 		449
5.2.1.1 STRUT 		449
5.2.1.2 ANTI-ROLL BAR 		455
5.2.1.3 LOWER ARM 		456
5.2.1.4 WHEEL BEARING 		458
5.2.2 REAR SUSPENSION COMPONENTS 		461
5.2.2.1 SHOCK ABSORBER 		462
5.2.2.2 COIL SPRING 		463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 		464
5.2.2.4 SEMI TRAILING ARM 		465
5.2.3 WHEEL HUB AND WHEEL BEARING 		468
5.3 WHEELS AND TYRES 		473
5.3.1 GENERAL INFORMATION 		473
5.3.1.1 TECHNICAL SPECIFICATIONS 		473
5.3.1.2 TIGHTENING TORQUE 		474
5.3.1.3 EXPLODED VIEW 		475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 		476
5.3.2 ON VEHICLE REPAIRS 		477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 		478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 		479
5.3.2.3 WHEEL BALANCING 		480
5.3.2.4 WHEEL RUNOUT 		481
5.3.2.5 TYRE REPLACEMENT 		482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 		483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 		483
5.3.2.8 TYRE DIAGNOSIS 		484
6. BRAKE SYSTEM 		493
6.1 GENERAL INFORMATION 		499
6.1.1 TECHNICAL SPECIFICATIONS 		499
6.1.2 TIGHTENING TORQUES 		500
6.1.3 SPECIAL TOOLS 		504
6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 		505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 		507
6.2.1 FRONT DRUM BRAKES 		507
6.2.2 REAR DRUM BRAKES 		508
6.2.3 AUTO INCREMENTAL BRAKE 		509
6.2.4 TANDEM MASTER CYLINDER (TMC) 		510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 		511
6.2.6 WHEEL CYLINDER 		514
6.2.7 PARKING BRAKES 		515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 		516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 		521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 		523
6.4 ON VEHICLE REPAIRS 		530
6.4.1 FRONT BRAKE COMPONENTS 		531
6.4.2 FRONT BRAKE DRUM 		532
6.4.3 FRONT BRAKE SHOES 		534
6.4.4 FRONT BRAKE BACK PLATE 		539
6.4.5 REAR BRAKE COMPONENTS 		540
6.4.6 REAR BRAKE DRUM 		541
6.4.7 REAR BRAKE SHOES 		542
6.4.8 REAR BRAKE BACK PLATE 		544
6.4.9 TMC 		546
6.4.10 WHEEL CYLINDER 		555
6.4.11 PARKING BRAKES 		561
6.4.12 VACUUM BRAKE BOOSTER 		564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 		565
6.4.14 VACUUM LINES 		567
7. STEERING 		569
7.1 GENERAL INFORMATION 		575
7.1.1 TECHNICAL SPECIFICATIONS 		575
7.1.2 TIGHTENING TORQUES 		576
7.1.3 SPECIAL TOOLS 		578
7.1.4 EXPLODED VIEWS 		579
7.1.5 SCHEMATIC OF STEERING SYSTEM 		581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 		583
7.3 ON VEHICLE REPAIRS 		584
7.3.1 STEERING WHEEL 		586
7.3.2 STEERING COLUMN ASSEMBLY 		587
7.3.3 STEERING UPPER COLUMN 		589
7.3.4 INTERMEDIATE SHAFT 		589
7.3.5 STEERING RACK AND PINION ASSEMBLY 		590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 		592
7.3.7 WHEEL ALIGNMENT 		601
7.3.8 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
8.21 CIRCUIT SCHEMATICS 		722-723
8.21.1. TOPOLOGY / GROUND POINT LOCATION 		726-727
8.21.2. POWER DISTRIBUTION 		728-729
8.21.3. EARTH 		742-743
8.21.4. STARTER AND CHARGING 		744-745
8.21.5. EMS ECU 		746-747
8.21.6. FUEL PUMP 		750-751
8.21.7. HVAC 		752-753
8.21.8. RADIATOR FAN 		756-757
8.21.9. POWER WINDOW 		758-759
8.21.10. CENTRAL DOOR LOCKING 		762-763
8.21.11. INSTRUMENT CLUSTER 		766-767
8.21.12. FRONT WIPER 		772-773
8.21.13. EXTERIOR LIGHTING 		774-775
8.21.14. CAN CIRCUIT 		788-789
8.21.15. IMMOBILISER 		790-791
8.21.16. INTERIOR LAMPS 		792-793
8.21.17. HORN AND ROOF LAMP 		794-795
8.21.18. POWER SHOCKET AND CIGAR LIGHTER 		796-797
8.21.19. REVERSE PARKING AID 		798-799
8.21.20. MUSIC SYSTEM 		800-801
8.21.21. FUSE BOX DETAILS 		802-803
9. BODY 		804
9.1 GENERAL INFORMATION 		810
9.1.1 TECHNICAL SPECIFICATIONS 		810
9.1.2 TIGHTENING TORQUE 		811
9.2 ON VEHICLE REPAIRS 		815
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		815
9.2.2 FRONT BUMPER 		816
9.2.3 FENDER (SIDE BONNET) 		817
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		818
9.2.5 FRONT DOOR 		822
9.2.6 REAR DOOR 		833
9.2.7 REAR SHELF 		842
9.2.8 TAILGATE 		842
9.2.9 REAR BUMPER 		843
9.2.10 DASHBOARD 		845
9.2.11 CENTER CONSOLE 		848
9.2.12 SEATS & BELTS 		849
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		859
9.2.14 SUN VISOR 		859
9.2.15 TRIMS 		860
9.2.16 FLOOR CARPET 		861
9.2.17 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
10.1.1 TECHNICAL SPECIFICATIONS 		882
10.1.2 TIGHTENING TORQUES 		883
10.1.3 GENERAL PRECAUTIONS 		885
10.1.4 SYSTEM LAYOUTS 		887
10.1.5 COMPONENT DESCRIPTION 		891
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		894
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		895
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		908
10.2.3 FLUSHING OF AC SYSTEM 		913
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		915
10.2.5 A/C SYSTEM PERFORMANCE TEST 		917
10.2.6 LEAK TEST SYSTEM 		917
10.3 ON VEHICLE REPAIRS 		918
10.3.1 CONTROL PANEL ASSEMBLY 		919
10.3.2 A/C COMPRESSOR 		920
10.3.3 HVAC UNIT 		931
10.3.4 BLOWER UNIT 		935
10.3.5 BLOWER RESISTER 		935
10.3.6 FILTER 		936
10.3.7 EVAPORATOR AND EXPANSION VALVE 		937
10.3.8 HEATER ASSEMBLY 		939
10.3.9 KINEMATICS 		940
10.3.10 PRESSURE SWITCH 		940
10.3.11 CONDENSER ASSEMBLY 		941
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		943
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		945
10.3.14 REFRIGERANT LINES 		946
10.3.15 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
3.1.1 TECHNICAL SPECIFICATIONS 		57
3.1.2 FEATURES OF 273 MPFI ENGINE 		58
3.1.3 TIGHTENING TORQUE 		59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 		61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 		65
3.2 ON VEHICLE PROCEDURES 		69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 		71
3.2.2 ENGINE OIL REPLACEMENT 		73
3.2.3 OIL FILTER REPLACEMENT 		74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		75
3.2.5 FUEL FILTER REPLACEMENT 		76
3.2.6 TAPPET SETTING 		77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 		78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 		79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 		81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 		86
3.2.11 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
3.3.1.1 GENERAL DESCRIPTION 		101
3.3.1.2 EXPLODED VIEW 		102
3.3.1.3 CYLINDER HEAD OVERHAUL 		104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 		104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 		108
3.3.1.6 INSPECTION & REPAIR DATA 		111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 		118
3.3.2 ENGINE BLOCK 		123
3.3.2.1 GENERAL DESCRIPTION 		125
3.3.2.2 EXPLODED VIEW 		126
3.3.2.3 ENGINE BLOCK OVERHAUL 		128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 		128
3.3.2.5 INSPECTION & REPAIR DATA 		133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 		143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 		156
3.3.2.8 ENGINE TESTING 		158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 		158
3.4 ACCELERATOR 		159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 		161
3.4.2 SYSTEM MAINTENANCE 		163
3.5 ENGINE COMPONENTS 		952
3.5.1 RADIATOR LOCATION ON VEHICLE 		956
3.5.2 TECHNICAL SPECIFICATIONS 		957
3.5.3 RADIATOR REMOVAL AND RE-FITMENT ON VEHICLE 		958
3.5.4 RADIATOR FAN REMOVAL AND RE-FITMENT ON VEHICLE 		967
3.5.5 COOLANT TANK REMOVAL AND RE-FITMENT ON VEHICLE 		971
3.5.6 OIL FILTER REMOVAL AND RE-FITMENT ON VEHICLE 		973
3.5.7 CATCON REMOVAL AND RE-FITMENT PROCEDURES ON VEHICLE 		978
3.5.8 ELECTRONIC THROTTLE CONTROL BODY ORIENTATION 		986
3.5.9 THERMOSTAT 		987
3.6 LUBRICATION SYSTEM 		183
3.6.1 GENERAL DESCRIPTION 		185
3.6.2 SYSTEM SCHEMATICS 		185
3.6.3 SPECIFICATIONS 		186
3.6.4 SYSTEM MAINTENANCE 		187
3.7 FUEL SYSTEM 		199
3.7.1 GENERAL DESCRIPTION 		201
3.7.2 SYSTEM SCHEMATICS 		201
3.7.3 EXPLODED VIEWS 		202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 		203
3.7.5 SYSTEM COMPONENTS 		204
3.7.6 SYSTEM MAINTENANCE 		208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 		218
3.8 INTAKE SYSTEM 		221
3.8.1 GENERAL DESCRIPTION 		223
3.8.2 EXPLODED VIEWS 		224
3.8.3 SYSTEM MAINTENANCE 		225
3.9 EXHAUST SYSTEM 		231
3.9.1 GENERAL DESCRIPTION 		233
3.9.2 EXPLODED VIEWS 		234
3.9.3 TIGHTENING TORQUE 		235
3.9.4 SYSTEM COMPONENTS 		236
3.9.5 SYSTEM MAINTENANCE 		238
3.10 IGNITION SYSTEM 		243
3.10.1 GENERAL DESCRIPTION 		245
3.10.2 SYSTEM SCHEMATICS 		245
3.10.3 SYSTEM MAINTENANCE 		246
3.11 ENGINE MANAGEMENT SYSTEM 		251
ABBREVIATIONS 		253
AN OVERVIEW 		254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 		255
3.11.1.1 ECU BLOCK DIAGRAM 		256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 		257
3.11.1.3 ECU HANDLING AND CARE 		258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 		259
3.11.2 SENSORS 		260
3.11.2.1 CRANK SHAFT POSITION SENSOR 		260
3.11.2.2 COOLANT TEMPERATURE SENSOR 		261
3.11.2.3 T-MAP SENSOR 		263
3.11.2.4 KNOCK SENSOR 		264
3.11.2.5 THROTTLE POSITION SENSOR 		265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 		268
3.11.2.7 VEHICLE SPEED SENSOR 		269
3.11.3 ACTUATORS 		271
3.11.3.1 CANISTER PURGE VALVE 		271
3.11.3.2 FUEL INJECTOR 		272
3.11.3.3 IGNITION COIL 		274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 		277
3.11.3.5 COMPONENT FITMENT DATA 		279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 		283
3.11.4.1 DTC LIST 		283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 		293
3.11.4.3 BLINK CODE 		308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 		310
3.11.5.1 REPAIRING STEPS 		310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 		311
3.11.5.3 SENSOR AND ACTUATOR TESTING 		312
3.11.5.4 EMERGENCY SERVICE TIPS 		314
4. DRIVETRAIN 		315
4.1 CLUTCH 		989
4.1.1 GENERAL INFORMATION 		989
4.1.1.1 TECHNICAL SPECIFICATION 		989
4.1.1.2 CONSTRUCTION 		992
4.1.1.3 PRECAUTIONS 		994
4.1.1.4 TIGHTENING TORQUES 		995
4.1.1.5 SPECIAL TOOLS 		996
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		997
4.1.1.7 TROUBLE SHOOTING 		999
4.1.1.8 MAINTENANCE AND REPAIRS 		1000
4.1.2 OVERHAULING 		1001
4.1.2.1 EXPLODED VIEW 		1001
4.1.2.2 PROCEDURE 		1002
4.1.2.2.1 REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 		1002
4.1.2.2.2 CLUTCH ACTUATION MECHANISM OVERHAUL 		1003
4.2 5-SPEED TRANSAXLE 		1006
4.2.1 GENERAL INFORMATION 		1006
4.2.1.1 TECHNICAL SPECIFICATION 		1006
4.2.1.2 PRECAUTIONS 		1007
4.2.1.3 TIGHTENING TORQUES 		1008
4.2.1.4 SPECIAL TOOLS 		1012
4.2.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 		1015
4.2.1.6 TRANSAXLE OIL REPLACEMENT 		1016
4.2.2 OVERHAULING (EXPLOADED VIEWS) 		1017
4.2.2.1 TRANSAXLE HOUSING 		1017
4.2.2.2 INPUT SHAFT AND LAY SHAFT 		1019
4.2.2.3 SHIFER SHAFT AND SHIFTER SLEEVE 		1020
4.2.2.4 DIFFERENTIAL 		1021
4.2.2.5 TOP COVER ASSEMBLY 		1022
4.2.2.6 SHIFTER LINKAGE 		1023
4.2.3 COMPONENT IDENTIFICATION 		1024
4.2.3.1 SHIFTER SHAFTS 		1024
4.2.3.2 SHIFTER FORKS (DOGS) 		1024
4.2.3.3 SHIFTER SLEEVE 		1025
4.2.4 REMOVAL OF TRANSAXLE 		1027
4.2.5 TRANSAXLE DISMANTLING 		1028
4.2.6 INPUT SHAFT ASSEMBLY 		1032
4.2.7 LAY SHAFT ASSEMBLY 		1035
4.2.8 SHIFTER SHAFT AND SHIFTER FORK 		1039
4.2.9 REVERSE GEAR SHIFTER BRACKET ASSEMBLY 		1042
4.2.10 DIFFERENTIAL ASSEMBLY 		1043
4.2.11 TOP COVER ASSEMBLY 		1046
4.2.12 REAR HALF HOUSING ASSEMBLY 		1049
4.2.13 FRONT HALF HOUSING ASSEMBLY 		1050
4.2.14 TRANSAXLE ASSEMBLY 		1052
4.2.14.1 SHIM SELECTION 		1052
4.2.14.2 ASSEMBLING THE TRANSAXLE 		1053
4.3 DRIVESHAFT 		411
4.3.1 GENERAL INFORMATION 		413
4.3.1.1 TIGHTENING TORQUE 		413
4.3.1.2 SPECIAL TOOL 		414
4.3.1.3 CONSTRUCTIONAL DETAILS 		415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 		415
4.3.1.5 COMPONENT DESCRIPTION 		416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 		417
4.3.2 ON VEHICLE REPAIRS 		418
4.3.2.1 PRECAUTIONS 		418
4.3.2.2 REMOVAL FROM VEHICLE 		420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 		423
4.4 AMT KIT 		1057
4.4.1 AMT KIT LOCATION ON VEHICLE 		1058
4.4.2 ABBREVIATION LIST 		1059
4.4.3 PRECAUTION (DO’S AND DON’TS) 		1060
4.4.4 TECHNICAL SPECIFICATIONS 		1062
4.4.5 TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS 		1063
4.4.6 TOOLS 		1065
4.4.7 AMT UNIT REMOVAL AND INSTALLATION PROCEDURES ON VEHICLE 		1067
4.4.8 MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT ON BENCH 		1074
4.4.9 TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT ON BENCH 		1077
4.4.10 OIL TANK REMOVAL AND RE-FITMENT ON BENCH 		1081
4.4.11 DC MOTOR REMOVAL AND RE-FITMENT ON BENCH 		1083
4.4.12 CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT ON BENCH 		1084
4.4.13 HYDRAULIC OIL ACCUMLATOR 		1084
4.4.14 POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH 		1085
4.5 GEAR SHIFTER CONSOLE 		1087
4.5.1 AMT GEARBOX SHIFTER AND SHIFTING MECHANISM 		1087
4.5.2 GEAR SHIFTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE 		1089
5. SUSPENSION SYSTEM 		429
5.1 GENERAL INFORMATION 		435
5.1.1 TECHNICAL SPECIFICATIONS 		435
5.1.2 TIGHTENING TORQUES 		436
5.1.3 SPECIAL TOOLS 		439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 		441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 		442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 		443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 		446
5.2 ON VEHICLE REPAIRS 		449
5.2.1 FRONT SUSPENSION COMPONENTS 		449
5.2.1.1 STRUT 		449
5.2.1.2 ANTI-ROLL BAR 		455
5.2.1.3 LOWER ARM 		456
5.2.1.4 WHEEL BEARING 		458
5.2.2 REAR SUSPENSION COMPONENTS 		461
5.2.2.1 SHOCK ABSORBER 		462
5.2.2.2 COIL SPRING 		463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 		464
5.2.2.4 SEMI TRAILING ARM 		465
5.2.3 WHEEL HUB AND WHEEL BEARING 		468
5.3 WHEELS AND TYRES 		473
5.3.1 GENERAL INFORMATION 		473
5.3.1.1 TECHNICAL SPECIFICATIONS 		473
5.3.1.2 TIGHTENING TORQUE 		474
5.3.1.3 EXPLODED VIEW 		475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 		476
5.3.2 ON VEHICLE REPAIRS 		477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 		478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 		479
5.3.2.3 WHEEL BALANCING 		480
5.3.2.4 WHEEL RUNOUT 		481
5.3.2.5 TYRE REPLACEMENT 		482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 		483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 		483
5.3.2.8 TYRE DIAGNOSIS 		484
6. BRAKE SYSTEM 		493
6.1 GENERAL INFORMATION 		499
6.1.1 TECHNICAL SPECIFICATIONS 		499
6.1.2 TIGHTENING TORQUES 		500
6.1.3 SPECIAL TOOLS 		504
6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 		505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 		507
6.2.1 FRONT DRUM BRAKES 		507
6.2.2 REAR DRUM BRAKES 		508
6.2.3 AUTO INCREMENTAL BRAKE 		509
6.2.4 TANDEM MASTER CYLINDER (TMC) 		510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 		511
6.2.6 WHEEL CYLINDER 		514
6.2.7 PARKING BRAKES 		515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 		516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 		521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 		523
6.4 ON VEHICLE REPAIRS 		530
6.4.1 FRONT BRAKE COMPONENTS 		531
6.4.2 FRONT BRAKE DRUM 		532
6.4.3 FRONT BRAKE SHOES 		542
6.4.4 FRONT BRAKE BACK PLATE 		539
6.4.5 REAR BRAKE COMPONENTS 		540
6.4.6 REAR BRAKE DRUM 		541
6.4.7 REAR BRAKE SHOES 		542
6.4.8 REAR BRAKE BACK PLATE 		544
6.4.9 TMC 		546
6.4.10 WHEEL CYLINDER 		555
6.4.11 PARKING BRAKES 		561
6.4.12 VACUUM BRAKE BOOSTER 		564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 		565
6.4.14 VACUUM LINES 		567
7. STEERING 		569
7.1 GENERAL INFORMATION 		575
7.1.1 TECHNICAL SPECIFICATIONS 		575
7.1.2 TIGHTENING TORQUES 		576
7.1.3 SPECIAL TOOLS 		578
7.1.4 EXPLODED VIEWS 		579
7.1.5 SCHEMATIC OF STEERING SYSTEM 		581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 		583
7.3 ON VEHICLE REPAIRS 		584
7.3.1 STEERING WHEEL 		586
7.3.2 STEERING COLUMN ASSEMBLY 		587
7.3.3 STEERING UPPER COLUMN 		589
7.3.4 INTERMEDIATE SHAFT 		589
7.3.5 STEERING RACK AND PINION ASSEMBLY 		590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 		592
7.3.7 WHEEL ALIGNMENT 		601
7.3.8 TROUBLESHOOTING AND DIAGNOSIS 		603
8. ELECTRICAL 		1093
8.1 EMS ECU AND AMT TCU CONNECTOR’S REMOVAL AND RE-FITMENT ON VEHICLE 		1095
8.1.1 PARTS LIST 		1095
8.1.2 EMS ECU CONNECTOR REMOVAL AND RE-FIMENT ON VEHICLE 		1097
8.1.3 AMT TCU UNIT CONNECTOR’S REMOVAL AND RE-FIMENT ON VEHICLE 		1102
8.2 FOG LAMP REMOVAL AND RE-FITMENT ON VEHICLE 		1106
8.3 HORN REMOVAL AND RE-FITMENT ON VEHICLE 		1109
8.4 AMBIENT TEMPERATURE SENSOR REMOVAL AND RE-FITMENT ON VEHICLE 		1112
8.5 TRANSMISSION INPUT SPEED SENSOR REMOVAL AND RE-FITMENT ON VEHICLE 		1116
8.6 EXHAUST FAN REMOVAL AND RE-FITMENT ON VEHICLE 		1118
8.7 DIAGNOSTIC TROUBLE CODES FOR ELECTRONIC POWER ASSISTED STEERING 		1121
8.8 BRAKE SWITCH FAILURE CASES AND RECOVERY ON VEHICLE 		1122
8.9 DIAGNOSTIC TROUBLE CODES FOR ENGINE MANAGEMENT SYSTEM 		1123
8.10 CIRCUIT SCHEMATICS 		1154-1155
8.10.1 INDEX AND COLOUR CODES 		1156-1157
8.10.2 SYMBOLS 		1158-1159
8.10.3 CONNECTOR DETAILS 		1160-1161
8.10.4 WIRING HARNESS TOPOLOGY 		1162-1163
8.10.5 POWER SUPPLY 		1164-1165
8.10.5.1 POWER SUPPLY - 1 		1164-1165
8.10.5.2 POWER SUPPLY - 2 		1166-1167
8.10.5.3 POWER SUPPLY - 3 		1168-1169
8.10.5.4 POWER SUPPLY - 4 		1170-1171
8.10.5.5 POWER SUPPLY - 5 		1172-1173
8.10.5.6 POWER SUPPLY - 6 		1174-1175
8.10.5.7 POWER SUPPLY - 7 		1176-1177
8.10.5.8 POWER SUPPLY - 8 		1178-1179
8.10.5.9 POWER SUPPLY - 9 		1180-1181
8.10.6 CIRCUIT SCHEMATIC - EARTH 		1182-1183
8.10.6.1 CIRCUIT SCHEMATIC - EARTH 1 		1182-1183
8.10.6.2 CIRCUIT SCHEMATIC - EARTH 2 		1184-1185
8.10.6.3 CIRCUIT SCHEMATIC - EARTH 3 		1186-1187
8.10.6.4 CIRCUIT SCHEMATIC - EARTH 4 		1188-1189
8.10.7 STARTING AND CHARGING 		1190-1191
8.10.8 ENGINE CONTROL (PETROL) 		1192-1193
8.10.8.1 ENGINE CONTROL (PETROL) - 1 		1192-1193
8.10.8.2 ENGINE CONTROL (PETROL) - 2 		1194-1195
8.10.8.3 ENGINE CONTROL (PETROL) - 3 		1196-1197
8.10.8.4 ENGINE CONTROL (PETROL) - 4 		1198-1199
8.10.9 FUEL PUMP 		1200-1201
8.10.10 HVAC (MANUAL) 		1202-1203
8.10.11 RADIATOR FAN 		1204-1205
8.10.12 POWER WINDOWS 		1206-1207
8.10.12.1 POWER WINDOWS - 1 		1206-1207
8.10.12.2 POWER WINDOWS - 2 		1208-1209
8.10.13 REMOTE KEYLESS ENTRY 		1210-1211
8.10.13.1 REMOTE KEYLESS ENTRY - 1 		1210-1211
8.10.13.2 REMOTE KEYLESS ENTRY - 2 		1212-1213
8.10.14 CENTRAL DOOR LOCKING 		1214-1215
8.10.15 CLUSTER 		1216-1217
8.10.15.1 CLUSTER - 1 		1216-1217
8.10.15.2 CLUSTER - 2 		1218-1219
8.10.16 FRONT WIPER (PASSIVE) 		1220-1221
8.10.17 EXTERIOR LIGHTING 		1222-1223
8.10.17.1 EXTERIOR LIGHTING - 1 		1222-1223
8.10.17.2 EXTERIOR LIGHTING - 2 		1224-1225
8.10.17.3 EXTERIOR LIGHTING - 3 		1226-1227
8.10.17.4 EXTERIOR LIGHTING - 4 		1228-1229
8.10.17.5 EXTERIOR LIGHTING - 5 		1230-1231
8.10.18 CAN 		1232-1233
8.10.19 INTERIOR LAMPS 		1234-1235
8.10.20 EPAS 		1236-1237
8.10.21 HORN 		1238-1239
8.10.22 POWER SOCKET AND CIGAR LIGHTER 		1240-1241
8.10.23 REAR PARKING AIS 		1242-1243
8.10.24 AUTO TRANSMISSION (AMT) 		1244-1245
8.10.25 AUDIO SYSTEM 		1246-1247
8.10.25.1 AUDIO SYSTEM - 1 		1246-1247
8.10.25.2 AUDIO SYSTEM - 2 		1248-1249
9. BODY 		804
9.1 GENERAL INFORMATION 		810
9.1.1 TECHNICAL SPECIFICATIONS 		810
9.1.2 TIGHTENING TORQUE 		811
9.2 ON VEHICLE REPAIRS 		815
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		815
9.2.2 FRONT BUMPER 		816
9.2.3 FENDER (SIDE BONNET) 		817
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		818
9.2.5 FRONT DOOR 		822
9.2.6 REAR DOOR 		833
9.2.7 REAR SHELF 		842
9.2.8 TAILGATE 		842
9.2.9 REAR BUMPER 		843
9.2.10 DASHBOARD 		845
9.2.11 CENTER CONSOLE 		848
9.2.12 SEATS & BELTS 		849
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		859
9.2.14 SUN VISOR 		859
9.2.15 TRIMS 		860
9.2.16 FLOOR CARPET 		861
9.2.17 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
10.1.1 TECHNICAL SPECIFICATIONS 		882
10.1.2 TIGHTENING TORQUES 		883
10.1.3 GENERAL PRECAUTIONS 		885
10.1.4 SYSTEM LAYOUTS 		887
10.1.5 COMPONENT DESCRIPTION 		891
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		894
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		895
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		908
10.2.3 FLUSHING OF AC SYSTEM 		913
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		915
10.2.5 A/C SYSTEM PERFORMANCE TEST 		917
10.2.6 LEAK TEST SYSTEM 		917
10.3 ON VEHICLE REPAIRS 		918
10.3.1 CONTROL PANEL ASSEMBLY 		919
10.3.2 AC COMPRESSOR 		1250
10.3.2.1 AC COMPRESSOR LOCATION ON VEHICLE 		1253
10.3.2.2 TECHNICAL SPECIFICATIONS 		1254
10.3.2.3 TIGHTENING TORQUES 		1255
10.3.2.4 PRECAUTIONS 		1256
10.3.2.5 EXPLODED VIEW AND PART LIST 		1259
10.3.2.6 AC COMPRESSOR REMOVAL AND RE-FITMENT ON VEHICLE 		1260
10.3.3 HVAC UNIT 		931
10.3.4 BLOWER UNIT 		935
10.3.5 BLOWER RESISTER 		935
10.3.6 FILTER 		936
10.3.7 EVAPORATOR AND EXPANSION VALVE 		937
10.3.8 HEATER ASSEMBLY 		939
10.3.9 KINEMATICS 		940
10.3.10 PRESSURE SWITCH 		940
10.3.11 CONDENSER ASSEMBLY 		941
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		943
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		945
10.3.14 REFRIGERANT LINES 		946
10.3.15 HEATER LINES 		948
NANO CNG 		1266
1. GENERAL 		1272
1.1. INTRODUCTION TO CNG SYSTEM 		1276
1.2. BENEFITS OF CNG 		1276
1.3. FEATURES OF CNG BI-FUEL SYSTEM 		1276
1.4. GENERAL INSTRUCTION / PRECAUTIONSWHILE WORKING ON CNG VEHICLE 		1277
1.5. IN CASE OF LEAKAGE 		1279
1.6. TECHNICAL SPECIFICATIONS 		1281
1.7. TIGHTENING TORQUE 		1285
1.8. SPECIAL TOOLS 		1290
1.9. LIST OF APPROVED CNG CYLINDER TESTING STATION 		1291
1.10. SERVICE SCHEDULE 		1292
1.11. LUBRICANTS AND COOLANTS 		1296
2. PRECAUTIONS 		35
2.1 GENERAL SAFETY PRECAUTIONS 		41
2.2 GENERAL SERVICE PRECAUTIONS 		45
3. ENGINE 		1298
3.1. TECHNICAL SPECIFICATION 		1302
3.2. REPAIR DATA 		1303
A. BELT TENSION VALUES 		1303
3.3. ENGINE CONTRUCTIONAL DETAIL 		1304
A. ENGINE 		1304
B. INTAKE MANIFOLD 		1304
3.4. GENERAL SYSTEM OVERVIEW OF Bi-FUEL ENGINE MANAGEMENT SYSTEM 		1306-1307
3.5. REMOVAL AND REFITMENT OF ENGINEACCESS WINDOW AND ENGINE COVER 		1310
3.6. GAS INJECTOR 		1313
3.7. GAS RAIL 		1315
3.8. PRESSURE AND TEMPERATURE (P&T)SENSOR 		1317
3.9. DIAGNOSTIC USER MANUAL 		1319
4. DRIVETRAIN 		315
4.1 CLUTCH 		321
4.1.1 GENERAL INFORMATION 		323
4.1.1.1 TECHNICAL SPECIFICATIONS 		323
4.1.1.2 CONSTRUCTION 		326
4.1.1.3 PRECAUTIONS 		328
4.1.1.4 TIGHTENING TORQUES 		329
4.1.1.5 SPECIAL TOOLS 		330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		331
4.1.1.7 TROUBLE SHOOTING 		334
4.1.1.8 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 		1340
4.2.1 GENERAL INFORMATION 		1346
A. TECHNICAL SPECIFICATIONS 		1346
B. PRECAUTIONS 		1347
C. TIGHTENING TORQUES 		1348
D. SPECIAL TOOLS 		1351
E. GENERAL SYMPTOMS AND DIAGNOSIS 		1355
F. TRANSAXLE OIL REPLACEMENT 		1356
4.2.2. OVERHAULING (EXPLODED VIEWS) 		1357
A. TRANSAXLE HOUSING 		1357
B. INPUT SHAFT AND LAY SHAFT 		1358
C. SHIFTER SHAFT AND SHIFTER SLEEVE 		1359
D. DIFFERENTIAL 		1360
E. TOP COVER ASSEMBLY 		1361
F. SHIFTER LINKAGE 		1362
4.2.3. COMPONENT IDENTIFICATION 		1364
A. SHIFTER SHAFTS 		1364
B. SHIFTER FORKS (DOGS) 		1364
C. SHIFTER SLEEVE 		1365
4.2.4. REMOVAL OF TRANSAXLE FROM VEHICLE 		1366
4.2.5. TRANSAXLE DISMANTLING 		1369
4.2.6. INPUT SHAFT ASSEMBLY 		1373
4.2.7. LAYSHAFT ASSEMBLY 		1378
4.2.8. SHIFTER SHAFT AND SHIFTER FORK 		1384
4.2.9. REVERSE GEAR SHIFTER BRACKET - ASSEMBLY 		1385
4.2.10. DIFFERENTIAL ASSEMBLY 		1387
4.2.11. REAR HALF HOUSING TOP COVER ASSEMBLY 		1391
4.2.12. REAR HALF HOUSING ASSEMBLY 		1398
4.2.13. FRONT HALF HOUSING 		1400
4.2.14. TRANSAXLE ASSEMBLY 		1402
A. SHIM SELECTION 		1402
B. ASSEMBLING THE TRANSAXLE 		1403
4.2.15. GEAR SHIFTER LINKAGE 		1408
A. GEAR SHIFTER CABLE REPLACEMENT 		1408
B. GEAR SHIFTER ADJUSTMENT 		1410
4.3 DRIVESHAFT 		411
4.3.1 GENERAL INFORMATION 		413
4.3.1.1 TIGHTENING TORQUE 		413
4.3.1.2 SPECIAL TOOL 		414
4.3.1.3 CONSTRUCTIONAL DETAILS 		415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 		415
4.3.1.5 COMPONENT DESCRIPTION 		416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 		417
4.3.2 ON VEHICLE REPAIRS 		418
4.3.2.1 PRECAUTIONS 		418
4.3.2.2 REMOVAL FROM VEHICLE 		420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 		423
5. SUSPENSION SYSTEM 		429
5.1 GENERAL INFORMATION 		435
5.1.1 TECHNICAL SPECIFICATIONS 		435
5.1.2 TIGHTENING TORQUES 		436
5.1.3 SPECIAL TOOLS 		439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 		441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 		442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 		443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 		446
5.2 ON VEHICLE REPAIRS 		449
5.2.1 FRONT SUSPENSION COMPONENTS 		449
5.2.1.1 STRUT 		449
5.2.1.2 ANTI-ROLL BAR 		455
5.2.1.3 LOWER ARM 		456
5.2.1.4 WHEEL BEARING 		458
5.2.2 REAR SUSPENSION COMPONENTS 		461
5.2.2.1 SHOCK ABSORBER 		462
5.2.2.2 COIL SPRING 		463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 		464
5.2.2.4 SEMI TRAILING ARM 		465
5.2.3 WHEEL HUB AND WHEEL BEARING 		468
5.3 WHEELS AND TYRES 		473
5.3.1 GENERAL INFORMATION 		473
5.3.1.1 TECHNICAL SPECIFICATIONS 		473
5.3.1.2 TIGHTENING TORQUE 		474
5.3.1.3 EXPLODED VIEW 		475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 		476
5.3.2 ON VEHICLE REPAIRS 		477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 		478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 		479
5.3.2.3 WHEEL BALANCING 		480
5.3.2.4 WHEEL RUNOUT 		481
5.3.2.5 TYRE REPLACEMENT 		482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 		483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 		483
5.3.2.8 TYRE DIAGNOSIS 		484
6. BRAKE SYSTEM 		493
6.1 GENERAL INFORMATION 		499
6.1.2 TECHNICAL SPECIFICATIONS 		499
6.1.3 TIGHTENING TORQUES 		500
6.1.4 SPECIAL TOOLS 		504
6.1.5 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 		505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 		507
6.2.1 FRONT DRUM BRAKES 		507
6.2.2 REAR DRUM BRAKES 		508
6.2.3 AUTO INCREMENTAL BRAKE 		509
6.2.4 TANDEM MASTER CYLINDER (TMC) 		510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 		511
6.2.6 WHEEL CYLINDER 		514
6.2.7 PARKING BRAKES 		515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 		516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 		521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 		523
6.4 ON VEHICLE REPAIRS 		530
6.4.1 FRONT BRAKE COMPONENTS 		531
6.4.2 FRONT BRAKE DRUM 		532
6.4.3 FRONT BRAKE SHOES 		534
6.4.4 FRONT BRAKE BACK PLATE 		539
6.4.5 REAR BRAKE COMPONENTS 		540
6.4.6 REAR BRAKE DRUM 		541
6.4.7 REAR BRAKE SHOES 		542
6.4.8 REAR BRAKE BACK PLATE 		544
6.4.8 TMC 		546
6.4.9 WHEEL CYLINDER 		555
6.4.10 PARKING BRAKES 		561
6.4.11 VACUUM BRAKE BOOSTER 		564
6.4.12 BRAKE HOSES/PIPES SCHEMATIC 		565
6.4.13 VACUUM LINES 		567
7. STEERING 		569
7.1 GENERAL INFORMATION 		575
7.1.1 TECHNICAL SPECIFICATIONS 		575
7.1.2 TIGHTENING TORQUES 		576
7.1.3 SPECIAL TOOLS 		578
7.1.4 EXPLODED VIEWS 		579
7.1.5 SCHEMATIC OF STEERING SYSTEM 		581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 		583
7.3 ON VEHICLE REPAIRS 		584
7.3.1 STEERING WHEEL 		586
7.3.2 STEERING COLUMN ASSEMBLY 		587
7.3.3 STEERING UPPER COLUMN 		589
7.3.4 INTERMEDIATE SHAFT 		589
7.3.5 STEERING RACK AND PINION ASSEMBLY 		590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 		592
7.3.7 WHEEL ALIGNMENT 		601
7.3.8 TROUBLESHOOTING AND DIAGNOSIS 		603
8. ELECTRICAL 		1446
8.1 TECHNICAL SPECIFICATION 		1450
8.2. LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE 		1451
8.3. INSTRUMENT CLUSTER 		1452
8.4. FUEL GAUGE 		1453
8.5. REMOVAL AND REFITTMENT OF BATTERY 		1454
8.6. STARTER MOTOR 		1455
A. EXPLODED VIEW 		1455
B. ON VEHICLE REMOVAL AND REFITTMENT OF STARTER MOTOR 		1455
C. STARTER MOTOR OVER HAULING 		1456
8.7 CIRCUIT SCHEMATICS 		1462-1463
8.7.1 FUSE BOX AND RELAY ( CABIN ) 		1466-1467
8.7.2 FUSE BOX AND RELAY ( BATTERY MOUNTED ) 		1468-1469
8.7.3 CIRCUIT SCHEMATIC OF EMS ECU 		1470-1471
A. CIRCUIT SCHEMATIC OF EMS ECU (SHEET 1 OF 5 ) 		1470-1471
B. CIRCUIT SCHEMATIC OF EMS ECU (SHEET 2 OF 5 		1472-1473
C. CIRCUIT SCHEMATIC OF EMS ECU (SHEET 3 OF 5 ) 		1474-1475
D. CIRCUIT SCHEMATIC OF EMS ECU (SHEET 4 OF 5) 		1476-1477
E. CIRCUIT SCHEMATIC OF EMS ECU (SHEET 5 OF 5) 		1478-1479
8.7.4 FUSE DISTRIBUTION 		1480-1481
A. FUSE DISTRIBUTION (SHEET 1 OF 6) 		1480-1481
B. FUSE DISTRIBUTION (SHEET 2 OF 6) 		1482-1483
C. FUSE DISTRIBUTION (SHEET 3 OF 6) 		1484-1485
D. FUSE DISTRIBUTION (SHEET 4 OF 6) 		1486-1487
E. FUSE DISTRIBUTION (SHEET 5 OF 6) 		1488-1489
F. FUSE DISTRIBUTION (SHEET 6 OF 6) 		1490-1491
DTC CODES 		1494-1495
9. BODY 		804
9.1 GENERAL INFORMATION 		810
9.1.1 TECHNICAL SPECIFICATIONS 		810
9.1.2 TIGHTENING TORQUE 		811
9.2 ON VEHICLE REPAIRS 		815
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		815
9.2.2 FRONT BUMPER 		816
9.2.3 FENDER (SIDE BONNET) 		817
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		818
9.2.5 FRONT DOOR 		822
9.2.6 REAR DOOR 		833
9.2.7 REAR SHELF 		842
9.2.8 TAILGATE 		842
9.2.9 REAR BUMPER 		843
9.2.10 DASHBOARD 		845
9.2.11 CENTER CONSOLE 		848
9.2.12 SEATS & BELTS 		849
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		859
9.2.14 SUN VISOR 		859
9.2.15 TRIMS 		860
9.2.16 FLOOR CARPET 		861
9.2.17 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
10.1.1 TECHNICAL SPECIFICATIONS 		882
10.1.2 TIGHTENING TORQUES 		883
10.1.3 GENERAL PRECAUTIONS 		885
10.1.4 SYSTEM LAYOUTS 		887
10.1.5 COMPONENT DESCRIPTION 		891
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		894
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		895
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		908
10.2.3 FLUSHING OF AC SYSTEM 		913
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		915
10.2.5 A/C SYSTEM PERFORMANCE TEST 		917
10.2.6 LEAK TEST SYSTEM 		917
10.3 ON VEHICLE REPAIRS 		918
10.3.1 CONTROL PANEL ASSEMBLY 		919
10.3.2 A/C COMPRESSOR 		920
10.3.3 HVAC UNIT 		931
10.3.4 BLOWER UNIT 		935
10.3.5 BLOWER RESISTER 		935
10.3.6 FILTER 		936
10.3.7 EVAPORATOR AND EXPANSION VALVE 		937
10.3.8 HEATER ASSEMBLY 		939
10.3.9 KINEMATICS 		940
10.3.10 PRESSURE SWITCH 		940
10.3.11 CONDENSER ASSEMBLY 		941
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		943
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		945
10.3.14 REFRIGERANT LINES 		946
10.3.15 HEATER LINES 		948
11. FUEL SYSTEM 		1412
11.1 INTRODUCTION 		1416
A. CNG LAYOUT (ON VEHICLE) 		1417
11.2. CNG FUEL SYSTEM COMPONENTS 		1418
A. CNG CYLINDER 		1418
B. CYLINDER VALVE 		1420
C. LOW PRESSURE CNG FILTER 		1425
D. PRESSURE GAUGE 		1428
E. PRESSURE REGULATOR 		1429
F. HIGH PRESSURE (H.P) SENSOR 		1434
G. CNG RECEPTACLE VALVE 		1436
11.3. CNG TUBE FITTINGS / JOINTS TIGHTENING INSTRUCTIONS 		1439
A. SWAGING PROCEDURE 		1439
B. PROCEDURE FOR NPT THREAD ASSEMBLY 		1441
11.4. CNG LEAK DETECTION TESTING 		1443
11.5. TROUBLE SHOOTING 		1444
NANO ePAS 		1532
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
3.1.1 TECHNICAL SPECIFICATIONS 		57
3.1.2 FEATURES OF 273 MPFI ENGINE 		58
3.1.3 TIGHTENING TORQUE 		59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 		61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 		65
3.2 ON VEHICLE PROCEDURES 		69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 		71
3.2.2 ENGINE OIL REPLACEMENT 		73
3.2.3 OIL FILTER REPLACEMENT 		74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		75
3.2.5 FUEL FILTER REPLACEMENT 		76
3.2.6 TAPPET SETTING 		77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 		78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 		79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 		81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 		86
3.2.11 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
3.3.1.1 GENERAL DESCRIPTION 		101
3.3.1.2 EXPLODED VIEW 		102
3.3.1.3 CYLINDER HEAD OVERHAUL 		104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 		104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 		108
3.3.1.6 INSPECTION & REPAIR DATA 		111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 		118
3.3.2 ENGINE BLOCK 		123
3.3.2.1 GENERAL DESCRIPTION 		125
3.3.2.2 EXPLODED VIEW 		126
3.3.2.3 ENGINE BLOCK OVERHAUL 		128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 		128
3.3.2.5 INSPECTION & REPAIR DATA 		133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 		143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 		156
3.3.2.8 ENGINE TESTING 		158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 		158
3.4 ACCELERATOR 		159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 		161
3.4.2 SYSTEM MAINTENANCE 		163
3.5 COOLING SYSTEM 		167
3.5.1 GENERAL DESCRIPTION 		169
3.5.3 EXPLODED VIEWS 		170
3.5.4 SPECIFICATIONS 		172
3.5.5 SYSTEM COMPONENTS 		173
3.5.6 SYSTEM MAINTENANCE 		174
3.6 LUBRICATION SYSTEM 		183
3.6.1 GENERAL DESCRIPTION 		185
3.6.2 SYSTEM SCHEMATICS 		185
3.6.3 SPECIFICATIONS 		186
3.6.4 SYSTEM MAINTENANCE 		187
3.7 FUEL SYSTEM 		199
3.7.1 GENERAL DESCRIPTION 		201
3.7.2 SYSTEM SCHEMATICS 		201
3.7.3 EXPLODED VIEWS 		202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 		203
3.7.5 SYSTEM COMPONENTS 		204
3.7.6 SYSTEM MAINTENANCE 		208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 		218
3.8 INTAKE SYSTEM 		221
3.8.1 GENERAL DESCRIPTION 		223
3.8.2 EXPLODED VIEWS 		224
3.8.3 SYSTEM MAINTENANCE 		225
3.9 EXHAUST SYSTEM 		231
3.9.1 GENERAL DESCRIPTION 		233
3.9.2 EXPLODED VIEWS 		234
3.9.3 TIGHTENING TORQUE 		235
3.9.4 SYSTEM COMPONENTS 		236
3.9.5 SYSTEM MAINTENANCE 		238
3.10 IGNITION SYSTEM 		243
3.10.1 GENERAL DESCRIPTION 		245
3.10.2 SYSTEM SCHEMATICS 		245
3.10.3 SYSTEM MAINTENANCE 		246
3.11 ENGINE MANAGEMENT SYSTEM 		251
ABBREVIATIONS 		251
AN OVERVIEW 		254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 		255
3.11.1.1 ECU BLOCK DIAGRAM 		256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 		257
3.11.1.3 ECU HANDLING AND CARE 		258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 		259
3.11.2 SENSORS 		260
3.11.2.1 CRANK SHAFT POSITION SENSOR 		260
3.11.2.2 COOLANT TEMPERATURE SENSOR 		261
3.11.2.3 T-MAP SENSOR 		263
3.11.2.4 KNOCK SENSOR 		264
3.11.2.5 THROTTLE POSITION SENSOR 		265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 		268
3.11.2.7 VEHICLE SPEED SENSOR 		269
3.11.3 ACTUATORS 		271
3.11.3.1 CANISTER PURGE VALVE 		271
3.11.3.2 FUEL INJECTOR 		272
3.11.3.3 IGNITION COIL 		274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 		277
3.11.3.5 COMPONENT FITMENT DATA 		279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 		283
3.11.4.1 DTC LIST 		283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 		293
3.11.4.3 BLINK CODE 		308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 		310
3.11.5.1 REPAIRING STEPS 		310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 		311
3.11.5.3 SENSOR AND ACTUATOR TESTING 		312
3.11.5.4 EMERGENCY SERVICE TIPS 		314
4. DRIVETRAIN 		315
4.1 CLUTCH 		321
4.1.1 GENERAL INFORMATION 		323
4.1.1.1 TECHNICAL SPECIFICATIONS 		323
4.1.1.2 CONSTRUCTION 		326
4.1.1.3 PRECAUTIONS 		328
4.1.1.4 TIGHTENING TORQUES 		329
4.1.1.5 SPECIAL TOOLS 		330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		331
4.1.1.7 TROUBLE SHOOTING 		334
4.1.1.8 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
4.2.1.1 TECHNICAL SPECIFICATION 		349
4.2.1.2 CONSTRUCTION 		349
4.2.1.3 PRECAUTIONS 		350
4.2.1.4 TIGHTENING TORQUES 		351
4.2.1.5 SPECIAL TOOLS 		354
4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		358
4.2.1.7 TRANSAXLE OIL REPLACEMENT 		359
4.2.2 OVERHAUL 		360
4.2.2.1 EXPLODED VIEWS 		360
4.2.2.2 COMPONENT IDENTIFICATION 		367
4.2.2.3 PRECAUTIONS 		369
4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE 		369
4.2.2.5 TRANSAXLE DISMANTLING 		372
4.2.2.6 INPUT SHAFT ASSEMBLY 		376
4.2.2.7 LAY SHAFT ASSEMBLY 		381
4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK 		387
4.2.2.9 DIFFERENTIAL ASSEMBLY 		390
4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY 		394
4.2.2.11 REAR HALF HOUSING ASSEMBLY 		400
4.2.2.12 FRONT HALF HOUSING 		402
4.2.2.13 TRANSAXLE ASSEMBLY 		404
A. SHIM SELECTION 		404
B. ASSEMBLING THE TRANSAXLE 		405
4.2.2.14 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
4.3.1.1 TIGHTENING TORQUE 		413
4.3.1.2 SPECIAL TOOL 		414
4.3.1.3 CONSTRUCTIONAL DETAILS 		415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 		415
4.3.1.5 COMPONENT DESCRIPTION 		416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 		417
4.3.2 ON VEHICLE REPAIRS 		418
4.3.2.1 PRECAUTIONS 		418
4.3.2.2 REMOVAL FROM VEHICLE 		420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 		423
5. SUSPENSION SYSTEM 		429
5.1 GENERAL INFORMATION 		435
5.1.1 TECHNICAL SPECIFICATIONS 		435
5.1.2 TIGHTENING TORQUES 		436
5.1.3 SPECIAL TOOLS 		439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 		441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 		442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 		443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 		446
5.2 ON VEHICLE REPAIRS 		449
5.2.1 FRONT SUSPENSION COMPONENTS 		449
5.2.1.1 STRUT 		449
5.2.1.2 ANTI-ROLL BAR 		455
5.2.1.3 LOWER ARM 		456
5.2.1.4 WHEEL BEARING 		458
5.2.2 REAR SUSPENSION COMPONENTS 		461
5.2.2.1 SHOCK ABSORBER 		462
5.2.2.2 COIL SPRING 		463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 		464
5.2.2.4 SEMI TRAILING ARM 		465
5.2.3 WHEEL HUB AND WHEEL BEARING 		468
5.3 WHEELS AND TYRES 		473
5.3.1 GENERAL INFORMATION 		473
5.3.1.1 TECHNICAL SPECIFICATIONS 		473
5.3.1.2 TIGHTENING TORQUE 		474
5.3.1.3 EXPLODED VIEW 		475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 		476
5.3.2 ON VEHICLE REPAIRS 		477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 		478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 		479
5.3.2.3 WHEEL BALANCING 		480
5.3.2.4 WHEEL RUNOUT 		481
5.3.2.5 TYRE REPLACEMENT 		482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 		483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 		483
5.3.2.8 TYRE DIAGNOSIS 		484
6. BRAKE SYSTEM 		493
6.1 GENERAL INFORMATION 		499
6.1.1 TECHNICAL SPECIFICATIONS 		499
6.1.2 TIGHTENING TORQUES 		500
6.1.3 SPECIAL TOOLS 		504
6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 		505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 		507
6.2.1 FRONT DRUM BRAKES 		507
6.2.2 REAR DRUM BRAKES 		508
6.2.3 AUTO INCREMENTAL BRAKE 		509
6.2.4 TANDEM MASTER CYLINDER (TMC) 		510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 		511
6.2.6 WHEEL CYLINDER 		514
6.2.7 PARKING BRAKES 		515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 		516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 		521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 		523
6.4 ON VEHICLE REPAIRS 		530
6.4.1 FRONT BRAKE COMPONENTS 		531
6.4.2 FRONT BRAKE DRUM 		532
6.4.3 FRONT BRAKE SHOES 		534
6.4.4 FRONT BRAKE BACK PLATE 		539
6.4.5 REAR BRAKE COMPONENTS 		540
6.4.6 REAR BRAKE DRUM 		541
6.4.7 REAR BRAKE SHOES 		542
6.4.8 REAR BRAKE BACK PLATE 		544
6.4.9 TMC 		546
6.4.10 WHEEL CYLINDER 		555
6.4.11 PARKING BRAKES 		561
6.4.12 VACUUM BRAKE BOOSTER 		564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 		565
6.4.14 VACUUM LINES 		567
7. STEERING 		1538
7.1 GENERAL INFORMATION 		1543
7.1.1 SPECIFICATIONS 		1543
7.1.2 SYSTEM LAYOUT 		1543
7.1.3 GENERAL DESCRIPTION 		1544
7.1.4 TIGHTENING TORQUES 		1545
7.1.5 SPECIAL TOOLS 		1547
7.2. MAINTENANCE, INSPECTION AND TEST 		1548
7.2.1 PRELIMINARY INSPECTION 		1548
7.2.2 REGULAR MAINTENANCE 		1549
7.2.3 ON VEHICLE REPAIRS 		1551
7.2.3.1 STEERING WHEEL REMOVAL 		1551
7.2.3.2 STEERING COLUMN REMOVAL 		1552
7.2.3.3 INTERMEDIATE SHAFT REMOVAL 		1553
7.2.3.4 ECU REMOVAL 		1554
7.2.3.5 RACK & PINION ASSEMBLY REMOVAL 		1555
7.3. OVERHAULING 		1557
7.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 		1557
7.3.2 PRECAUTIONS 		1558
7.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 		1558
7.3.3.1 DISASSEMBLY OF RACK & PINON 		1558
7.3.3.2 INSPECTION OF DISMANTLED PARTS 		1559
7.3.3.3 ASSEMBLY OF RACK & PINON 		1560
7.3.3.4 OBJ ON-VEHICLE REMOVAL 		1561
7.3.3.5 DO’S & DON’TS 		1562
7.3.3.6 WHEEL ALIGNMENT 		1562
7.3.4 TROUBLESHOOTING AND DIAGNOSIS 		1564
8. ELECTRICAL 		1570
8.1. TECHNICAL SPECIFICATION 		1576
8.2. INSTRUMENT CLUSTER 		1578
8.2.1. ART WORK 		1578
8.2.2. TELL TALES 		1578
8.2.3. SPECIFICATION 		1579
8.2.4. CONNECTION DETAILS 		1579
8.2.5. CONNECTOR DETAILS 		1579
8.2.6. PINOUT DETAILS 		1579
8.2.7 FREQUENTLY ASKED QUESTIONSDistance to Empty (DTE) 		1580
8.2.8 SEASON ODOMETER WRITING /UPDATING PROCEDURE 		1582
8.3. EPAS ECU 		1583
8.3.1. SPECIFICATION 		1583
8.3.2. LOCATION 		1583
8.3.3. CONNECTION DETAILS 		1584
8.3.4. PINOUT DETAILS 		1584
8.4. FUSEBOX & RELAY DETAILS 		1585
8.4.1 LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE 		1585
8.4.2. BATTERY MOUNTED FUSE BOX DETAILS (FOR NANO CNG AND MY13) 		1585
8.4.3. CABIN FUSE BOX DETAILS(NANO MY13 EPAS) 		1586
8.4.4. RELAY BOX DETAILS (FOR NANO CNG AND MY13) 		1588
8.4.5. DIAGNOSTIC CONNECTOR LOCATION 		1588
8.4.6 ECU AND STEERING COLUMN PAIRING PROCESS 		1589
8.5 DIAGNOSTIC USER MANUAL 		1590
8.6 DIAGNOSTIC TROUBLE CODES - EPAS 		1600
8.7 DIAGNOSTIC TROUBLE CODES – EMS ECU 		1607
8.8 DIAGNOSTIC TROUBLE CODES – INSTRUMENT CLUSTER 		1608-1609
8.9. CIRCUIT SCHEMATICS NANO MY13 EPAS 		1630-1631
8.9.1. SYMBOLS & COLOUR CODES 		1638-1639
8.9.2. FUSE & RELAY BOX 		1640-1641
8.9.3. GROUND TOPOLOGY 		1642-1643
8.9.4. POWER SUPPLY 		1644-1645
8.9.5. EARTH 		1660-1661
8.9.6. STARTER & CHARGING 		1666-1667
8.9.7. ENGINE CONTROL (PETROL) 		1668-1669
8.9.8. FUEL PUMP 		1676-1677
8.9.9. MANUAL HVAC 		1678-1679
8.9.10. RADIATOR FAN 		1680-1681
8.9.11. POWER WINDOWS 		1682-1683
8.9.12. CENTRAL DOOR LOCKING 		1686-1687
8.9.13. INSTRUMENT CLUSTER 		1692-1693
8.9.14. FRONT WIPER 		1696-1697
8.9.15. EXTERIOR LIGHTS 		1698-1699
8.9.16. CAN 		1708-1709
8.9.17. IMMOBILISER 		1710-1711
8.9.18. INTERIOR LAMPS 		1712-1713
8.9.19. EPAS 		1714-1715
8.9.20. HORN 		1716-1717
8.9.21. POWER SOCKET & CIGAR LIGHTER 		1718-1719
8.9.22. REVERSE PARKING 		1720-1721
8.9.23. AUDIO SYSTEM 		1722-1723
8.10. CIRCUIT SCHEMATICS NANAO CNG EPAS 		1726-1727
8.10.1 SYMBOLS & SCHEMATIC CODES 		1734-1735
8.10.2 FUSE & RELAY BOX 		1736-1737
8.10.3 GROUND TOPOLOGY 		1738-1739
8.10.4 POWER SUPPLY 		1740-1741
8.10.5 EARTH 		1756-1757
8.10.6 STARTER & CHARGING 		1762-1763
8.10.7 ENGINE CONTROL (PETROL) 		1764-1765
8.10.8 FUEL PUMP 		1774-1775
8.10.9 MANUAL HVAC 		1776-1777
8.10.10 RADIATOR FAN 		1778-1779
8.10.11 POWER WINDOWS 		1780-1781
8.10.12 CENTRAL DOOR LOCKING 		1784-1785
8.10.13 INSTRUMENT CLUSTER 		1788-1789
8.10.14 FRONT WIPER 		1794-1795
8.10.15 EXTERIOR LIGHT 		1796-1797
8.10.16 CAN 		1804-1805
8.10.17 IMMOBILISER 		1808-1809
8.10.18 INTERIOR LAMPS 		1810-1811
8.10.19 HORN 		1812-1813
8.10.20 POWER SOCKET & CIGAR LIGHTER 		1814-1815
8.10.21 REVERSE PARKING 		1816-1817
8.10.22 AUDIO SYSTEM 		1818-1819
8.10.23 EPAS 		1820-1821
9. BODY 		804
9.1 GENERAL INFORMATION 		810
9.1.1 TECHNICAL SPECIFICATIONS 		810
9.1.2 TIGHTENING TORQUE 		811
9.2 ON VEHICLE REPAIRS 		815
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		815
9.2.2 FRONT BUMPER 		816
9.2.3 FENDER (SIDE BONNET) 		817
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		818
9.2.5 FRONT DOOR 		822
9.2.6 REAR DOOR 		833
9.2.7 REAR SHELF 		842
9.2.8 TAILGATE 		842
9.2.9 REAR BUMPER 		843
9.2.10 DASHBOARD 		845
9.2.11 CENTER CONSOLE 		848
9.2.12 SEATS & BELTS 		849
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		859
9.2.14 SUN VISOR 		859
9.2.15 TRIMS 		860
9.2.16 FLOOR CARPET 		861
9.2.17 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
10.1.1 TECHNICAL SPECIFICATIONS 		882
10.1.2 TIGHTENING TORQUES 		883
10.1.3 GENERAL PRECAUTIONS 		885
10.1.4 SYSTEM LAYOUTS 		887
10.1.5 COMPONENT DESCRIPTION 		891
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		894
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		895
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		908
10.2.3 FLUSHING OF AC SYSTEM 		913
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		915
10.2.5 A/C SYSTEM PERFORMANCE TEST 		917
10.2.6 LEAK TEST SYSTEM 		917
10.3 ON VEHICLE REPAIRS 		918
10.3.1 CONTROL PANEL ASSEMBLY 		919
10.3.2 A/C COMPRESSOR 		920
10.3.3 HVAC UNIT 		931
10.3.4 BLOWER UNIT 		935
10.3.5 BLOWER RESISTER 		935
10.3.6 FILTER 		936
10.3.7 EVAPORATOR AND EXPANSION VALVE 		937
10.3.8 HEATER ASSEMBLY 		939
10.3.9 KINEMATICS 		940
10.3.10 PRESSURE SWITCH 		940
10.3.11 CONDENSER ASSEMBLY 		941
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		943
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		945
10.3.14 REFRIGERANT LINES 		946
10.3.15 HEATER LINES 		948
NANO OTG 		1822
1. GENERAL 		1826
1.1 TECHNICAL SPECIFICATION 		1830
1.2 FUEL, LUBRICANTS AND COOLANTS 		1832
1.3 SERVICE SCHEDULE 		1833
2. PRECAUTIONS 		35
2.1 GENERAL SAFETY PRECAUTIONS 		41
2.2 GENERAL SERVICE PRECAUTIONS 		45
3. ENGINE 		47
3.1 GENERAL INFORMATION 		55
3.1.1 TECHNICAL SPECIFICATIONS 		57
3.1.2 FEATURES OF 273 MPFI ENGINE 		58
3.1.3 TIGHTENING TORQUE 		59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 		61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 		65
3.2 ON VEHICLE PROCEDURES 		69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 		71
3.2.2 ENGINE OIL REPLACEMENT 		73
3.2.3 OIL FILTER REPLACEMENT 		74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		75
3.2.5 FUEL FILTER REPLACEMENT 		76
3.2.6 TAPPET SETTING 		77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 		78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 		79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 		81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 		86
3.2.11 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
3.3.1.1 GENERAL DESCRIPTION 		101
3.3.1.2 EXPLODED VIEW 		102
3.3.1.3 CYLINDER HEAD OVERHAUL 		104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 		104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 		108
3.3.1.6 INSPECTION & REPAIR DATA 		111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 		118
3.3.2 ENGINE BLOCK 		123
3.3.2.1 GENERAL DESCRIPTION 		125
3.3.2.2 EXPLODED VIEW 		126
3.3.2.3 ENGINE BLOCK OVERHAUL 		128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 		128
3.3.2.5 INSPECTION & REPAIR DATA 		133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 		143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 		156
3.3.2.8 ENGINE TESTING 		158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 		158
3.4 ACCELERATOR 		159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 		161
3.4.2 SYSTEM MAINTENANCE 		163
3.5 COOLING SYSTEM 		167
3.5.1 GENERAL DESCRIPTION 		169
3.5.2 SYSTEM SCHEMATICS 		169
3.5.3 EXPLODED VIEWS 		170
3.5.4 SPECIFICATIONS 		172
3.5.5 SYSTEM COMPONENTS 		173
3.5.6 SYSTEM MAINTENANCE 		174
3.6 LUBRICATION SYSTEM 		183
3.6.1 GENERAL DESCRIPTION 		185
3.6.2 SYSTEM SCHEMATICS 		185
3.6.3 SPECIFICATIONS 		186
3.6.4 SYSTEM MAINTENANCE 		187
3.7 FUEL SYSTEM 		199
3.7.1 GENERAL DESCRIPTION 		201
3.7.2 SYSTEM SCHEMATICS 		201
3.7.3 EXPLODED VIEWS 		202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 		203
3.7.5 SYSTEM COMPONENTS 		204
3.7.6 SYSTEM MAINTENANCE 		208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 		218
3.8 INTAKE SYSTEM 		221
3.8.1 GENERAL DESCRIPTION 		223
3.8.2 EXPLODED VIEWS 		224
3.8.3 SYSTEM MAINTENANCE 		225
3.9 EXHAUST SYSTEM 		231
3.9.1 GENERAL DESCRIPTION 		233
3.9.2 EXPLODED VIEWS 		234
3.9.3 TIGHTENING TORQUE 		235
3.9.4 SYSTEM COMPONENTS 		236
3.9.5 SYSTEM MAINTENANCE 		238
3.10 IGNITION SYSTEM 		243
3.10.1 GENERAL DESCRIPTION 		245
3.10.2 SYSTEM SCHEMATICS 		245
3.10.3 SYSTEM MAINTENANCE 		246
3.11 ENGINE MANAGEMENT SYSTEM 		251
ABBREVIATIONS 		253
AN OVERVIEW 		254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 		255
3.11.1.1 ECU BLOCK DIAGRAM 		256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 		257
3.11.1.3 ECU HANDLING AND CARE 		258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 		259
3.11.2 SENSORS 		260
3.11.2.1 CRANK SHAFT POSITION SENSOR 		260
3.11.2.2 COOLANT TEMPERATURE SENSOR 		261
3.11.2.3 TMAP SENSOR 		263
3.11.2.4 KNOCK SENSOR 		264
3.11.2.5 THROTTLE POSITION SENSOR 		265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 		268
3.11.2.7 VEHICLE SPEED SENSOR 		269
3.11.3 ACTUATORS 		271
3.11.3.1 CANISTER PURGE VALVE 		271
3.11.3.2 FUEL INJECTOR 		272
3.11.3.3 IGNITION COIL 		274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 		277
3.11.3.5 COMPONENT FITMENT DATA 		279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 		283
3.11.4.1 DTC LIST 		283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 		293
3.11.4.3 BLINK CODE 		308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 		310
3.11.5.1 REPAIRING STEPS 		310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 		311
3.11.5.3 SENSOR AND ACTUATOR TESTING 		312
3.11.5.4 EMERGENCY SERVICE TIPS 		314
4. DRIVETRAIN 		315
4.1 CLUTCH 		321
4.1.1 GENERAL INFORMATION 		323
4.1.1.1 TECHNICAL SPECIFICATIONS 		323
4.1.1.2 CONSTRUCTION 		326
4.1.1.3 PRECAUTIONS 		328
4.1.1.4 TIGHTENING TORQUES 		329
4.1.1.5 SPECIAL TOOLS 		330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		331
4.1.1.7 TROUBLE SHOOTING 		334
4.1.1.8 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
4.2.1.1 TECHNICAL SPECIFICATION 		349
4.2.1.2 CONSTRUCTION 		349
4.2.1.3 PRECAUTIONS 		350
4.2.1.4 TIGHTENING TORQUES 		351
4.2.1.5 SPECIAL TOOLS 		354
4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		358
4.2.1.7 TRANSAXLE OIL REPLACEMENT 		359
4.2.2 OVERHAUL 		360
4.2.2.1 EXPLODED VIEWS 		360
4.2.2.2 COMPONENT IDENTIFICATION 		367
4.2.2.3 PRECAUTIONS 		369
4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE 		369
4.2.2.5 TRANSAXLE DISMANTLING 		372
4.2.2.6 INPUT SHAFT ASSEMBLY 		376
4.2.2.7 LAY SHAFT ASSEMBLY 		381
4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK 		387
4.2.2.9 DIFFERENTIAL ASSEMBLY 		390
4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY 		394
4.2.2.11 REAR HALF HOUSING ASSEMBLY 		400
4.2.2.12 FRONT HALF HOUSING 		402
4.2.2.13 TRANSAXLE ASSEMBLY 		404
A. SHIM SELECTION 		404
B. ASSEMBLING THE TRANSAXLE 		405
4.2.2.14 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
4.3.1.1 TIGHTENING TORQUE 		413
4.3.1.2 SPECIAL TOOL 		414
4.3.1.3 CONSTRUCTIONAL DETAILS 		415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 		415
4.3.1.5 COMPONENT DESCRIPTION 		416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 		417
4.3.2 ON VEHICLE REPAIRS 		418
4.3.2.1 PRECAUTIONS 		418
4.3.2.2 REMOVAL FROM VEHICLE 		420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 		423
5. SUSPENSION SYSTEM 		429
5.1 GENERAL INFORMATION 		435
5.1.1 TECHNICAL SPECIFICATIONS 		435
5.1.2 TIGHTENING TORQUES 		436
5.1.3 SPECIAL TOOLS 		439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 		441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 		442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 		443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 		446
5.2 ON VEHICLE REPAIRS 		449
5.2.1 FRONT SUSPENSION COMPONENTS 		449
5.2.1.1 STRUT 		449
5.2.1.2 ANTI-ROLL BAR 		455
5.2.1.3 LOWER ARM 		456
5.2.1.4 WHEEL BEARING 		458
5.2.2 REAR SUSPENSION COMPONENTS 		461
5.2.2.1 SHOCK ABSORBER 		462
5.2.2.2 COIL SPRING 		463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 		464
5.2.2.4 SEMI TRAILING ARM 		465
5.2.3 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
6.1.1 TECHNICAL SPECIFICATIONS 		499
6.1.2 TIGHTENING TORQUES 		500
6.1.3 SPECIAL TOOLS 		504
6.1.4 BRAKE CIRCUIT 		1866
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 		507
6.2.1 FRONT DRUM BRAKES 		507
6.2.2 REAR DRUM BRAKES 		508
6.2.3 AUTO INCREMENTAL BRAKE 		509
6.2.4 TANDEM MASTER CYLINDER (TMC) 		510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 		511
6.2.6 WHEEL CYLINDER 		514
6.2.7 PARKING BRAKES 		515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 		516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 		521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 		523
6.4 ON VEHICLE REPAIRS 		530
6.4.1 FRONT BRAKE COMPONENTS 		531
6.4.2 FRONT BRAKE DRUM 		532
6.4.3 FRONT BRAKE SHOES 		534
6.4.4 FRONT BRAKE BACK PLATE 		539
6.4.5 REAR BRAKE COMPONENTS 		540
6.4.6 REAR BRAKE DRUM 		541
6.4.7 REAR BRAKE SHOES 		542
6.4.8 REAR BRAKE BACK PLATE 		544
6.4.9 TMC 		546
6.4.10 WHEEL CYLINDER 		555
6.4.11 PARKING BRAKES 		561
6.4.12 VACUUM BRAKE BOOSTER 		564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 		565
6.4.14 VACUUM LINES 		567
7. STEERING 		569
7.1 GENERAL INFORMATION 		575
7.1.1 TECHNICAL SPECIFICATIONS 		575
7.1.2 TIGHTENING TORQUES 		576
7.1.3 SPECIAL TOOLS 		578
7.1.4 EXPLODED VIEWS 		579
7.1.5 SCHEMATIC OF STEERING SYSTEM 		581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 		583
7.3 ON VEHICLE REPAIRS 		584
7.3.1 STEERING WHEEL 		586
7.3.2 STEERING COLUMN ASSEMBLY 		587
7.3.3 STEERING UPPER COLUMN 		589
7.3.4 INTERMEDIATE SHAFT 		589
7.3.5 STEERING RACK AND PINION ASSEMBLY 		590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 		592
7.3.7 WHEEL ALIGNMENT 		601
7.3.8 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
8.21 CIRCUIT SCHEMATICS NANO MY14 		1868-1869
8.21.1 INDEX 		1870-1871
8.21.2 FUSE AND RELAY DETAILS 		1872-1873
8.21.3 TOPOLOGY 		1874-1875
8.21.4 POWER SUPPLY 		1876-1877
8.21.5 EARTH 		1894-1895
8.21.6 STARTER AND CHARGING 		1900-1901
8.21.7 ENGINE CONTROL (PETROL) 		1902-1903
8.21.8 FUEL PUMP 		1910-1911
8.21.9 HVAC (MANUAL) 		1912-1913
8.21.10 RADIATOR FANS 		1914-1915
8.21.11 POWER WINDOWS 		1916-1917
8.21.12 CENTRAL DOOR LOCKING 		1920-1921
8.21.13 CLUSTER 		1926-1927
8.21.14 FRONT WIPER PASSIVE 		1930-1931
8.21.15 EXTERIOR LIGHTING 		1932-1933
8.21.16 DATA COMMUNICATION (CAN) 		1942-1943
8.21.17 INTERIOR LAMPS 		1946-1947
8.21.18 EPAS 		1948-1949
8.21.19 HORN 		1950-1951
8.21.20 POWER SOCKET AND CIGAR LIGHTER 		1952-1953
8.21.21 REAR PARKING AIS 		1954-1955
8.21.22 AUDIO SYSTEM 		1956-1957
8.21.23 CONNECTOR DETAILS 		1960-1961
9. BODY 		1836
9.1 TIGHTENING TORQUES 		1840
9.2 FRONT BUMPER REMOVAL AND REFITMENT 		1841
9.3 REAR BUMPER REMOVAL AND REFITMENT 		1842
9.4 TAILGATE REMOVAL AND REFITMENT 		1843
9.5 TAIL LAMP ASSEMBLY REMOVAL ANDREFITMENT 		1846
9.6 FRONT FOG LAMP REMOVAL AND REFITMENT 		1847
9.7 LIGHT STALK REMOVAL AND REFITMENT 		1848
9.8 COMBINATION SWITCH REMOVAL AND REFITMENT 		1850
10. HVAC 		876
10.1 GENERAL INFORMATION 		882
10.1.1 TECHNICAL SPECIFICATIONS 		882
10.1.2 TIGHTENING TORQUES 		883
10.1.3 GENERAL PRECAUTIONS 		885
10.1.4 SYSTEM LAYOUTS 		887
10.1.5 COMPONENT DESCRIPTION 		891
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		894
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		895
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		908
10.2.3 FLUSHING OF AC SYSTEM 		913
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		915
10.2.5 A/C SYSTEM PERFORMANCE TEST 		917
10.2.6 LEAK TEST SYSTEM 		917
10.3 ON VEHICLE REPAIRS 		918
10.3.1 CONTROL PANEL ASSEMBLY 		919
10.3.2 A/C COMPRESSOR 		920
10.3.3 HVAC UNIT 		931
10.3.4 BLOWER UNIT 		935
10.3.5 BLOWER RESISTER 		935
10.3.6 FILTER 		936
10.3.7 EVAPORATOR AND EXPANSION VALVE 		937
10.3.8 HEATER ASSEMBLY 		939
10.3.9 KINEMATICS 		940
10.3.10 PRESSURE SWITCH 		940
10.3.11 CONDENSER ASSEMBLY 		941
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		943
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		945
10.3.14 REFRIGERANT LINES 		946
10.3.15 HEATER LINES 		948
11. FUEL SYSTEM 		1854
11.1 INTRODUCTION 		1858
11.2 PRECAUTIONS 		1858
11.3 SPECIFICATIONS 		1858
11.4 TIGHTENING TORQUE 		1859
11.5 FUEL TANK UNIT REMOVAL AND REFITMENT 		1860
11.6 FUEL TANK REMOVAL AND REFITMENT 		1861
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