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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
9. BODY 		721
9.1 GENERAL INFORMATION 		727
9.1.1 TECHNICAL SPECIFICATIONS 		727
9.1.2 TIGHTENING TORQUE 		728
9.2 ON VEHICLE REPAIRS 		732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		732
9.2.2 FRONT BUMPER 		733
9.2.3 FENDER (SIDE BONNET) 		734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		735
9.2.5 FRONT DOOR 		739
9.2.6 REAR DOOR 		750
9.2.7 REAR SHELF 		759
9.2.8 TAILGATE 		759
9.2.9 REAR BUMPER 		760
9.2.10 DASHBOARD 		762
9.2.11 CENTER CONSOLE 		765
9.2.12 SEATS & BELTS 		766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		776
9.2.14 SUN VISOR 		776
9.2.15 TRIMS 		777
9.2.16 FLOOR CARPET 		778
9.2.17 WINDSHIELD 		781
9.3 PAINT CARE 		783
9.4 BODY REPAIR DATA 		786
9.5 TROUBLESHOOTING AND DIAGNOSIS 		791
10. HVAC 		793
10.1 GENERAL INFORMATION 		799
10.1.1 TECHNICAL SPECIFICATIONS 		799
10.1.2 TIGHTENING TORQUES 		800
10.1.3 GENERAL PRECAUTIONS 		802
10.1.4 SYSTEM LAYOUTS 		804
10.1.5 COMPONENT DESCRIPTION 		808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		825
10.2.3 FLUSHING OF AC SYSTEM 		830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		832
10.2.5 A/C SYSTEM PERFORMANCE TEST 		834
10.2.6 LEAK TEST SYSTEM 		834
10.3 ON VEHICLE REPAIRS 		835
10.3.1 CONTROL PANEL ASSEMBLY 		836
10.3.2 A/C COMPRESSOR 		837
10.3.3 HVAC UNIT 		848
10.3.4 BLOWER UNIT 		852
10.3.5 BLOWER RESISTER 		852
10.3.6 FILTER 		853
10.3.7 EVAPORATOR AND EXPANSION VALVE 		854
10.3.8 HEATER ASSEMBLY 		856
10.3.9 KINEMATICS 		857
10.3.10 PRESSURE SWITCH 		857
10.3.11 CONDENSER ASSEMBLY 		858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		862
10.3.14 REFRIGERANT LINES 		863
10.3.15 HEATER LINES 		865
NANO AMT 		867
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 		869
3.5.1 RADIATOR LOCATION ON VEHICLE 		873
3.5.2 TECHNICAL SPECIFICATIONS 		874
3.5.3 RADIATOR REMOVAL AND RE-FITMENT ON VEHICLE 		875
3.5.4 RADIATOR FAN REMOVAL AND RE-FITMENT ON VEHICLE 		884
3.5.5 COOLANT TANK REMOVAL AND RE-FITMENT ON VEHICLE 		888
3.5.6 OIL FILTER REMOVAL AND RE-FITMENT ON VEHICLE 		890
3.5.7 CATCON REMOVAL AND RE-FITMENT PROCEDURES ON VEHICLE 		895
3.5.8 ELECTRONIC THROTTLE CONTROL BODY ORIENTATION 		903
3.5.9 THERMOSTAT 		904
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 		906
4.1.1 GENERAL INFORMATION 		906
4.1.1.1 TECHNICAL SPECIFICATION 		906
4.1.1.2 CONSTRUCTION 		909
4.1.1.3 PRECAUTIONS 		911
4.1.1.4 TIGHTENING TORQUES 		912
4.1.1.5 SPECIAL TOOLS 		913
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 		914
4.1.1.7 TROUBLE SHOOTING 		916
4.1.1.8 MAINTENANCE AND REPAIRS 		917
4.1.2 OVERHAULING 		918
4.1.2.1 EXPLODED VIEW 		918
4.1.2.2 PROCEDURE 		919
4.1.2.2.1 REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 		919
4.1.2.2.2 CLUTCH ACTUATION MECHANISM OVERHAUL 		920
4.2 5-SPEED TRANSAXLE 		923
4.2.1 GENERAL INFORMATION 		923
4.2.1.1 TECHNICAL SPECIFICATION 		923
4.2.1.2 PRECAUTIONS 		924
4.2.1.3 TIGHTENING TORQUES 		925
4.2.1.4 SPECIAL TOOLS 		929
4.2.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 		932
4.2.1.6 TRANSAXLE OIL REPLACEMENT 		933
4.2.2 OVERHAULING (EXPLOADED VIEWS) 		934
4.2.2.1 TRANSAXLE HOUSING 		934
4.2.2.2 INPUT SHAFT AND LAY SHAFT 		936
4.2.2.3 SHIFER SHAFT AND SHIFTER SLEEVE 		937
4.2.2.4 DIFFERENTIAL 		938
4.2.2.5 TOP COVER ASSEMBLY 		939
4.2.2.6 SHIFTER LINKAGE 		940
4.2.3 COMPONENT IDENTIFICATION 		941
4.2.3.1 SHIFTER SHAFTS 		941
4.2.3.2 SHIFTER FORKS (DOGS) 		941
4.2.3.3 SHIFTER SLEEVE 		942
4.2.4 REMOVAL OF TRANSAXLE 		944
4.2.5 TRANSAXLE DISMANTLING 		945
4.2.6 INPUT SHAFT ASSEMBLY 		949
4.2.7 LAY SHAFT ASSEMBLY 		952
4.2.8 SHIFTER SHAFT AND SHIFTER FORK 		956
4.2.9 REVERSE GEAR SHIFTER BRACKET ASSEMBLY 		959
4.2.10 DIFFERENTIAL ASSEMBLY 		960
4.2.11 TOP COVER ASSEMBLY 		963
4.2.12 REAR HALF HOUSING ASSEMBLY 		966
4.2.13 FRONT HALF HOUSING ASSEMBLY 		967
4.2.14 TRANSAXLE ASSEMBLY 		969
4.2.14.1 SHIM SELECTION 		969
4.2.14.2 ASSEMBLING THE TRANSAXLE 		970
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 		974
4.4.1 AMT KIT LOCATION ON VEHICLE 		975
4.4.2 ABBREVIATION LIST 		976
4.4.3 PRECAUTION (DO’S AND DON’TS) 		977
4.4.4 TECHNICAL SPECIFICATIONS 		979
4.4.5 TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS 		980
4.4.6 TOOLS 		982
4.4.7 AMT UNIT REMOVAL AND INSTALLATION PROCEDURES ON VEHICLE 		984
4.4.8 MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT ON BENCH 		991
4.4.9 TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT ON BENCH 		994
4.4.10 OIL TANK REMOVAL AND RE-FITMENT ON BENCH 		998
4.4.11 DC MOTOR REMOVAL AND RE-FITMENT ON BENCH 		1000
4.4.12 CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT ON BENCH 		1001
4.4.13 HYDRAULIC OIL ACCUMLATOR 		1001
4.4.14 POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH 		1002
4.5 GEAR SHIFTER CONSOLE 		1004
4.5.1 AMT GEARBOX SHIFTER AND SHIFTING MECHANISM 		1004
4.5.2 GEAR SHIFTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE 		1006
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 		1010
8.1 EMS ECU AND AMT TCU CONNECTOR’S REMOVAL AND RE-FITMENT ON VEHICLE 		1012
8.1.1 PARTS LIST 		1012
8.1.2 EMS ECU CONNECTOR REMOVAL AND RE-FIMENT ON VEHICLE 		1014
8.1.3 AMT TCU UNIT CONNECTOR’S REMOVAL AND RE-FIMENT ON VEHICLE 		1019
8.2 FOG LAMP REMOVAL AND RE-FITMENT ON VEHICLE 		1023
8.3 HORN REMOVAL AND RE-FITMENT ON VEHICLE 		1026
8.4 AMBIENT TEMPERATURE SENSOR REMOVAL AND RE-FITMENT ON VEHICLE 		1029
8.5 TRANSMISSION INPUT SPEED SENSOR REMOVAL AND RE-FITMENT ON VEHICLE 		1033
8.6 EXHAUST FAN REMOVAL AND RE-FITMENT ON VEHICLE 		1035
8.7 DIAGNOSTIC TROUBLE CODES FOR ELECTRONIC POWER ASSISTED STEERING 		1038
8.8 BRAKE SWITCH FAILURE CASES AND RECOVERY ON VEHICLE 		1039
8.9 DIAGNOSTIC TROUBLE CODES FOR ENGINE MANAGEMENT SYSTEM 		1040
9. BODY 		721
9.1 GENERAL INFORMATION 		727
9.1.1 TECHNICAL SPECIFICATIONS 		727
9.1.2 TIGHTENING TORQUE 		728
9.2 ON VEHICLE REPAIRS 		732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		732
9.2.2 FRONT BUMPER 		733
9.2.3 FENDER (SIDE BONNET) 		734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		735
9.2.5 FRONT DOOR 		739
9.2.6 REAR DOOR 		750
9.2.7 REAR SHELF 		759
9.2.8 TAILGATE 		759
9.2.9 REAR BUMPER 		760
9.2.10 DASHBOARD 		762
9.2.11 CENTER CONSOLE 		765
9.2.12 SEATS & BELTS 		766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		776
9.2.14 SUN VISOR 		776
9.2.15 TRIMS 		777
9.2.16 FLOOR CARPET 		778
9.2.17 WINDSHIELD 		781
9.3 PAINT CARE 		783
9.4 BODY REPAIR DATA 		786
9.5 TROUBLESHOOTING AND DIAGNOSIS 		791
10. HVAC 		793
10.1 GENERAL INFORMATION 		799
10.1.1 TECHNICAL SPECIFICATIONS 		799
10.1.2 TIGHTENING TORQUES 		800
10.1.3 GENERAL PRECAUTIONS 		802
10.1.4 SYSTEM LAYOUTS 		804
10.1.5 COMPONENT DESCRIPTION 		808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		825
10.2.3 FLUSHING OF AC SYSTEM 		830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		832
10.2.5 A/C SYSTEM PERFORMANCE TEST 		834
10.2.6 LEAK TEST SYSTEM 		834
10.3 ON VEHICLE REPAIRS 		835
10.3.1 CONTROL PANEL ASSEMBLY 		836
10.3.2 AC COMPRESSOR 		1068
10.3.2.1 AC COMPRESSOR LOCATION ON VEHICLE 		1071
10.3.2.2 TECHNICAL SPECIFICATIONS 		1072
10.3.2.3 TIGHTENING TORQUES 		1073
10.3.2.4 PRECAUTIONS 		1074
10.3.2.5 EXPLODED VIEW AND PART LIST 		1077
10.3.2.6 AC COMPRESSOR REMOVAL AND RE-FITMENT ON VEHICLE 		1078
10.3.3 HVAC UNIT 		848
10.3.4 BLOWER UNIT 		852
10.3.5 BLOWER RESISTER 		852
10.3.6 FILTER 		853
10.3.7 EVAPORATOR AND EXPANSION VALVE 		854
10.3.8 HEATER ASSEMBLY 		856
10.3.9 KINEMATICS 		857
10.3.10 PRESSURE SWITCH 		857
10.3.11 CONDENSER ASSEMBLY 		858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		862
10.3.14 REFRIGERANT LINES 		863
10.3.15 HEATER LINES 		865
NANO CNG 		1084
1. GENERAL 		1090
1.1. INTRODUCTION TO CNG SYSTEM 		1094
1.2. BENEFITS OF CNG 		1094
1.3. FEATURES OF CNG BI-FUEL SYSTEM 		1094
1.4. GENERAL INSTRUCTION / PRECAUTIONSWHILE WORKING ON CNG VEHICLE 		1095
1.5. IN CASE OF LEAKAGE 		1097
1.6. TECHNICAL SPECIFICATIONS 		1099
1.7. TIGHTENING TORQUE 		1103
1.8. SPECIAL TOOLS 		1108
1.9. LIST OF APPROVED CNG CYLINDER TESTING STATION 		1109
1.10. SERVICE SCHEDULE 		1110
1.11. LUBRICANTS AND COOLANTS 		1114
2. PRECAUTIONS 		35
2.1 GENERAL SAFETY PRECAUTIONS 		41
2.2 GENERAL SERVICE PRECAUTIONS 		45
3. ENGINE 		1116
3.1. TECHNICAL SPECIFICATION 		1120
3.2. REPAIR DATA 		1121
A. BELT TENSION VALUES 		1121
3.3. ENGINE CONTRUCTIONAL DETAIL 		1122
A. ENGINE 		1122
B. INTAKE MANIFOLD 		1122
3.4. GENERAL SYSTEM OVERVIEW OF Bi-FUEL ENGINE MANAGEMENT SYSTEM 		1123
3.5. REMOVAL AND REFITMENT OF ENGINEACCESS WINDOW AND ENGINE COVER 		1126
3.6. GAS INJECTOR 		1129
3.7. GAS RAIL 		1131
3.8. PRESSURE AND TEMPERATURE (P&T)SENSOR 		1133
3.9. DIAGNOSTIC USER MANUAL 		1135
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 		1156
4.2.1 GENERAL INFORMATION 		1162
A. TECHNICAL SPECIFICATIONS 		1162
B. PRECAUTIONS 		1163
C. TIGHTENING TORQUES 		1164
D. SPECIAL TOOLS 		1167
E. GENERAL SYMPTOMS AND DIAGNOSIS 		1171
F. TRANSAXLE OIL REPLACEMENT 		1172
4.2.2. OVERHAULING (EXPLODED VIEWS) 		1173
A. TRANSAXLE HOUSING 		1173
B. INPUT SHAFT AND LAY SHAFT 		1174
C. SHIFTER SHAFT AND SHIFTER SLEEVE 		1175
D. DIFFERENTIAL 		1176
E. TOP COVER ASSEMBLY 		1177
F. SHIFTER LINKAGE 		1178
4.2.3. COMPONENT IDENTIFICATION 		1180
A. SHIFTER SHAFTS 		1180
B. SHIFTER FORKS (DOGS) 		1180
C. SHIFTER SLEEVE 		1181
4.2.4. REMOVAL OF TRANSAXLE FROM VEHICLE 		1182
4.2.5. TRANSAXLE DISMANTLING 		1185
4.2.6. INPUT SHAFT ASSEMBLY 		1189
4.2.7. LAYSHAFT ASSEMBLY 		1194
4.2.8. SHIFTER SHAFT AND SHIFTER FORK 		1200
4.2.9. REVERSE GEAR SHIFTER BRACKET - ASSEMBLY 		1201
4.2.10. DIFFERENTIAL ASSEMBLY 		1203
4.2.11. REAR HALF HOUSING TOP COVER ASSEMBLY 		1207
4.2.12. REAR HALF HOUSING ASSEMBLY 		1214
4.2.13. FRONT HALF HOUSING 		1216
4.2.14. TRANSAXLE ASSEMBLY 		1218
A. SHIM SELECTION 		1218
B. ASSEMBLING THE TRANSAXLE 		1219
4.2.15. GEAR SHIFTER LINKAGE 		1224
A. GEAR SHIFTER CABLE REPLACEMENT 		1224
B. GEAR SHIFTER ADJUSTMENT 		1226
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 		1262
8.1 TECHNICAL SPECIFICATION 		1266
8.2. LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE 		1267
8.3. INSTRUMENT CLUSTER 		1268
8.4. FUEL GAUGE 		1269
8.5. REMOVAL AND REFITTMENT OF BATTERY 		1270
8.6. STARTER MOTOR 		1271
A. EXPLODED VIEW 		1271
B. ON VEHICLE REMOVAL AND REFITTMENT OF STARTER MOTOR 		1271
C. STARTER MOTOR OVER HAULING 		1272
DTC CODES 		1278
9. BODY 		721
9.1 GENERAL INFORMATION 		727
9.1.1 TECHNICAL SPECIFICATIONS 		727
9.1.2 TIGHTENING TORQUE 		728
9.2 ON VEHICLE REPAIRS 		732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		732
9.2.2 FRONT BUMPER 		733
9.2.3 FENDER (SIDE BONNET) 		734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		735
9.2.5 FRONT DOOR 		739
9.2.6 REAR DOOR 		750
9.2.7 REAR SHELF 		759
9.2.8 TAILGATE 		759
9.2.9 REAR BUMPER 		760
9.2.10 DASHBOARD 		762
9.2.11 CENTER CONSOLE 		765
9.2.12 SEATS & BELTS 		766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		776
9.2.14 SUN VISOR 		776
9.2.15 TRIMS 		777
9.2.16 FLOOR CARPET 		778
9.2.17 WINDSHIELD 		781
9.3 PAINT CARE 		783
9.4 BODY REPAIR DATA 		786
9.5 TROUBLESHOOTING AND DIAGNOSIS 		791
10. HVAC 		793
10.1 GENERAL INFORMATION 		799
10.1.1 TECHNICAL SPECIFICATIONS 		799
10.1.2 TIGHTENING TORQUES 		800
10.1.3 GENERAL PRECAUTIONS 		802
10.1.4 SYSTEM LAYOUTS 		804
10.1.5 COMPONENT DESCRIPTION 		808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		825
10.2.3 FLUSHING OF AC SYSTEM 		830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		832
10.2.5 A/C SYSTEM PERFORMANCE TEST 		834
10.2.6 LEAK TEST SYSTEM 		834
10.3 ON VEHICLE REPAIRS 		835
10.3.1 CONTROL PANEL ASSEMBLY 		836
10.3.2 A/C COMPRESSOR 		837
10.3.3 HVAC UNIT 		848
10.3.4 BLOWER UNIT 		852
10.3.5 BLOWER RESISTER 		852
10.3.6 FILTER 		853
10.3.7 EVAPORATOR AND EXPANSION VALVE 		854
10.3.8 HEATER ASSEMBLY 		856
10.3.9 KINEMATICS 		857
10.3.10 PRESSURE SWITCH 		857
10.3.11 CONDENSER ASSEMBLY 		858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		862
10.3.14 REFRIGERANT LINES 		863
10.3.15 HEATER LINES 		865
11. FUEL SYSTEM 		1228
11.1 INTRODUCTION 		1232
A. CNG LAYOUT (ON VEHICLE) 		1233
11.2. CNG FUEL SYSTEM COMPONENTS 		1234
A. CNG CYLINDER 		1234
B. CYLINDER VALVE 		1236
C. LOW PRESSURE CNG FILTER 		1241
D. PRESSURE GAUGE 		1244
E. PRESSURE REGULATOR 		1245
F. HIGH PRESSURE (H.P) SENSOR 		1250
G. CNG RECEPTACLE VALVE 		1252
11.3. CNG TUBE FITTINGS / JOINTS TIGHTENING INSTRUCTIONS 		1255
A. SWAGING PROCEDURE 		1255
B. PROCEDURE FOR NPT THREAD ASSEMBLY 		1257
11.4. CNG LEAK DETECTION TESTING 		1259
11.5. TROUBLE SHOOTING 		1260
NANO ePAS 		1296
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 		1302
7.1 GENERAL INFORMATION 		1307
7.1.1 SPECIFICATIONS 		1307
7.1.2 SYSTEM LAYOUT 		1307
7.1.3 GENERAL DESCRIPTION 		1308
7.1.4 TIGHTENING TORQUES 		1309
7.1.5 SPECIAL TOOLS 		1311
7.2. MAINTENANCE, INSPECTION AND TEST 		1312
7.2.1 PRELIMINARY INSPECTION 		1312
7.2.2 REGULAR MAINTENANCE 		1313
7.2.3 ON VEHICLE REPAIRS 		1315
7.2.3.1 STEERING WHEEL REMOVAL 		1315
7.2.3.2 STEERING COLUMN REMOVAL 		1316
7.2.3.3 INTERMEDIATE SHAFT REMOVAL 		1317
7.2.3.4 ECU REMOVAL 		1318
7.2.3.5 RACK & PINION ASSEMBLY REMOVAL 		1319
7.3. OVERHAULING 		1321
7.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 		1321
7.3.2 PRECAUTIONS 		1322
7.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 		1322
7.3.3.1 DISASSEMBLY OF RACK & PINON 		1322
7.3.3.2 INSPECTION OF DISMANTLED PARTS 		1323
7.3.3.3 ASSEMBLY OF RACK & PINON 		1324
7.3.3.4 OBJ ON-VEHICLE REMOVAL 		1325
7.3.3.5 DO’S & DON’TS 		1326
7.3.3.6 WHEEL ALIGNMENT 		1326
7.3.4 TROUBLESHOOTING AND DIAGNOSIS 		1328
8. ELECTRICAL 		1334
8.1. TECHNICAL SPECIFICATION 		1340
8.2. INSTRUMENT CLUSTER 		1342
8.2.1. ART WORK 		1342
8.2.2. TELL TALES 		1342
8.2.3. SPECIFICATION 		1343
8.2.4. CONNECTION DETAILS 		1343
8.2.5. CONNECTOR DETAILS 		1343
8.2.6. PINOUT DETAILS 		1343
8.2.7 FREQUENTLY ASKED QUESTIONSDistance to Empty (DTE) 		1344
8.2.8 SEASON ODOMETER WRITING /UPDATING PROCEDURE 		1346
8.3. EPAS ECU 		1347
8.3.1. SPECIFICATION 		1347
8.3.2. LOCATION 		1347
8.3.3. CONNECTION DETAILS 		1348
8.3.4. PINOUT DETAILS 		1348
8.4. FUSEBOX & RELAY DETAILS 		1349
8.4.1 LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE 		1349
8.4.2. BATTERY MOUNTED FUSE BOX DETAILS (FOR NANO CNG AND MY13) 		1349
8.4.3. CABIN FUSE BOX DETAILS(NANO MY13 EPAS) 		1350
8.4.4. RELAY BOX DETAILS (FOR NANO CNG AND MY13) 		1352
8.4.5. DIAGNOSTIC CONNECTOR LOCATION 		1352
8.4.6 ECU AND STEERING COLUMN PAIRING PROCESS 		1353
8.5 DIAGNOSTIC USER MANUAL 		1354
8.6 DIAGNOSTIC TROUBLE CODES - EPAS 		1364
8.7 DIAGNOSTIC TROUBLE CODES – EMS ECU 		1371
9. BODY 		721
9.1 GENERAL INFORMATION 		727
9.1.1 TECHNICAL SPECIFICATIONS 		727
9.1.2 TIGHTENING TORQUE 		728
9.2 ON VEHICLE REPAIRS 		732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 		732
9.2.2 FRONT BUMPER 		733
9.2.3 FENDER (SIDE BONNET) 		734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 		735
9.2.5 FRONT DOOR 		739
9.2.6 REAR DOOR 		750
9.2.7 REAR SHELF 		759
9.2.8 TAILGATE 		759
9.2.9 REAR BUMPER 		760
9.2.10 DASHBOARD 		762
9.2.11 CENTER CONSOLE 		765
9.2.12 SEATS & BELTS 		766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 		776
9.2.14 SUN VISOR 		776
9.2.15 TRIMS 		777
9.2.16 FLOOR CARPET 		778
9.2.17 WINDSHIELD 		781
9.3 PAINT CARE 		783
9.4 BODY REPAIR DATA 		786
9.5 TROUBLESHOOTING AND DIAGNOSIS 		791
10. HVAC 		793
10.1 GENERAL INFORMATION 		799
10.1.1 TECHNICAL SPECIFICATIONS 		799
10.1.2 TIGHTENING TORQUES 		800
10.1.3 GENERAL PRECAUTIONS 		802
10.1.4 SYSTEM LAYOUTS 		804
10.1.5 COMPONENT DESCRIPTION 		808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		825
10.2.3 FLUSHING OF AC SYSTEM 		830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		832
10.2.5 A/C SYSTEM PERFORMANCE TEST 		834
10.2.6 LEAK TEST SYSTEM 		834
10.3 ON VEHICLE REPAIRS 		835
10.3.1 CONTROL PANEL ASSEMBLY 		836
10.3.2 A/C COMPRESSOR 		837
10.3.3 HVAC UNIT 		848
10.3.4 BLOWER UNIT 		852
10.3.5 BLOWER RESISTER 		852
10.3.6 FILTER 		853
10.3.7 EVAPORATOR AND EXPANSION VALVE 		854
10.3.8 HEATER ASSEMBLY 		856
10.3.9 KINEMATICS 		857
10.3.10 PRESSURE SWITCH 		857
10.3.11 CONDENSER ASSEMBLY 		858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		862
10.3.14 REFRIGERANT LINES 		863
10.3.15 HEATER LINES 		865
NANO OTG 		1383
1. GENERAL 		1387
1.1 TECHNICAL SPECIFICATION 		1391
1.2 FUEL, LUBRICANTS AND COOLANTS 		1393
1.3 SERVICE SCHEDULE 		1394
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 		1427
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
9. BODY 		1397
9.1 TIGHTENING TORQUES 		1401
9.2 FRONT BUMPER REMOVAL AND REFITMENT 		1402
9.3 REAR BUMPER REMOVAL AND REFITMENT 		1403
9.4 TAILGATE REMOVAL AND REFITMENT 		1404
9.5 TAIL LAMP ASSEMBLY REMOVAL ANDREFITMENT 		1407
9.6 FRONT FOG LAMP REMOVAL AND REFITMENT 		1408
9.7 LIGHT STALK REMOVAL AND REFITMENT 		1409
9.8 COMBINATION SWITCH REMOVAL AND REFITMENT 		1411
10. HVAC 		793
10.1 GENERAL INFORMATION 		799
10.1.1 TECHNICAL SPECIFICATIONS 		799
10.1.2 TIGHTENING TORQUES 		800
10.1.3 GENERAL PRECAUTIONS 		802
10.1.4 SYSTEM LAYOUTS 		804
10.1.5 COMPONENT DESCRIPTION 		808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 		811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 		812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 		825
10.2.3 FLUSHING OF AC SYSTEM 		830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		832
10.2.5 A/C SYSTEM PERFORMANCE TEST 		834
10.2.6 LEAK TEST SYSTEM 		834
10.3 ON VEHICLE REPAIRS 		835
10.3.1 CONTROL PANEL ASSEMBLY 		836
10.3.2 A/C COMPRESSOR 		837
10.3.3 HVAC UNIT 		848
10.3.4 BLOWER UNIT 		852
10.3.5 BLOWER RESISTER 		852
10.3.6 FILTER 		853
10.3.7 EVAPORATOR AND EXPANSION VALVE 		854
10.3.8 HEATER ASSEMBLY 		856
10.3.9 KINEMATICS 		857
10.3.10 PRESSURE SWITCH 		857
10.3.11 CONDENSER ASSEMBLY 		858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 		860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 		862
10.3.14 REFRIGERANT LINES 		863
10.3.15 HEATER LINES 		865
11. FUEL SYSTEM 		1415
11.1 INTRODUCTION 		1419
11.2 PRECAUTIONS 		1419
11.3 SPECIFICATIONS 		1419
11.4 TIGHTENING TORQUE 		1420
11.5 FUEL TANK UNIT REMOVAL AND REFITMENT 		1421
11.6 FUEL TANK REMOVAL AND REFITMENT 		1422
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