ZICA
|
1. GENERAL |
6 |
|
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS |
9 |
|
1.2. PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE |
10 |
|
1.3. PRECAUTIONS OF COMMON RAIL SYSTEM (CR SYSTEM) |
11 |
|
1.4. VEHICLE JACKING AND LIFTING POINTS |
13 |
|
1.5. JACK, AND TOOL BAG LOCATION |
14 |
|
1.6. NUMBERING SYSTEM |
15 |
|
1.6.1. CHASSIS NUMBERING SYSTEM |
15 |
|
1.6.2. AGGREGATE NUMBERING SYSTEM |
16 |
|
1.7. CHASSIS TYPE AND SALES DESIGNATIONS |
17 |
|
1.8. TECHNICAL SPECIFICATIONS (PETROL) |
18 |
|
1.9. TECHNICAL SPECIFICATIONS (DIESEL) |
21 |
|
1.10. VEHICLE DIMENSIONS |
23 |
|
1.11. RECOMMENDED LUBRICANTS & COOLANTS |
25 |
|
1.12. SERVICE AND MAINTENANCE |
27 |
|
2. PETROL ENGINE |
29 |
|
2.1. GENERAL INFORMATION |
35 |
|
A. ENGINE INTRODUCTION |
35 |
|
B. ELECTRONIC FUEL INJECTION CONTROL |
36 |
|
C. TECHNICAL SPECIFICATION |
37 |
|
D. SPECIAL TOOLS |
38 |
|
E. ASSEMBLY CLEARANCES |
41 |
|
F. SEALANTS |
41 |
|
G. LEAKAGE RATES |
41 |
|
H. RECOMMENDED LUBRICANTS & COOLANTS |
42 |
|
I. SERVICE SCHEDULE |
42 |
|
2.2. TROUBLESHOOTING |
43 |
|
2.3. CONSTRUCTIONAL AND SERVICE DETAILS |
50 |
|
A. ENGINE LIFTING |
50 |
|
B. INTAKE MANIFOLD |
51 |
|
C. CYLINDER HEAD AND COVER |
53 |
|
D. CYLINDER HEAD-A |
55 |
|
E. CYLINDER HEAD-B |
57 |
|
F. CYLINDER BLOCK |
59 |
|
G. OIL SUMP |
61 |
|
H. MOVING PARTS |
63 |
|
I. ENGINE TIMING |
65 |
|
J. EXHAUST MANIFOLD |
67 |
|
K. FUEL INJECTION EQUIPMENT |
69 |
|
L. LUBRICATION PUMP AND COMPONENTS |
71 |
|
M. AIR INTAKE SYSTEM |
73 |
|
N. SPECIAL INSTALLATION |
75 |
|
O. ENGINE SUSPENSION |
78 |
|
2.4. ENGINE TESTS AND MAINTENANCE |
81 |
|
A. PRELIMINARY INSPECTION |
81 |
|
B. ENGINE TESTS |
82 |
|
I. ENGINE COMPRESSION TEST |
82 |
|
II. ENGINE OIL CONSUMPTION TEST |
83 |
|
III. ENGINE OIL PRESSURE TEST |
84 |
|
C. REGULAR MAINTENANCE |
85 |
|
I. ENGINE OIL AND FILTER CHANGE |
85 |
|
II. ENGINE COOLANT REPLACEMENT |
86 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
87 |
|
IV. SPARK PLUG REPLACEMENT |
88 |
|
V. FUEL FILTER REPLACEMENT |
91 |
|
VI. AIR CONDITIONER COMPRESSOR BELT REPLACEMENT |
92 |
|
2.5. REPAIR AND INSPECTION DETAILS |
93 |
|
A. ACCESSORY DRIVING BELT |
93 |
|
B. TIMING CHAIN |
93 |
|
C. CYLINDER HEAD |
93 |
|
D. VALVES |
94 |
|
E. CYLINDER HEAD VALVE SEATS |
96 |
|
F. ROCKER ARM AND SHAFTS |
97 |
|
G. HYDRAULIC LASH ADJUSTER |
97 |
|
H. CAMSHAFT |
97 |
|
I. PISTON AND PISTON RINGS |
99 |
|
J. CONNECTING RODS |
100 |
|
K. CRANKSHAFT |
102 |
|
L. CRANK CASE |
104 |
|
M. FUEL TANK |
105 |
|
N. CANISTER PURGE VALVE |
105 |
|
O. CANISTER |
106 |
|
2.6. ENGINE SYSTEM |
107 |
|
A. AIR INTAKE SYSTEM |
107 |
|
B. BLOW BY SYSTEM |
109 |
|
C. LUBRICATION SYSTEM |
110 |
|
D. EXHAUST SYSTEM |
114 |
|
E. COOLING SYSTEM |
117 |
|
F. FUEL SYSTEM |
120 |
|
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
123 |
|
A. ENGINE REMOVAL AND INSTALLATION |
123 |
|
B. AIR FILTER ASSEMBLY REMOVAL |
128 |
|
C. INJECTOR REMOVAL |
129 |
|
D. SPARK PLUG REMOVAL |
130 |
|
E. EXHAUST SYSTEM REMOVAL |
130 |
|
F. FUEL SYSTEM |
133 |
|
G. COOLING SYSTEM |
139 |
|
H. REMOVAL OF ACCESSORIES |
142 |
|
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
143 |
|
A. ENGINE DIS-ASSEMBLY |
143 |
|
I. REMOVAL OF INTAKE MANIFOLD |
143 |
|
II. REMOVAL OF EXHAUST MANIFOLD |
144 |
|
III. REMOVAL OF OIL SUMP |
146 |
|
IV. REMOVAL OF SENSORS |
146 |
|
V. REMOVAL OF ACCESSORIES |
147 |
|
VI. REMOVAL OF TIMING CHAIN |
150 |
|
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
151 |
|
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
152 |
|
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
154 |
|
B. ENGINE ASSEMBLY |
157 |
|
I. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
157 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
159 |
|
III. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
161 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
162 |
|
V. ASSEMBLY OF TIMING CHAIN |
164 |
|
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
167 |
|
VII. FITMENT OF ENGINE SENSORS AND PERIPHERALS |
169 |
|
VIII. FITMENT OF OIL SUMP |
170 |
|
IX. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
170 |
|
X. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
172 |
|
2.9. ENGINE MANAGEMENT SYSTEM |
175 |
|
A. ABBREVIATIONS |
175 |
|
B. AN OVERVIEW |
176 |
|
C. ELECTRONIC CONTROL UNIT |
177 |
|
D. SENSORS |
182 |
|
I. T-MAP SENSOR |
183 |
|
II. LAMBDA SENSOR |
184 |
|
III. CAMSHAFT POSITION SENSOR |
186 |
|
IV. KNOCK SENSOR |
187 |
|
V. CRANKSHAFT POSITION SENSOR |
188 |
|
VI. COOLANT TEMPERATURE SENSOR |
189 |
|
E. ACTUATORS |
191 |
|
I. IGNITION COIL |
192 |
|
II. PURGE CONTROL VALVE |
193 |
|
III. SOLENOID VALVE (OCV) |
194 |
|
IV. FUEL INJECTOR |
195 |
|
V. ELECTRONIC THROTTLE BODY |
196 |
|
F. SWITCH |
198 |
|
I. OIL PRESSURE SWITCH |
198 |
|
II. THROTTLE PEDAL SENSOR |
199 |
|
III. CLUTCH SWITCH |
200 |
|
IV. BRAKE SWITCH |
201 |
|
V. VEHICLE SPEED SENSOR |
202 |
|
VI. WHEEL SPEED SENSOR |
203 |
|
2.10. LIST OF DIAGNOSTIC TROUBLE SHOOTING CODES |
204 |
|
3. DIESEL ENGINE |
210 |
|
3.1. GENERAL INFORMATION |
215 |
|
A. ENGINE INTRODUCTION |
215 |
|
B. TECHNICAL SPECIFICATION |
216 |
|
C. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
217 |
|
D. SERVICE SCHEDULE |
218 |
|
E. ASSEMBLY CLEARANCES |
219 |
|
F. SPECIAL TOOLS |
220 |
|
3.2. TROUBLESHOOTING |
224 |
|
3.3. CONSTRUCTIONAL AND SERVICE DETAILS |
232 |
|
A. ENGINE MOUNTING SYSTEM |
232 |
|
B. CYLINDER HEAD AND COVER |
234 |
|
C. LUBRICATION SYSTEM |
236 |
|
D. ENGINE |
238 |
|
E. OIL SUMP |
240 |
|
F. CYLINDER HEAD |
242 |
|
G. SPECIAL INSTALLATION |
244 |
|
H. EXHAUST SYSTEM |
246 |
|
I. INTAKE SYSTEM |
248 |
|
J. ENGINE SUSPENSION |
250 |
|
K. MOVING PARTS |
252 |
|
L. ENGINE TIMING |
254 |
|
M. FUEL INJECTION EQUIPMENT |
256 |
|
3.4. ENGINE TESTS AND MAINTENANCE |
258 |
|
A. PRELIMINARY INSPECTION |
258 |
|
B. ENGINE TESTS |
258 |
|
C. REGULAR MAINTENANCE |
262 |
|
I. ENGINE OIL AND FILTER CHANGE |
262 |
|
II. ENGINE COOLANT REPLACEMENT |
263 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
264 |
|
IV. FUEL FILTER REPLACEMENT |
265 |
|
V. DRAINING WATER FROM PRE-FILTER |
266 |
|
VI. PRE-FILTER REPLACEMENT |
266 |
|
VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
267 |
|
3.5. REPAIR AND INSPECTION DETAILS |
268 |
|
A. TIMING BELT |
268 |
|
B. FUEL TANK |
268 |
|
C. CYLINDER HEAD |
269 |
|
D. VALVES |
270 |
|
E. VALVE SEATS |
271 |
|
F. CRANKCASE |
272 |
|
G. VALVE SEAT INSERT |
273 |
|
H. HYDRAULIC LASH ADJUSTER |
273 |
|
I. VALVE GUIDES |
274 |
|
J. CAMSHAFT |
275 |
|
K. PISTON AND PISTON RINGS |
276 |
|
L. CONNECTING ROD |
277 |
|
M. CRANKSHAFT |
279 |
|
3.6. ENGINE SYSTEM |
281 |
|
A. AIR INTAKE SYSTEM |
281 |
|
B. EXHAUST SYSTEM |
283 |
|
C. COOLING SYSTEM |
287 |
|
D. LUBRICATION SYSTEM |
290 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM |
293 |
|
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM |
295 |
|
G. VACUUM MANAGEMENT SYSTEM |
296 |
|
H. FUEL SYSTEM |
297 |
|
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
303 |
|
A. ENGINE REMOVAL |
303 |
|
B. ENGINE INSTALLATION |
307 |
|
C. EXHAUST SYSTEM |
308 |
|
D. COOLING SYSTEM |
310 |
|
E. FUEL SYSTEM |
312 |
|
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
319 |
|
A. ENGINE DIS-ASSEMBLY |
319 |
|
I. ON OVERHAUL STAND |
319 |
|
II. REMOVAL OF INTAKE MANIFOLD |
322 |
|
III. REMOVAL OF EXHAUST MANIFOLD |
324 |
|
IV. REMOVAL OF OIL SUMP |
328 |
|
V. REMOVAL OF TIMING BELT |
329 |
|
VI. REMOVAL OF CYLINDER HEAD |
332 |
|
VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
333 |
|
VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
335 |
|
IX. PISTON CONNECTING ROD DIS-ASSEMBLY |
337 |
|
B. ENGINE ASSEMBLY |
343 |
|
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
343 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
344 |
|
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
345 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
346 |
|
V. FITMENT OF TIMING BELT |
347 |
|
VI. FITMENT OF OIL SUMP |
350 |
|
VII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
352 |
|
VIII. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
356 |
|
IX. ON ENGINE SUPPORT STAND |
358 |
|
3.9. ENGINE MANAGEMENT SYSTEM |
362 |
|
A. ABBREVIATIONS |
362 |
|
B. AN OVERVIEW |
363 |
|
C. ELECTRONIC CONTROL UNIT (ECU) |
364 |
|
D. EMS SENSORS |
368 |
|
I. CRANK POSITION SENSOR |
368 |
|
II. VEHICLE SPEED SENSOR |
369 |
|
III. WHEEL SPEED SENSOR |
370 |
|
IV. CAMSHAFT POSITION SENSOR |
371 |
|
V. AIR MASS FLOW SENSOR |
372 |
|
VI. INLET METERING VALVE |
373 |
|
VII. VENTURI |
373 |
|
VIII. RAIL PRESSURE SENSOR |
373 |
|
IX. THROTTLE PEDAL SENSOR |
374 |
|
X. WATER IN FUEL SENSOR |
375 |
|
XI. CLUTCH SWITCH |
375 |
|
XII. OIL PRESSURE SWITCH |
376 |
|
XIII. BRAKE SWITCH |
378 |
|
XIV. COOLANT TEMPERATURE SENSOR |
379 |
|
XV. GLOW PLUG |
380 |
|
XVI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
381 |
|
3.10. LIST OF DIAGNOSTIC TROUBLE SHOOTING CODES |
382 |
|
4. DRIVETRAIN |
388 |
|
4.1 PRECAUTION |
392 |
|
4.2 SPECIFCICATIONS & TIGHTENING TORQUES |
393 |
|
A. CLUTCH |
393 |
|
B. TRANSAXLE |
398 |
|
C. TIGHTENING TORQUES |
399 |
|
4.3 SPECIAL TOOLS |
400 |
|
A. CLUTCH |
400 |
|
B. TRANSAXLE |
400 |
|
4.4 DIAGNOSIS |
405 |
|
A. CLUTCH |
405 |
|
B. TRANSAXLE |
408 |
|
4.5 MAINTENANCE, ADJUSTMENT & TEST |
409 |
|
A. PRELIMINARY INSPECTION OF CLUTCH |
409 |
|
B. DRIVESHAFT |
410 |
|
4.6 CLUTCH |
412 |
|
A. THEORY OF DIAPHRAGM SPRING CLUTCH |
412 |
|
B. CONSTRUCTIONAL DETAILS |
413 |
|
C. FACTOR AFFECTING CLUTCH WEAR |
415 |
|
D. CLUTCH CABLE – REMOVAL AND INSPECTION |
416 |
|
E. CLUTCH SWITCH ADJUSTMENT PROCEDURE |
417 |
|
F. REMOVAL OF CLUTCH FROM THE CAR |
417 |
|
G. INSTALLATION OF CLUTCH ON THE CAR |
417 |
|
H. PROCEDURE FOR CLUTCH ADJUSTMENT |
418 |
|
4.7 TRANSAXLE |
419 |
|
A. GENERAL DISCRIPTION |
419 |
|
B. CUT SECTION OF TRANSAXLE TA 65 STAR |
421 |
|
C. CUT SECTION OF TOP COVER ASSEMBLY |
422 |
|
D. EXPLODED VIEW OF TRANSAXLE |
423 |
|
E. EXPLODED VIEWS OF DIFFERENTIAL |
425 |
|
F. EXPLODED VIEW OF SHIFTER FORK |
427 |
|
G. EXPLODED VIEWS OF GEAR SHIFT LINKAGE ASSSEMBLY |
429 |
|
H. EXPLODED VIEWS OF LAY SHAFT AND INPUT SHAFT |
430 |
|
I. REMOVAL OF CLUTCH FROM THE CAR |
433 |
|
J. TRANSAXLE TA65 STAR (ON BENCH) DISASSSEMBLY |
435 |
|
K. INPUT SHAFT SUB- ASSEMBLY |
441 |
|
L. INPUT SHAFT ASSEMBLY |
441 |
|
M. DISASSEMBLY OF LAY SHAFT |
442 |
|
N. IDENTIFICATION OF COMPONENTS |
444 |
|
O. SUBASSEMBLIE |
447 |
|
P. LAY SHAFT ASSEMBLY |
449 |
|
Q. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL |
452 |
|
R. ASSEMBLY OF TRANSAXLE |
454 |
|
S. ASSEMBLY OF TOP COVER |
457 |
|
T. INSTALLATION OF TRANSAXLE ON CAR |
461 |
|
U. REMOVAL OF GEARSHIFT HOUSING, GEAR SHIFTER AND SELECTOR CABLE |
462 |
|
4.8 DRIVE SHAFT |
464 |
|
A. DRIVE SHAFT PARTS |
464 |
|
B. DISASSEMBLY AND ASSEMBLY PROCEDURE DRIVESHAFT TRIPOT JOINT |
465 |
|
C. DISASSEMBLY AND ASSEMBLY CV JOINT ASSEMBLY (OUTER) |
468 |
|
5. SUSPENSION |
472 |
|
5.1. TECHNICAL SPECIFICATION AND TIGHTENING TORQUE |
476 |
|
5.1.1 SPECIFCICATIONS |
476 |
|
5.1.2 TIGHTENING TORQUES |
477 |
|
5.2. SPECIAL TOOLS |
479 |
|
5.2.1 FRONT SUSPENSION |
479 |
|
5.2.2 REAR SUSPENSION |
484 |
|
5.3. DIAGNOSIS |
485 |
|
5.4. PRECAUTION |
486 |
|
5.5. SUSPENSION SYSTEM |
487 |
|
5.6. EXPLODED VIEWS FRONT SUSPENSION SYSTEM |
491 |
|
5.6.1. ASSEMBLY FRONT STRUT EXPLODED VIEW |
491 |
|
5.6.2. LOWER ARM LINK EXPLODED VIEW |
492 |
|
5.6.3. ANTI ROLL BAR MOUNTING EXPLODED VIEW |
494 |
|
5.6.4. FRONT AXLE ASSEMBLY EXPLODED VIEW |
495 |
|
5.7. ON VEHICLE REPAIRS FRONT SUSPENSION |
496 |
|
5.7.1 REMOVAL AND INSTALLATION OF STRUT ASSEMBLY |
496 |
|
5.7.2 DISASSEMBLY AND ASSEMBLY OF FRONT STRUT |
497 |
|
5.7.3 REMOVAL AND INSTALLATION OF WHEEL HUB |
500 |
|
5.7.4 REMOVAL AND INSTALLATION OF ANTI ROLL BAR |
503 |
|
5.7.5 REMOVAL AND INSTALLATION OF LOWER ARM ASSEMBLY |
505 |
|
5.7.6 REMOVAL AND INSTALLATION OF LOWER ARM BALL JOINT |
506 |
|
5.7.7 REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES |
508 |
|
5.7.8 PROCEDURE FOR CHECKING BALL JOINT PLAY ON LOWER ARM |
509 |
|
5.8. EXPLODED VIEWS REAR SUSPENSION SYSTEM |
510 |
|
5.8.1. REAR SHOCK ABSORBER EXPLODED VIEW |
510 |
|
5.8.2. REAR HUB ASSEMBLY EXPLODED VIEW |
511 |
|
5.8.3. PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW |
512 |
|
5.9. ON VEHICLE REPAIRS REAR SUSPENSION |
513 |
|
5.9.1. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER FROM VEHICLE |
513 |
|
5.9.2. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER |
513 |
|
5.9.3. REMOVAL AND INSTALLATION OF TORSION BEAM |
516 |
|
5.9.4. TWIST BEAM BUSH REMOVAL |
519 |
|
5.10. WHEELS AND TYRES |
521 |
|
A. TYRE INSPECTION |
521 |
|
B. PRLACEMENT OF TYRE |
521 |
|
REPLACEMENT OF WHEELS |
521 |
|
5.10.1. HOW TO MEASURE WHEEL RUNOUT |
521 |
|
5.10.2. INFLATION OF TYRES |
522 |
|
5.10.3. TYRE ROTATION |
523 |
|
5.10.4. WHEEL REMOVAL |
523 |
|
5.10.5. TYRE MOUNTING AND DEMOUNTING |
523 |
|
5.10.6. BALANCING WHEELS |
524 |
|
5.10.7. TYRE CARE |
524 |
|
6. BRAKE |
525 |
|
6.1. PRECAUTIONS |
529 |
|
6.2. TECHNICAL SPECIFICATIONS |
530 |
|
6.3. TIGHTENING TORQUES |
532 |
|
6.4. DIAGNOSIS |
533 |
|
6.5. NESSECITY OF ABS WITH EBD |
536 |
|
6.6. BRAKE HYDRAULIC LINES |
537 |
|
6.7. VACUUM BRAKE BOOSTER |
539 |
|
6.8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
540 |
|
6.9. ABS COMPONENTS |
544 |
|
6.9.1. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
544 |
|
6.9.2. HYDRAULIC CONTROL UNIT |
546 |
|
6.9.3. WHEEL SPEED SENSOR: (MONITORS WHEEL SPEED) |
547 |
|
6.9.4. ABS SYSTEM FAILURE WARNING LIGHT |
548 |
|
6.10. MAINTENANCE, ADJUSTMENTS & TEST |
549 |
|
6.10.1. FRONT BRAKE MAINTENANCE |
549 |
|
6.10.2. REAR BRAKE MAINTENANCE |
551 |
|
6.10.3. BRAKE TROUBLE SHOOTING |
556 |
|
6.10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
557 |
|
6.11. BRAKE PEDAL ASSEMBLY |
559 |
|
6.12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE |
560 |
|
6.13. REPAIRS |
561 |
|
6.13.1. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT |
562 |
|
6.13.2. REMOVAL OF FRONT BRAKE DISC |
568 |
|
6.13.3. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
569 |
|
6.13.4. REAR BRAKE ASSEMBLY |
571 |
|
6.13.5. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY |
573 |
|
6.13.6. REMOVAL OF PARKING BRAKE LEVER |
579 |
|
6.13.7. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE |
580 |
|
6.13.8A. PARKING BRAKE CABLE ADJUSTMENT |
581 |
|
6.13.8B. PARKING BRAKE LEVER PRIMARY CABLE GREASING |
581 |
|
6.13.9. REMOVAL AND REFITMENT OF ABS ECU / HCU |
582 |
|
6.13.10. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR |
583 |
|
6.13.11. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR |
584 |
|
6.14. DTC CODES |
586 |
|
6.15. TROUBLE SHOOTING & DIAGNOSIS |
588 |
|
6.16. ABS ECU CONNECTOR |
590 |
|
7. STEERING -EPAS |
592 |
|
7.1. GENERAL INFORMATION |
595 |
|
7.1.1. SPECIFICATIONS |
595 |
|
7.1.2. SYSTEM LAYOUT |
595 |
|
7.1.3. GENERAL DISCRIPTION |
596 |
|
7.1.4. TIGHTENING TORQUES |
597 |
|
7.1.5. SPECIAL TOOLS |
599 |
|
7.2. MAINTENANCE, INSPECTION AND TEST |
600 |
|
7.2.1. PRELIMINARY INSPECTION |
600 |
|
7.2.2. REGULAR MAINTENANCE |
601 |
|
7.2.3. ON VEHICLE REPAIRS |
602 |
|
7.2.3.1. STEERING WHEEL REMOVAL |
602 |
|
7.2.3.2. STEERING COLUMN REMOVAL |
603 |
|
7.2.3.3. INTERMEDIATE SHAFT REMOVAL |
605 |
|
7.2.3.4. ECU REMOVAL |
605 |
|
7.2.3.5. RACK & PINION ASSEMBLY REMOVAL |
607 |
|
7.3. OVERHAULING |
609 |
|
7.3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY |
609 |
|
7.3.2. PRECAUTIONS |
610 |
|
7.3.3. DISMANTLING, INSPECTION & ASSEMBLY |
610 |
|
7.3.3.1. DISASSEMBLY OF RACK & PINOIN |
610 |
|
7.3.3.2. INSPECTION OF DISMANTLED PARTS |
611 |
|
7.3.3.3. ASSEMBLY OF RACK & PINOIN |
611 |
|
7.3.3.4. OBJ ON VEHICLE REMOVAL |
612 |
|
7.3.3.5. DO'S & DON’T'S |
612 |
|
7.3.3.6. WHEEL ALIGNMENT |
613 |
|
7.4. TROUBLESHOOTING AND DIAGNOSIS |
615 |
|
7.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS |
619 |
|
7.6. STEERING SYSTEM DTC CODES |
622 |
|
7.7. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
624 |
|
8. ELECTRICAL |
630 |
|
8.1. TECHNICAL SPECIFICATION |
635 |
|
8.2. GENERAL PRECAUTIONS |
637 |
|
8.3. FUSE BOX / RELAY LOCATIONS |
641 |
|
8.4. BATTERY |
642 |
|
8.5. ALTERNATOR |
644 |
|
8.6. STARTER MOTOR |
647 |
|
8.7. LIGHTING SYSTEM |
654 |
|
8.7.1. BULB SPECIFICATIONS |
654 |
|
8.7.2. FASTENERS TORQUE VALUE TABLE |
655 |
|
8.7.3. GENERAL SYMPTOMS AND DIAGNOSTICS |
655 |
|
8.7.4. HEAD LAMP |
659 |
|
8.7.5. SIDE REPEATER LAMP |
665 |
|
8.7.6. ROOF LAMP |
666 |
|
8.7.7. HIGH MOUNTED STOP LAMP |
667 |
|
8.7.8. TAIL LAMP |
668 |
|
8.7.9. FRONT FOG LAMP |
671 |
|
8.7.10. REGISTRATION PLATE LAMP |
672 |
|
8.8. HORN |
673 |
|
8.9. WIPER & WASHER SYSTEM |
675 |
|
8.9.1. FRONT AND REAR WIPER AND WAHSER SYSTEM LAYOUT |
676 |
|
8.9.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
677 |
|
8.9.3. WIPER AND WIPER CARE |
681 |
|
8.10. POWER SOCKETS |
683 |
|
8.11. GLOW PLUG CONTROL UNIT |
684 |
|
8.12. FUEL GAUGE AND FUEL LEVEL METER |
686 |
|
8.13. COMBI-SWITCH |
688 |
|
8.14. STEERING LOCK CUM IGNITION SWITCH |
693 |
|
8.15. FASCIA SWITCHES |
696 |
|
8.16. HAZARD SWITCH |
700 |
|
8.17. MIRROR SWITCH |
701 |
|
8.18. INFOTAINMENT SYSTEM |
702 |
|
8.18.1. USB/AUX PORT |
705 |
|
8.18.2. SPEAKERS |
706 |
|
8.18.3. TWEETER |
708 |
|
8.18.4. ANTENNA |
709 |
|
8.18.5. MICROPHONE |
710 |
|
8.18.6. DTC FOR INFOTAINMENT SYSTEM |
711 |
|
8.19. WINDOW WINDING MODULE |
712 |
|
8.20. POWER WINDOW SWITCHES |
715 |
|
8.21. STEERING WHEEL SWITCHES |
720 |
|
8.22. IGNITION E-KEY |
723 |
|
8.23. INSTRUMENT CLUSTER |
726 |
|
8.23.1. BASIC FUNCTIONAL MATRIX |
728 |
|
8.23.2. TELL TALES MATRIX |
729 |
|
8.23.3. DRIVER INFORMATION SYSTEM |
735 |
|
8.23.4. DTC FOR INSTRUMENT CLUSTER |
740 |
|
8.23.5. CONNECTOR DETAILS |
743 |
|
8.23.6. FUEL GAUGE DETAILS |
745 |
|
8.23.7. TEMPERATURE BAR GRAPH DETAILS |
746 |
|
8.23.8. CHIME TABLE |
747 |
|
8.23.9. DISPLAY SCREEN FLOW AND SETTINGS |
747 |
|
8.24. IMMOBILIZER SYSTEM |
751 |
|
8.24.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
756 |
|
8.24.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
757 |
|
8.24.3. DTC FOR IMMOBILIZER |
759 |
|
8.24.4. IGNITION KEYLEARNING PROCEDURE |
761 |
|
8.25. BODY CONTROL MODULE (BCM) |
764 |
|
8.25.1. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
770 |
|
8.25.2. BCM FUNCTIONS |
782 |
|
8.25.3. DTC FOR BCM |
820 |
|
8.26. CLUTCH PEDAL SENSOR |
827 |
|
8.27. FUSE AND RELAY BOX DETAILS |
830 |
|
8.27.1. BATTERY MOUNTED FUSE BOX (BDU) |
832 |
|
8.27.2. ENGINE FUSE AND RELAY BOX |
833 |
|
8.27.3. CABIN FUSE AND RELAY BOX |
838 |
|
8.27.4. CIRCUIT SCHMATICS |
842 |
|
8.27.5. DTC |
842 |
|
8.28. REVERSE PARK ASSIST SYSTEM |
843 |
|
8.28.1. PARK ASSIST |
843 |
|
8.28.2. PARK ASSIST FUNCTIONALITY OVERVIEW |
843 |
|
8.28.3.PARK ASSIST ACTIVATION PROCEDURE |
843 |
|
8.28.4.PARK ASSIST DEACTIVATION PROCEDURE |
844 |
|
8.28.5. PARK ASSIST AUDIO SETTING |
844 |
|
8.28.6. PARK ASSIST VOLUME |
844 |
|
8.28.7. MIX WITH AUDIO |
844 |
|
8.28.8. PARK ASSIST TONE |
845 |
|
8.28.9. PARK ASSIST DELAY TIMER |
845 |
|
8.28.10. PARK ASSIST HMI INDICATIONS |
845 |
|
8.28.11. PARK ASSIST LIMITATIONS |
846 |
|
8.28.12. PARK ASSIST SYSTEM MAINTENANCE |
846 |
|
8.28.13. PARK ASSIST SYSTEM ARCHITECTURE |
847 |
|
8.28.14. ECU TO SENSOR ELECTRICAL INTERFACE |
848 |
|
8.28.15. ECU MOUNTING |
848 |
|
8.28.16. PHYSICAL IMAGES |
850 |
|
8.28.17. SENSOR FITMENT TO THE BUMPER |
851 |
|
8.28.18. DTC FOR REVERSE PARK ASSIST SYSTEM (RPAS) |
853 |
|
9. BODY |
855 |
|
9.1. GENERAL INFORMATION |
859 |
|
9.1.1. LAYOUT |
859 |
|
9.1.2. TIGHTENING TORQUES |
860 |
|
9.1.3. SPECIAL TOOLS |
863 |
|
9.2. ON VEHICLE REPAIRS |
864 |
|
9.2.1. BONNET |
864 |
|
9.2.2. FLOOR CONSOLE |
866 |
|
9.2.3. DASHBOARD |
868 |
|
9.2.4. GLOVE BOX |
877 |
|
9.2.5. SIDE AIR VENTS |
878 |
|
9.2.6. FRONT BUMPER |
878 |
|
9.2.7. REAR BUMPER |
879 |
|
9.2.8. FRONT DOOR |
881 |
|
9.2.9. FRONT DOOR TRIMS |
882 |
|
9.2.10. DOOR INNER LOCK HANDLE |
883 |
|
9.2.11. FRONT OUTER DOOR LOCK |
884 |
|
9.2.12. FRONT DOOR LATCH |
885 |
|
9.2.13. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
887 |
|
9.2.14. REAR DOOR |
888 |
|
9.2.15. REAR DOOR TRIM |
889 |
|
9.2.16. REAR OUTER DOOR LOCK |
891 |
|
9.2.17. DOOR LATCH REAR |
892 |
|
9.2.18. TAIL GATE |
893 |
|
9.2.19. TAIL GATE LATCH CABLE |
896 |
|
9.2.20. TAILGATE TRIM |
897 |
|
9.2.21. ORVM |
898 |
|
9.2.22. INNER REAR VIEW MIRROR |
899 |
|
9.2.23. FRONT ROW SEAT |
899 |
|
9.2.24. REAR ROW SEAT |
900 |
|
9.2.25. FRONT SEAT BELTS |
903 |
|
9.2.26. REAR SEAT BELT |
905 |
|
9.2.27. “A” PILLAR TRIM |
906 |
|
9.2.28. FRONT SCUFF PLATE |
908 |
|
9.2.29. “B" PILLAR TRIMS |
908 |
|
9.2.30. “C” PILLAR TRIM |
909 |
|
9.2.31. GRAB HANDLES |
910 |
|
9.2.32. SUNVISOR |
911 |
|
9.2.33. ROOF LINER |
911 |
|
9.2.34. PLENUM COVER |
912 |
|
9.2.35. GEAR LEVER BOOT |
913 |
|
9.2.36. BONNET INSULATION |
913 |
|
9.2.37. GLASS |
914 |
|
9.2.38. FUEL FILLER ASSEMBLY |
915 |
|
9.2.39. FRONT WHEEL ARCH LINER |
917 |
|
9.2.40. REAR WHEEL ARCH LINER |
918 |
|
9.2.41. FRONT FENDER |
919 |
|
9.2.42. REAR WIPER MOTOR |
921 |
|
9.2.43. FRONT WIPER |
922 |
|
10. HVAC |
923 |
|
10.1. GENERAL INFORMATION |
926 |
|
10.1.1. SPECIFICATIONS |
926 |
|
10.1.2. TIGHTENING TORQUES |
928 |
|
10.1.3. PRECAUTIONS |
936 |
|
10.1.4. HVAC SYSTEM LAYOUT & WORKING |
938 |
|
10.1.5. COMPONENTS OF HVAC |
940 |
|
10.1.5.1. CONTROL PANEL |
940 |
|
10.1.5.2. HVAC UNIT |
943 |
|
10.1.5.3. COMPRESSOR |
946 |
|
10.1.5.4. CONDENSOR & RECEIVER DRIER |
947 |
|
10.1.5.5. THERMISTOR / THERMO SENSOR |
948 |
|
10.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR |
950 |
|
10.1.5.7. AIR INLET ACTUATOR |
951 |
|
10.1.6. TROUBLESHOOTING |
952 |
|
10.2. MAINTAINANCE |
966 |
|
10.2.1. PRELIMINARY INSPECTION |
966 |
|
10.2.2. REGULAR MAINTENANCE |
968 |
|
10.3. ON VEHICLE REPAIR |
972 |
|
10.3.1. CONTROL PANEL ASSEMBLY |
972 |
|
10.3.2. COMPRESSOR |
977 |
|
10.3.3. BLOWER |
977 |
|
10.3.4. BLOWER RESISTER |
978 |
|
10.3.5. FILTER |
978 |
|
10.3.6. TXV |
979 |
|
10.3.7. PRESSURE SENSOR / SWITCH |
979 |
|
10.3.8. HVAC UNIT |
980 |
|
10.3.9. CONDENSER SEALING DUCT |
980 |
|
10.3.10. CONDENSER |
981 |
|
10.3.11. REFRIGERANT HOSES |
982 |
|
10.3.12. DO's & DON’T's |
984 |
|
10.4. OVERHAULING HVAC UNIT |
985 |
|
11. SRS |
992 |
|
11.1.1. TIGHTENING TORQUES |
995 |
|
11.1.2. WORKING OF RESTRAINTS |
997 |
|
11.1.2.1. RESTRAINTS WITHOUT AIRBAGS |
997 |
|
11.1.2.2. RESTRAINTS WITH AIRBAGS |
997 |
|
11.1.3. SYSTEM LAYOUT |
998 |
|
11.1.3.1. RESTRAINT WITHOUT AIRBAG |
998 |
|
11.1.3.2. RESTRAINT WITH AIRBAG |
998 |
|
11.1.4. SAFETY PRECAUTIONS |
999 |
|
11.1.5. DISPOSAL OF FAULTY AIR BAG UNIT |
1001 |
|
11.1.6. COMPONENTS |
1002 |
|
11.1.6.1. RESTRAINT WITHOUT AIRBAGS |
1002 |
|
A. SEAT BELT |
1002 |
|
B. EMERGENCY LOCKING RETRACTOR (ELR) |
1002 |
|
C. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP |
1002 |
|
11.1.6.2. RESTRAINT WITH AIRBAGS |
1003 |
|
A. ECU |
1003 |
|
B. SENSORS |
1007 |
|
C. AIR BAGS |
1008 |
|
D. RPLL BELTS |
1011 |
|
E. CLOCK SPRING |
1013 |
|
11.1.7. LIST OF DIAGNOSTIC TROUBLE SHOOTING CODES |
1016 |