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1. GENERAL 		4
1.1 TECHNICAL SPECIFICATIONS 		6
1.2 CHASSIS TYPE AND SALES DESIGNATION 		12
1.3 LUBRICANTS AND COOLANT RECOMMENDATIONS 		13
1.4 SERVICE AND MAINTENANCE SCHEDULE 		15
1.5 ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS 		20
2. PRECAUTIONS 		21
2.1 GENERAL PRECAUTIONS 		23
2.2 SAFETY AGAINST PERSONAL INJURY 		24
A. WORKING WITH VEHICLES FITTED WITH AIRBAG 		24
B. WORKING WITH ENGINE 'ON' 		25
2.3 AVOIDING DAMAGE 		26
2.4 USED OIL HANDLING AND DISPOSAL 		26
2.5 FUEL HANDLING PRECAUTIONS 		27
2.6 HAZARDOUS MATERIAL 		28
3. ENGINE 		29
3.1 GENERAL INFORMATION 		33
3.1.1 SPECIFICATION 		33
3.1.2 TIGHTENING TORQUES 		34
3.1.3 SPECIAL TOOLS 		52
3.1.4 GENERAL SYMPTOMS DIAGNOSIS 		53
3.2 MAINTENANCE, INSPECTION AND TESTS 		56
3.2.1 PRELIMINARY INSPECTION 		56
3.2.2 REGULAR MAINTENANCE 		58
A. ENGINE OIL REPLACEMENT 		58
B. OIL FILTER REPLACEMENT 		59
C. AIR FILTER CLEANING 		59
D. FUEL FILTER REPLACEMENT 		60
E. DRAINING WATER FROM PREFILTER CUM SEDIMENTOR 		61
F. PREFILTER CUM SEDIMENTOR REPLACEMENT 		61
G. PREFILTER CARTIRDGE REPLACEMENT 		62
H. COOLANT REPLACEMENT 		66
3.2.3 ON VEHICLE PROCEDURES 		67
A. ENGINE REMOVAL 		67
B. AIR FILTER ASSEMBLY REMOVAL 		69
C. POWER STEERING PUMP BELT (STRETCH BELT) 		69
D. ALTERNATOR AND AC BELT 		70
E. INJECTOR REMOVAL 		71
F. TIMING BELT REMOVAL 		72
G. TIMING BELT FITMENT 		74
3.3 OVERHAULING 		77
3.3.1 ENGINE DISMANTLING (ON STAND) 		77
3.3.2 CYLINDER HEAD 		84
3.3.3 TIMING SYSTEM 		96
3.3.4 ENGINE BLOCK 		99
3.3.5 ENGINE ASSEMBLY 		124
3.4 AIR INTAKE SYSTEM 		133
3.5 COOLING SYSTEM 		142
3.6 LUBRICATION SYSTEM 		149
3.7 FUEL SYSTEM 		155
3.8 EXHAUST SYSTEM 		171
3.9 ENGINE MANAGEMENT SYSTEM (EMS) 		189
3.10 DIAGNOSTIC USER MANUAL 		222
4. CLUTCH 		232
4.1 GENERAL INFORMATION 		235
4.1.1 SPECIFICATIONS 		235
A. CLUTCH DISC ASSEMBLY 		235
B. SELF ADJUSTING CLUTCH COVER ASSEMBLY 		236
C. SINGLE MASS FLYWHEEL 		237
4.1.2 CLUTCH SYSTEM LAYOUT 		238
A. CLUTCH MASTER CYLINDER 		239
B. CONCENTRIC SLAVE CYLINDER 		239
C. PEAK TORQUE LIMITER 		239
D. HYDRAULIC ADAPTER 		240
E. SINGLE MASS FLYWHEEL 		240
F. SELF ADJUSTING CLUTCH 		240
4.1.3 TIGHTENING TORQUES 		241
4.1.4 SPECIAL TOOLS 		244
4.1.5 GENERAL SYMPTOMS DIAGNOSIS 		245
4.2 MAINTENANCE, INSPECTION AND TESTS 		247
4.2.1 PRELIMINARY INSPECTION 		247
4.2.2 REGULAR MAINTENANCE 		248
A. CLUTCH SWITCH ADJUSTMENT 		248
B. CLUTCH BLEEDING PROCEDURE 		248
C. CLUTCH FLUID DRAINING PROCEDURE 		249
4.2.3 REPAIRS 		250
A. CLUTCH PEDAL ASSEMBLY 		250
B. SELF ADJUSTING CLUTCH ASSEMBLY 		255
C. CLUTCH HYDRAULIC SYSTEM COMPONENTS 		260
D. SINGLE MASS FLYWHEEL (ON VEHICLE) 		265
5A. 5 SPEED GEARBOX- G 76 MK II 		266
5A.1 GENERAL INFORMATION 		270
5A.1.1 SPECIFICATIONS 		270
5A.1.2 TIGHTENING TORQUES 		271
5A.1.3 SPECIAL TOOLS 		275
5A.1.4 GENERAL SYMPTOMS DIAGNOSIS 		279
5A.2 MAINTENANCE, INSPECTION AND TEST 		280
5A.2.1 PRELIMINARY INSPECTION 		280
5A.2.2 REGULAR MAINTENANCE 		280
5A.2.3 ON VEHICLE PROCEDURES 		281
A. GEARBOX REMOVAL 		281
5A.3 OVERHAULING 		283
5A.3.1 INFORMATION FOR OVERHAULING 		283
A. COMPONENT INDENTIFICATION 		283
B. PRECAUTIONS 		286
C. CONSTRUCTIONAL DETAILS 		287
5A.3.2 GEARBOX DISMANTLING (ON BENCH) 		290
5A.3.3 DISMANTLING OF SUB-ASSEMBLIES 		297
A. MAIN SHAFT 		297
B. DRIVE SHAFT 		308
C. REVERSE IDLER SHAFT 		309
D. COUNTER SHAFT 		311
E. FRONT COVER 		314
F. TOP COVER 		315
G. REAR COVER (4X2) 		317
H. ADAPTOR (4X4) 		318
I. SHIFTER SHAFTS & FORKS 		319
J. NON-ADJUSTABLE SHIFTER LINKAGE 		321
5A.3.4 GEAR BOX ASSEMBLY 		325
5B. 6 SPEED GEARBOX - G 6450 		334
5B.1 GENERAL INFORMATION 		338
5B.1.1 SPECIFICATIONS 		338
5B.1.2 TIGHTENING TORQUE 		339
5B.1.3 SPECIAL TOOLS 		344
5B.1.4 GENERAL SYMPTOMS DIAGNOSIS 		348
5B.2 MAINTENANCE, INSPECTION AND TEST 		349
5B.2.1 PRELIMINARY INSPECTION 		349
5B.2.2 REGULAR MAINTENANCE 		349
5B.2.3 ON VEHICLE PROCEDURE 		350
A. GEARBOX REMOVAL 		350
5B.2.4A CONSTRUCTION OF GEAR BOX (4X2) 		352
5B.2.4B CONSTRUCTION OF GEAR BOX (4X4) 		353
5B.3 OVERHAULING 		354
5B.3.1 INFORMATION FOR OVERHAULING 		354
A. COMPONENT INDENTIFICATION 		354
B. PRECAUTIONS 		356
5B.3.2 GEAR BOX DISMANTLING ON BENCH PROCEDURE 		357
5B.3.3 INSPECTION 		367
5B.3.4 GEAR BOX ASSEMBLY ON BENCH PROCEDURE 		369
6. TRANSFER CASE 		385
6.1 GENERAL INFORMATION 		389
6.1.1 SPECIFICATIONS 		389
6.1.2 CONSTRUCTION 		390
6.1.3 COMPONENTS OF TRANSFER CASE 		392
A. ECU 		392
B. TRANSFER CASE SWITCH 		394
C. WARNING LAMP 		394
D. GEROTOR PUMP 		394
6.1.4 WORKING OF TRANSFER CASE 		395
6.1.5 TIGHTENING TORQUES 		399
6.1.6 SPECIAL TOOLS 		402
6.1.7 GENERAL SYMPTOMS & DIAGNOSIS 		405
6.2 MAINTENANCE 		406
6.2.1 PRELIMINARY INSPECTION 		406
6.2.2 REGULAR MAINTENANCE 		406
A. CHANGING TRANSFER CASE OIL 		406
B. TRANSFER CASE OIL CHECK 		406
6.2.3 ON VEHICLE REPAIRS 		407
A. TRANSFER CASE 		407
B. TRANSFER CASE ELECTRONIC CONTROL UNIT (ECU) 		408
C TRANSFER CASE SWITCH 		409
6.3 OVERHAULING 		409
6.3.1 PRECAUTIONS 		409
6.3.2 DISMANTLING 		409
A. REAR YOKE 		409
B. REAR COVER ASSEMBLY 		410
C. LOCKUP SHIFT PART 		412
D. CHAIN DRIVE 		413
E. GEROTOR PUMP 		413
F. REDUCTION SHIFT PART 		414
G. FRONT OUTPUT SHAFT AND YOKE 		415
H. ADAPTER, INPUT SHAFT & CARRIER ASSEMBLY 		416
6.3.3 INSPECTION & CLEANING 		419
6.3.4 ASSEMBLY 		419
A. ADAPTER & INPUT SHAFT 		419
B. FRONT OUTPUT SHAFT & YOKE 		421
C. ASSEMBLY OF REDUCTION SHIFT PART 		422
D. ASSEMBLY OF OUTPUT SHAFT & GEROTOR PUMP 		423
E. CHAIN DRIVE 		425
F. ASSEMBLY OF LOCK UP SHIFT PART 		426
G. REAR COVER ASSEMBLY 		426
H. REAR OUTPUT YOKE 		429
6.4 DIAGNOSTIC OF ECU 		430
7. SUSPENSION 		433
7.1 FRONT SUSPENSION 		435
7.1.1 GENERAL INFORMATION 		438
7.1.1.1 SPECIFICATIONS 		438
7.1.1.2 CONSTRUCTION 		439
7.1.1.3 TIGHTENING TORQUES 		440
7.1.1.4 SPECIAL TOOLS 		445
7.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 		448
7.1.2 MAINTENANCE 		449
7.1.2.1 PRELIMINARY INSPECTION 		449
7.1.2.2 REGULAR MAINTENANCE 		449
A. WHEEL ALIGNMENT 		449
B. ANTI ROLL BAR MOUNTING GREASING 		450
7.1.2.3 ON VEHICLE REPAIRS 		451
A. ANTI ROLL BAR (ARB) 		451
B. FRONT STRUT ASSEMBLY 		452
C. LOWER WISHBONE 		453
D. UPPER WISHBONE 		454
E. BUMP STOPPER 		456
7.1.3 OVERHAULING 		456
7.1.3.1 PRECAUTIONS 		456
7.1.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 		457
A. FRONT STRUT 		457
B. UPPER WISHBONE BUSH 		458
C. UPPER WISHBONE BALL JOINT 		460
D. LOWER WISHBONE BALL JOINT REMOVAL 		460
7.2 REAR SUSPENSION 		436
7.2.1 GENERAL INFORMATION 		461
7.2.1.1 SPECIFICATIONS 		461
7.2.1.2 CONSTRUCTION 		462
7.2.1.3 TIGHTENING TORQUES 		463
7.2.1.4 SPECIAL TOOLS 		466
7.2.2 MAINTENANCE 		469
7.2.2.1 ON VEHICLE REPAIRS 		469
A. ANTIROLL BAR 		469
B. UPPER LINK 		471
C. LOWER LINK 		472
D. PAN HARD ROD 		472
E. REAR SHOCK ABSORBER 		473
F. REAR COIL SPRING 		474
7.2.3 OVERHAULING 		475
7.2.3.1 PRECAUTIONS 		475
7.2.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 		475
A. UPPER LINK BUSH 		475
B. LOWER LINK BUSH 		476
C. PAN HARD ROD BUSH 		477
7.3 WHEELS AND TYRES 		437
7.3.1 GENERAL INFORMATION 		479
7.3.1.1 SPECIFICATIONS 		479
7.3.1.2 CONSTRUCTION 		480
7.3.1.3 TIGHTENING TORQUES 		481
7.3.1.4 GENERAL SYMPTOMS DIAGNOSIS 		482
A. DIAGNOSIS CHART 		482
B. TYRE WEAR PATTERN 		485
C. WEAR CAUSES 		487
D. TYRE VIBRATION DIAGNOSIS 		489
7.3.2 MAINTENANCE, INSPECTION AND TESTS 		490
7.3.2.1 PRELIMINARY INSPECTION 		490
7.3.2.2 REGULAR MAINTENANCE 		491
A. INFLATION 		491
B. WHEEL BALANCING 		491
C. TYRE ROTATION 		492
D WHEEL RUN OUT 		493
E. DO'S AND DON’TS 		494
7.3.2.3 WHEEL AND TYRE REPLACEMENT 		495
A. PRECAUTIONS DURING TYRE REPLACEMENT 		495
B. TYRE REPLACEMENT 		496
C. WHEEL ASSEMBLY REPLACEMENT 		496
8. FRONT AXLE 		497
8.1 FRONT AXLE (4X4) 		497
8.1.1 GENERAL INFORMATION 		500
8.1.1.1 SPECIFICATION 		500
8.1.1.2 SYSTEM LAYOUT 4X4 		501
8.1.1.3 TIGHTENING TORQUES 		502
8.1.1.4 SPECIAL TOOLS 		506
8.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 		511
8.1.2 MAINTENANCE 		512
8.1.2.1 PRELIMINARY INSPECTION 		512
8.1.2.2 REGULAR MAINTENANCE 		512
8.1.2.3 ON VEHICLE REPAIRS 		513
A. FRONT AXLE ASSEMBLY 		513
B. ELECTRICAL DISCONNECT ASSEMBLY 		517
C. TONER RING 		518
8.1.3 OVERHAULING 		519
8.1.3.1 PRECAUTIONS 		519
8.1.3.2 CONSTRUCTIONAL DETAILS 		519
8.1.3.3 DISMANTLING INSPECTION AND ASSEMBLY 		523
8.2 FRONT AXLE (4X2) 		553
8.2.1 GENERAL INFORMATION 		556
8.2.1.1 TECHNICAL SPECIFICATIONS 		556
8.2.1.2 CONSTRUCTION AND LAYOUT 		556
8.2.1.3 TIGHTENING TORQUE 		557
8.2.1.4 SPECIAL TOOLS 		558
8.2.2 MAINTENANCE 		560
8.2.2.1 ON VEHICLE REPAIRS 		560
8.2.3 OVERHAULING 		564
8.2.3.1 FRONT AXLE EXPLODED VIEW 		564
8.2.3.2 HUB REPLACEMENT 		565
8.2.3.3 TONER RING REPLACEMENT 		567
8.2.3.4 HUB BEARING REPLACEMENT 		568
9. REAR AXLE 15” 		569
9.1 SECTION - 1 		572
9.1.1 AXLE SPECIFICATION AND SERVICE DATA 		573
9.1.2 AXLE LUBRICATION 		574
9.1.3 AXLE IDENTIFICATION 		574
9.1.4 EXPLODED VIEW 		575
9.1.5 PARTS DESCRIPTIONS 		576
9.2 DISASSEMBLY OF AXLE 		577
9.2.1 AXLE SHAFT DISASSEMBLY / OIL SEAL REMOVAL 		577
9.2.2 REMOVAL OF CARRIER SECTION FROM BANJO 		578
9.3 CARRIER SECTION DISASSEMBLY 		578
9.3.1 DISASSEMBLY OF CARRIER SECTION & DIFFERENTIAL 		578
9.3.2 RING GEAR REMOVAL 		579
9.3.3 CASE DISASSEMBLY STD 		580
9.3.4 DRIVE PINION REMOVAL 		581
9.3.5 RING GEAR PINION ASSEMBLY THEORY 		582
9.3.6 ESTABLISHING PINION & GEAR DEPTH USING SERVICE TOOLS 		584
9.3.7 CASE REASSEMBLY (STANDARD DIFFCASE ASSEMBLY) 		586
9.3.8 ASSEMBLY OF DIFFERENTIAL IN CARRIER 		587
9.3.9 INTERPRETATION OF CONTACT PATTERN 		590
9.4 DIS-ASSEMBLY & REASSEMBLY OF LIMITED SLIP DIFFERENTIAL 		591
9.4.1 DIS-ASSEMBLY OF TRAC-LOK DIFFERENTIAL 		591
9.4.2 INSPECTION OF ALL THE PARTS FOR WEAR, SCORE, ETC 		593
9.4.3 RE ASSEMBLY 		593
9.5 AXLE SHAFT DIS-ASSEMBLY & RE-ASSEMBLY 		595
9.5.1 DIS-ASSEMBLY OF AXLE SHAFT ASSEMBLY 		595
9.5.2 ASSEMBLY OF AXLE SHAFT ASSEMBLY 		596
9.6 RE-ASSEMBLY OF AXLE 		597
9.6.1 INSTALL CARRIER SECTION ON BANJO BEAM 		597
9.6.2 INSTALL AXLE SHAFT ASSEMBLY ON BANJO BEAM 		597
9.7 TROUBLE SHOOTING 		599
10. PROPELLER SHAFT 		601
10.1 GENERAL INFORMATION 		604
10.1.1 ADJUSTMENT / REPAIR DATA 		604
10.1.2 SYSTEM LAYOUT 		605
A. FOR 4X2 DRIVE 		605
B. FOR 4X4 DRIVE 		606
10.1.3 TIGHTENING TORQUE 		607
10.1.4 SPECIAL TOOL 		608
10.1.5 GENERAL SYMPTOMS DIAGNOSIS 		609
10.2 MAINTENANCE, INSPECTION AND TESTS 		610
10.2.1 PRELIMINARY INSPECTION 		610
10.2.2 REGULAR MAINTENANCE 		610
10.2.3 ON VEHICLE REPAIRS 		611
A. PROPELLER SHAFT (4X2) 		612
B. PROPELLER SHAFT (4X4) 		613
C. TVD (TORSIONAL VIBRATION DAMPERS) 		614
10.3 OVERHAULING 		615
10.3.1 CONSTRUCTIONAL DETAILS 		615
A. PROPELLER SHAFT 4X2 DRIVE 		615
B. PROPELLER SHAFT 4X4 DRIVE 		616
10.3.2 UNIVERSAL JOINT 		617
10.3.3 CENTRE BEARING 		620
11. BRAKES 		623
11.1 GENERAL INFORMATION 		627
11.1.1 SPECIFICATION 		627
11.1.2 SYSTEM DETAILS 		628
11.1.3 TIGHTENING TORQUES 		632
11.1.4 GENERAL SYMPTOMS DIAGNOSIS 		636
11.2 MAINTENANCE, INSPECTION AND TEST 		638
11.2.1 PRELIMINARY INSPECTION 		638
A. FRONT BRAKE AND REAR BRAKE 		638
B. PARKING BRAKE 		638
C. BRAKE HOSES AND LINES 		638
D. ROAD TEST 		638
E. REAR DRUM BRAKES 		639
F. WHEEL CYLINDER SERVICING 		645
11.2.2 REGULAR MAINTENANCE 		647
A. BRAKE BLEEDING PROCEDURE 		647
B. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) 		648
C. CALIPER PAD REPLACEMENT 		653
D. PARKING BRAKE ADJUSTMENT 		654
E. BRAKE FLUID DRAINING PROCEDURE 		655
F. BRAKE LIGHT SWITCH ADJUSTMENT 		656
G. BOOSTER FILTER REPLACEMENT 		657
H. GREASING 		658
I. DISC RUN-OUT MEASUREMENT PROCEDURE 		659
11.2.3 ON VEHICLE REPAIRS 		659
A. CALIPER ASSEMBLY WITH CARRIER 		659
B. BRAKE DISC REMOVAL 		660
C. PARKING BRAKE 		663
D. BRAKE PEDAL 		667
E. VACUUM LINES 		670
F. BOOSTER ASSEMBLY 		671
G. PARKING BRAKE (DRUM IN HAT) 		676
11.3 OVERHAULING 		678
11.3.1 PRECAUTIONS 		678
11.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 		679
A. FRONT CALIPER ASSEMBLY 		679
B. REAR CALIPER ASSEMBLY 		684
11.4 LOAD SENSING PRESSURE VALVE (LSPV) (FOR NON ABS VEHICLE ONLY) 		688
12. ANTI-LOCK BRAKING SYSTEM (ABS) 		690
12.1 GENERAL INFORMATION 		693
12.1.1 NECESSITY OF ABS WITH EBD 		693
12.1.2 TECHNICAL SPECIFICATIONS 		694
12.1.3 TIGHTENING TORQUES 		695
12.1.4 SCHEMATIC OF HYDRAULIC CIRCUIT 		697
12.1.5 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 		698
12.1.6 COMPONENTS 		702
A. ABS ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 		703
B. WHEEL SPEED SENSOR (WSS) 		706
C. ABS SYSTEM FAILURE WARNING LIGHT 		707
12.2 REPAIRS 		708
A. ABS ECU / HCU 		708
B. FRONT WHEEL SPEED SENSOR 		711
C. FRONT TONER RING 		712
D. REAR WHEEL SPEED SENSOR 		712
E. REAR TONER RING 		713
12.3 TROUBLE SHOOTING AND DIAGNOSIS 		714
A. ROAD TEST 		714
B. TABLE OF ABS 8.1 - FALL-BACK LEVEL 		714
12.4 ABS DIAGNOSTIC USER MANUAL 		715
12.4.1 GENERAL 		715
12.4.2 OPERATING PROCEDURE 		716
13. STEERING 		726
13.1 GENERAL INFORMATION 		730
13.1.1 SPECIFICATIONS 		730
13.1.2 SYSTEM LAYOUT 		731
13.1.3 TIGHTENING TORQUES 		732
13.1.4 SPECIAL TOOLS 		738
13.1.5 GENERAL SYMPTOMS DIAGNOSIS 		739
13.2 MAINTENANCE, INSPECTION AND TEST 		746
13.2.1 PRELIMINARY INSPECTION 		746
13.2.2 REGULAR MAINTENANCE 		747
A. POWER STEERING OIL REPLACEMENT 		747
B. POWER STEERING RESERVOIR ASSY 		748
C. HYDRAULIC SYSTEM AIR BLEEDING 		749
D. TOE IN ADJSUTMENT 		750
E. STEERING WHEEL ALIGNMENT/ CENTRALISING 		750
F. STEERING WHEEL PLAY 		751
G. POWER STEERING OIL FLUSHING PROCEDURE 		751
13.2.3 REPAIRS 		752
13.2.3.1 STEERING WHEEL 		752
13.2.3.2 SYSTEM LAYOUT 		757
13.2.3.3 STEERING RESERVOIR & POWER STEERING PUMP 		762
A. STEERING RESERVOIR 		763
B. POWER STEERING PUMP 		763
13.2.3.4 RACK AND PINION ASSEMBLY 		764
13.3 RACK & PINION UNIT OVERHAULING 		765
13.3.1 GENERAL INSTRUCTIONS 		765
13.3.2 RACK AND PINION ASSEMBLY 		766
13.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 		767
13.3.3.1 OUTER BALL JOINT (OBJ) 		767
13.3.3.2 BELLOW KIT 		768
13.3.3.3 INNER BALL JOINT (IBJ) 		769
13.3.3.4 FEED PIPE 		770
13.3.3.5 DO’S & DON’TS 		771
14. ELECTRICAL 		774
14.1 TECHNICAL SPECIFICATIONS 		779
14.2 GENERAL ELECTRCIAL PRECAUTIONS 		782
14.3 STARTING AND CHARGING SYSTEM 		785
14.3.1 BATTERY 		785
14.3.2 ALTERNATOR 		791
14.3.3 STARTER MOTOR 		804
14.4 LIGHTING SYSTEM 		818
14.4.1 BULB SPECIFICATIONS 		818
14.4.2 TORQUE VALUE TABLE 		818
14.4.3 DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS 		819
14.4.4 HEAD LAMP 		822
14.4.5 FRONT FOG LAMP 		828
14.4.6 FRONT ROOF LAMP 		829
14.4.7 SECOND AND THIRD ROW ROOF LAMP 		830
14.4.8 REGISTRATION PLATE LAMP 		831
14.4.9 CENTER HIGH MOUNTED STOP LAMP 		831
14.4.10 PUDDLE LAMP 		833
14.4.11 GLOVE BOX LAMP 		834
14.4.12 TAIL LAMP 		834
14.4.13 REAR FOG LAMP (IF FITTED) 		835
14.5 HORN 		837
14.6 POWER SOCKET 		839
14.7 CIGAR LIGHTER 		841
14.8 BUZZER 		842
14.9 WIPER & WASHER SYSTEM 		843
14.9.1 FRONT AND REAR WIPER AND WAHSER SYSTEM COMPONENT LOCATIONS 		843
14.9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 		844
14.9.3 FRONT AND REAR WIPER SYSTEM COMPONENTS 		845
14.9.3.1 FRONT WIPER MOTOR 		845
14.9.3.2 FRONT WIPER ARM & BLADE 		848
14.9.3.3 REAR WIPER ARM & BLADE 		849
14.9.3.4 REAR WIPER MOTOR 		850
14.9.3.5 WIPER CARE 		852
14.9.4 WAHSER SYSTEM COMPONENT 		853
14.9.4.1 WAHSER BOTTLE 		853
14.9.4.2 WASHER PUMP 		853
14.9.4.3 FRONT WAHSER NOZZLE 		854
14.9.4.4 REAR WASHER NOZZLE 		855
14.9.5 DIAGNOSTIC INFORMATION AND PROCEDURES 		856
14.10 ELECTRICAL SWITCHES 		857
14.10.1 COMBINATION – SWITCH 		857
14.10.2 IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION 		864
14.10.3 MASTER LIGHT SWITCH 		867
14.10.4 ORVM SWITCH 		870
14.10.5 WINDOW WINDING SWITCHES 		873
14.10.6 BONNET SWITCH 		879
14.10.7 HAZARD WARNING SWITCH 		880
14.10.8 TRANSFER CASE SWITCH 		881
14.10.9 GLOVE BOX SWITCH 		882
14.10.10 REVERSE LIGHT SWITCH 		883
14.10.11 HAND BRAKE SWITCH 		885
14.10.12 INERTIA SWITCH 		886
14.11 WINDOW WINDING CONTROLLER 		888
14.12 BODY CONTROL MODULE (BCM) 		905
14.13 IMMOBILIZER SYSTEM 		948
14.14 INSTRUMENT CLUSTER 		970
14.15 REVERSE PARKING SYSTEM WITH ULTRASONIC SENSOR (IF EQUIPPED) 		983
14.16 ENTERTAINMENT SYSTEM 		999
14.17 GENERAL ELECTRICAL INFORMATION 		1013
15. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) 		1021
15.1 TIGHTENING TORQUES 		1026
15.2 WORKING OF RESTRAINTS 		1026
A. RESTRAINTS WITHOUT AIRBAGS 		1026
B. RESTRAINTS WITH AIRBAGS 		1026
15.3 SYSTEM LAYOUT 		1027
A. RESTRAINTS WITHOUT AIRBAGS 		1027
B. RESTRAINTS WITH AIRBAGS 		1027
15.4 SAFETY PRECAUTIONS 		1028
15.5 DISPOSAL OF FAULTY AIR BAG UNIT 		1030
15.6 COMPONENTS 		1031
15.6.1 RESTRAINT WITHOUT AIRBAGS 		1031
A. SEAT BELT 		1031
B. EMERGENCY LOCKING RETRACTOR (ELR) 		1031
C. MICROSWITCH AND SEAT BELT REMINDER (SBR) WARNING LAMP 		1031
15.6.2 RESTRAINT WITH AIRBAGS 		1032
A. ECU 		1032
B. SENSORS 		1037
C. AIR BAGS 		1039
D. CLOCK SPRING 		1041
E. RPLL BELTS 		1044
F. SRS WARNING LAMP 		1046
15.7 DIAGNOSTIC USER MANUAL 		1047
15.8. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 		1055
16. BODY 		1056
16.1 GENERAL INFORMATION 		1061
16.1.1 SPECIFICATIONS 		1061
16.1.2 LAYOUT 		1065
16.1.3 TIGHTENING TORQUES 		1066
16.1.4 SPECIAL TOOL 		1069
16.2 ON VEHICLE REPAIRS 		1070
16.2.1 BONNET 		1070
16.2.2 FLOOR CONSOLE 		1074
16.2.3 DASHBOARD 		1076
16.2.4 TOP UTILITY BIN 		1080
16.2.5 GLOVE BOX 		1080
16.2.6 SIDE AIR VENTS 		1081
16.2.7 CENTRAL FINISHER 		1083
16.2.8 FRONT BUMPER 		1084
16.2.9 REAR BUMPER 		1087
16.2.10 DOOR TRIMS 		1090
16.2.11 FRONT DOOR 		1093
16.2.12 DOOR LOCK HANDLE AND DOOR LATCH 		1096
16.2.13 FRONT OUTER DOOR LOCK BARREL AND HANDLE 		1097
16.2.14 FRONT DOOR LATCH 		1098
16.2.15 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 		1100
16.2.16 REAR DOOR 		1102
16.2.17 REAR OUTER DOOR LOCK 		1104
16.2.18 DOOR LATCH REAR 		1106
16.2.19 TAILGATE TRIM 		1107
16.2.20 TAIL GATE 		1110
16.2.21 ORVM 		1115
16.2.22 INNER REAR VIEW MIRROR 		1116
16.2.23 FRONT ROW SEAT 		1116
16.2.24 SECOND ROW SEAT 		1117
16.2.25 THIRD ROW SEAT 		1118
16.2.26 SEAT BELTS 		1119
16.2.27 SECOND ROW SEAT BELT 		1121
16.2.28 “A” PILLAR TRIM 		1122
16.2.29 “B” PILLAR TRIMS 		1123
16.2.30 “C” PILLAR TRIM 		1124
16.2.31 “D” PILLAR TRIM 		1125
16.2.32 REAR QUARTER TRIM 		1126
16.2.33 GRAB HANDLES 		1126
16.2.34 SUNVISOR 		1127
16.2.35 PLENUM COVER ASSEMBLY 		1128
16.2.36 STONE GUARD 		1128
16.2.37 FRONT WHEEL ARCH LINER 		1128
16.2.38 GEAR LEVER BOOT 		1129
16.2.39 BONNET INSULATION 		1129
16.2.40 FUEL FILLER ASSEMBLY 		1130
16.2.41 GLASS 		1132
16.2.42 ROOF LINER ASSEMBLY 		1137
16.2.43 FRONT FENDER 		1138
16.2.44 FRONT WHEEL ARCH COVER 		1139
16.2.45 SILL FINISHER 		1139
16.2.46 REAR WHEEL ARCH LINER 		1140
16.2.47 SIDE FOOT STEP 		1141
16.2.48 SPOILER 		1142
16.3 BODY REPAIR 		1143
17. HVAC 		1155
17.1 GENERAL INFORMATION 		1159
17.1.1 SPECIFICATIONS 		1159
17.1.2 TIGHTENING TORQUES 		1161
17.1.3 PRECAUTIONS 		1166
17.1.4 HVAC SYSTEM LAYOUT AND WORKING 		1168
17.1.5 COMPONENTS OF HVAC 		1172
17.1.5.1 CONTROL PANEL 		1173
17.1.5.2 FRONT HVAC UNIT 		1176
17.1.5.3 ROOF AC UNIT (IF FITTED) 		1178
17.1.5.4 COMPRESSOR 		1180
17.1.5.5 CONDENSER 		1181
17.1.5.6 THERMISTER OR THERMO SENSOR 		1182
17.1.5.7 TRINARY PRESSURE SWITCH 		1184
17.1.5.8 ACTUATOR 		1185
17.1.5.9 AIR INLET ACTUATOR 		1189
17.1.5.10 REAR BLOWER SWITCH 		1189
17.1.6 TROUBLESHOOTING 		1191
17.2 MAINTENANCE 		1204
17.2.1 PRELIMINARY INSPECTION 		1204
A. AC SYSTEM PERFORMANCE TEST 		1204
B. LEAK DETECTION 		1206
17.2.2 REGULAR MAINTENANCE 		1206
A. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 		1206
B. FLUSHING OF AC SYSTEM 		1208
C. REPLENISHING COMPRESSOR OIL 		1209
D. PRESSURE TEST USING MANIFOLD GAUGES 		1210
17.3 ON VEHICLE REPAIRS 		1212
17.3.1 CONTROL PANEL ASSEMBLY 		1212
17.3.2 COMPRESSOR 		1212
17.3.3 FRONT HVAC UNIT 		1213
17.3.4 ROOF AC UNIT 		1214
17.3.5 HEATER HOSE 		1215
17.3.6 BLOWER (FRONT HVAC UNIT) 		1216
17.3.7 BLOWER CONTROL MODULE 		1216
17.3.8 PRESSURE SWITCH 		1217
17.3.9 CONDENSER 		1217
17.3.10 REFRIGERANT HOSES/PIPES 		1218
17.3.11 FRONT AC DUCTING 		1219
17.3.12 CONDENSER SEALING DUCT 		1220
17.3.13 RECEIVER DRIER BOTTLE 		1220
17.4 OVERHAULING 		1221
17.4.1 BLOWER 		1221
17.4.2 FRONT HVAC UNIT 		1223
17.4.3 ROOF AC 		1230
17.4.4 COMPRESSOR 		1232
17.4.5 DO’S AND DONT’S FOR A/C SYSTEM 		1235
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