TIAGO
|
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 |
17 |
|
1.7. CHASSIS TYPE AND SALES DESIGNATIONS |
18 |
|
1.8. TECHNICAL SPECIFICATIONS (PETROL) |
19 |
|
1.9. TECHNICAL SPECIFICATIONS (DIESEL) |
22 |
|
1.10. VEHICLE DIMENSIONS |
25 |
|
1.11. RECOMMENDED LUBRICANTS & COOLANTS |
26 |
|
1.12. SERVICE AND MAINTENANCE |
28 |
|
2. 1.2L REVOTRON ENGINE |
32 |
|
2.1. GENERAL INFORMATION |
38 |
|
A. ENGINE INTRODUCTION |
38 |
|
B. ELECTRONIC FUEL INJECTION CONTROL |
39 |
|
C. TECHNICAL SPECIFICATION |
40 |
|
D. SPECIAL TOOLS |
41 |
|
E. ASSEMBLY CLEARANCES |
44 |
|
F. SEALANTS |
44 |
|
G. LEAKAGE RATES |
44 |
|
H. RECOMMENDED LUBRICANTS & COOLANTS |
44 |
|
I. SERVICE SCHEDULE |
45 |
|
2.2. TROUBLESHOOTING |
46 |
|
2.3. CONSTRUCTIONAL AND SERVICE DETAILS |
53 |
|
A. ENGINE LIFTING |
53 |
|
B. INTAKE MANIFOLD |
54 |
|
C. CYLINDER HEAD AND COVER |
56 |
|
D. CYLINDER HEAD-A |
58 |
|
E. CYLINDER HEAD-B |
60 |
|
F. CYLINDER BLOCK |
62 |
|
G. OIL SUMP |
64 |
|
H. MOVING PARTS |
66 |
|
I. ENGINE TIMING |
68 |
|
J. EXHAUST MANIFOLD |
70 |
|
K. FUEL INJECTION EQUIPMENT |
72 |
|
L. LUBRICATION PUMP AND COMPONENTS |
74 |
|
M. AIR INTAKE SYSTEM |
76 |
|
N. SPECIAL INSTALLATION |
78 |
|
O. ENGINE SUSPENSION |
81 |
|
2.4. ENGINE TESTS AND MAINTENANCE |
84 |
|
A. PRELIMINARY INSPECTION |
84 |
|
B. ENGINE TESTS |
85 |
|
I. ENGINE COMPRESSION TEST |
85 |
|
II. ENGINE OIL CONSUMPTION TEST |
86 |
|
III. ENGINE OIL PRESSURE TEST |
87 |
|
C. REGULAR MAINTENANCE |
88 |
|
I. ENGINE OIL AND FILTER CHANGE |
88 |
|
II. ENGINE COOLANT REPLACEMENT |
89 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
90 |
|
IV. SPARK PLUG REPLACEMENT |
91 |
|
V. FUEL FILTER REPLACEMENT |
94 |
|
VI. AIR CONDITIONER COMPRESSOR BELT REPLACEMENT |
95 |
|
2.5. REPAIR AND INSPECTION DETAILS |
96 |
|
A. ACCESSORY DRIVING BELT |
96 |
|
B. TIMING CHAIN |
96 |
|
C. CYLINDER HEAD |
96 |
|
D. VALVES |
97 |
|
E. CYLINDER HEAD VALVE SEATS |
99 |
|
F. ROLLER FINGER FOLLOWER |
100 |
|
G. HYDRAULIC LASH ADJUSTER |
100 |
|
H. CAMSHAFT |
100 |
|
I. PISTON AND PISTON RINGS |
102 |
|
J. CONNECTING RODS |
103 |
|
K. CRANKSHAFT |
105 |
|
L. CRANK CASE |
107 |
|
M. FUEL TANK |
108 |
|
N. CANISTER PURGE VALVE |
108 |
|
O. CANISTER |
109 |
|
2.6. ENGINE SYSTEM |
110 |
|
A. AIR INTAKE SYSTEM |
110 |
|
B. BLOW BY SYSTEM |
112 |
|
C. LUBRICATION SYSTEM |
113 |
|
D. EXHAUST SYSTEM |
117 |
|
E. COOLING SYSTEM |
120 |
|
F. FUEL SYSTEM |
123 |
|
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
126 |
|
A. ENGINE REMOVAL AND INSTALLATION |
126 |
|
B. AIR FILTER ASSY |
131 |
|
C. INJECTION SYSTEM |
132 |
|
D. SPARK PLUG |
133 |
|
E. EXHAUST SYSTEM |
133 |
|
F. FUEL SYSTEM |
136 |
|
G. COOLING SYSTEM |
142 |
|
H. REMOVAL OF ACCESSORIES |
145 |
|
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
146 |
|
A. ENGINE DIS-ASSEMBLY |
146 |
|
I. REMOVAL OF INTAKE MANIFOLD |
146 |
|
II. REMOVAL OF EXHAUST MANIFOLD |
147 |
|
III. REMOVAL OF OIL SUMP |
149 |
|
IV. REMOVAL OF SENSORS |
149 |
|
V. REMOVAL OF ACCESSORIES |
150 |
|
VI. REMOVAL OF TIMING CHAIN |
153 |
|
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
154 |
|
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
155 |
|
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
157 |
|
B. ENGINE ASSEMBLY |
160 |
|
I. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
160 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
162 |
|
III. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
164 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
165 |
|
V. ASSEMBLY OF TIMING CHAIN |
167 |
|
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
170 |
|
VII. FITMENT OF ENGINE SENSORS AND PERIPHERALS |
172 |
|
VIII. FITMENT OF OIL SUMP |
173 |
|
IX. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
173 |
|
X. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
175 |
|
2.9. ENGINE MANAGEMENT SYSTEM |
178 |
|
A. ABBREVIATIONS |
178 |
|
B. AN OVERVIEW |
179 |
|
C. ELECTRONIC CONTROL UNIT |
180 |
|
D. SENSORS |
185 |
|
I. T-MAP SENSOR |
186 |
|
II. LAMBDA SENSOR |
187 |
|
III. CAMSHAFT POSITION SENSOR |
189 |
|
IV. KNOCK SENSOR |
190 |
|
V. CRANKSHAFT POSITION SENSOR |
191 |
|
VI. COOLANT TEMPERATURE SENSOR |
192 |
|
E. ACTUATORS |
194 |
|
I. IGNITION COIL |
195 |
|
II. PURGE CONTROL VALVE |
196 |
|
III. SOLENOID VALVE (OCV) |
197 |
|
IV. FUEL INJECTOR |
198 |
|
V. ELECTRONIC THROTTLE BODY |
199 |
|
F. SWITCH |
201 |
|
I. OIL PRESSURE SWITCH |
201 |
|
II. THROTTLE PEDAL SENSOR |
202 |
|
III. CLUTCH SWITCH |
203 |
|
IV. BRAKE SWITCH |
204 |
|
V. VEHICLE SPEED SENSOR |
205 |
|
WHEEL SPEED SENSOR |
206 |
|
3. 1.05L REVOTORQ ENGINE |
207 |
|
3.1. GENERAL INFORMATION |
212 |
|
A. ENGINE INTRODUCTION |
212 |
|
B. TECHNICAL SPECIFICATION |
213 |
|
C. SPECIAL TOOLS |
214 |
|
D. ASSEMBLY CLEARANCES |
218 |
|
E. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
219 |
|
F. SERVICE SCHEDULE |
220 |
|
3.2. TROUBLESHOOTING |
221 |
|
3.3. CONSTRUCTIONAL AND SERVICE DETAILS |
229 |
|
A. ENGINE MOUNTING SYSTEM |
229 |
|
B. CYLINDER HEAD AND COVER |
231 |
|
C. LUBRICATION SYSTEM |
233 |
|
D. ENGINE |
235 |
|
E. OIL SUMP |
237 |
|
F. CYLINDER HEAD |
239 |
|
G. SPECIAL INSTALLATION |
241 |
|
H. EXHAUST SYSTEM |
243 |
|
I. INTAKE SYSTEM |
245 |
|
J. ENGINE SUSPENSION |
247 |
|
K. MOVING PARTS |
249 |
|
L. ENGINE TIMING |
251 |
|
M. FUEL INJECTION EQUIPMENT |
253 |
|
3.4. ENGINE TESTS AND MAINTENANCE |
255 |
|
A. PRELIMINARY INSPECTION |
255 |
|
B. ENGINE TESTS |
255 |
|
C. REGULAR MAINTENANCE |
259 |
|
I. ENGINE OIL AND FILTER CHANGE |
259 |
|
II. ENGINE COOLANT REPLACEMENT |
260 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
261 |
|
IV. FUEL FILTER REPLACEMENT |
262 |
|
V. DRAINING WATER FROM PRE-FILTER |
263 |
|
VI. PRE-FILTER REPLACEMENT |
263 |
|
VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
264 |
|
3.5. REPAIR AND INSPECTION DETAILS |
265 |
|
A. TIMING BELT |
265 |
|
B. FUEL TANK |
265 |
|
C. CYLINDER HEAD |
266 |
|
D. VALVES |
267 |
|
E. VALVE SEATS |
268 |
|
F. CRANKCASE |
269 |
|
G. VALVE SEAT INSERT |
270 |
|
H. HYDRAULIC LASH ADJUSTER |
270 |
|
I. VALVE GUIDES |
271 |
|
J. CAMSHAFT |
272 |
|
K. PISTON AND PISTON RINGS |
273 |
|
L. CONNECTING ROD |
274 |
|
M. CRANKSHAFT |
276 |
|
3.6. ENGINE SYSTEM |
278 |
|
A. AIR INTAKE SYSTEM |
278 |
|
B. EXHAUST SYSTEM |
280 |
|
C. COOLING SYSTEM |
284 |
|
D. LUBRICATION SYSTEM |
287 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM |
290 |
|
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM |
292 |
|
G. VACUUM MANAGEMENT SYSTEM |
293 |
|
H. FUEL SYSTEM |
294 |
|
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
300 |
|
A. ENGINE REMOVAL |
300 |
|
B. ENGINE INSTALLATION |
304 |
|
C. EXHAUST SYSTEM |
305 |
|
D. COOLING SYSTEM |
307 |
|
E. FUEL SYSTEM |
309 |
|
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
316 |
|
A. ENGINE DIS-ASSEMBLY |
316 |
|
I. ON OVERHAUL STAND |
316 |
|
II. REMOVAL OF INTAKE MANIFOLD |
319 |
|
III. REMOVAL OF EXHAUST MANIFOLD |
321 |
|
IV. REMOVAL OF OIL SUMP |
325 |
|
V. REMOVAL OF TIMING BELT |
326 |
|
VI. REMOVAL OF CYLINDER HEAD |
329 |
|
VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
330 |
|
VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
332 |
|
IX. PISTON CONNECTING ROD DIS-ASSEMBLY |
334 |
|
B. ENGINE ASSEMBLY |
340 |
|
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
340 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
341 |
|
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
342 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
343 |
|
V. FITMENT OFTIMING BELT |
344 |
|
VI. FITMENT OF OIL SUMP |
347 |
|
VII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
349 |
|
VIII. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
353 |
|
IX. ON ENGINE SUPPORT STAND |
355 |
|
3.9. ENGINE MANAGEMENT SYSTEM |
359 |
|
A. ABBREVIATIONS |
359 |
|
B. AN OVERVIEW |
360 |
|
C. ELECTRONIC CONTROL UNIT (ECU) |
361 |
|
D. EMS SENSORS |
365 |
|
I. CRANK POSITION SENSOR |
365 |
|
II. VEHICLE SPEED SENSOR |
366 |
|
III. WHEEL SPEED SENSOR |
367 |
|
IV. CAMSHAFT POSITION SENSOR |
368 |
|
V. AIR MASS FLOW SENSOR |
369 |
|
VI. INLET METERING VALVE |
370 |
|
VII. VENTURI |
370 |
|
VIII. RAIL PRESSURE SENSOR |
370 |
|
IX. THROTTLE PEDAL SENSOR |
371 |
|
X. WATER IN FUEL SENSOR |
372 |
|
XI. CLUTCH SWITCH |
372 |
|
XII. OIL PRESSURE SWITCH |
373 |
|
XIII. BRAKE SWITCH |
375 |
|
XIV. COOLANT TEMPERATURE SENSOR |
376 |
|
XV. GLOW PLUG |
377 |
|
XVI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
378 |
|
4A. DRIVETRAIN - MANUAL TRANSMISSION- TA 65 STAR |
379 |
|
4.1 PRECAUTION |
383 |
|
4.2 SPECIFCICATIONS & TIGHTENING TORQUES |
384 |
|
A. CLUTCH |
384 |
|
B. TRANSAXLE |
389 |
|
C. TIGHTENING TORQUES |
390 |
|
4.3 SPECIAL TOOLS |
391 |
|
A. CLUTCH |
391 |
|
B. TRANSAXLE |
391 |
|
4.4 DIAGNOSIS |
396 |
|
A. CLUTCH |
396 |
|
B. TRANSAXLE |
399 |
|
4.5 MAINTENANCE, ADJUSTMENT & TEST |
400 |
|
A. PRELIMINARY INSPECTION OF CLUTCH |
400 |
|
B. DRIVESHAFT |
401 |
|
4.6 CLUTCH |
403 |
|
A. THEORY OF DIAPHRAGM SPRING CLUTCH |
403 |
|
B. CONSTRUCTIONAL DETAILS |
404 |
|
C. FACTOR AFFECTING CLUTCH WEAR |
406 |
|
D. CLUTCH CABLE - REMOVAL AND INSPECTION |
407 |
|
E. REMOVAL OF CLUTCH FROM THE CAR |
408 |
|
F. INSTALLATION OF CLUTCH ON THE CAR |
408 |
|
H. PROCEDURE FOR CLUTCH ADJUSTMENT |
409 |
|
4.7 TRANSAXLE |
410 |
|
A. GENERAL DISCRIPTION |
410 |
|
B. CUT SECTION OF TRANSAXLE TA 65 STAR |
412 |
|
C. CUT SECTION OF TOP COVER ASSEMBLY |
413 |
|
D. EXPLODED VIEW OF TRANSAXLE |
414 |
|
E. EXPLODED VIEWS OF DIFFERENTIAL |
416 |
|
F. EXPLODED VIEW OF SHIFTER FORK |
418 |
|
G. EXPLODED VIEWS OF GEAR SHIFT LINKAGE ASSSEMBLY |
420 |
|
H. EXPLODED VIEWS OF LAY SHAFT AND INPUT SHAFT |
421 |
|
I. REMOVAL OF CLUTCH FROM THE CAR |
424 |
|
J. TRANSAXLE TA65 STAR (ON BENCH) DISASSSEMBLY |
426 |
|
K. INPUT SHAFT SUB- ASSEMBLY |
432 |
|
L. INPUT SHAFT ASSEMBLY |
432 |
|
M. DISASSEMBLY OF LAY SHAFT |
433 |
|
N. IDENTIFICATION OF COMPONENTS |
435 |
|
O. SUBASSEMBLIE |
438 |
|
P. LAY SHAFT ASSEMBLY |
440 |
|
Q. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL |
443 |
|
R. ASSEMBLY OF TRANSAXLE |
445 |
|
S. ASSEMBLY OF TOP COVER |
448 |
|
T. INSTALLATION OF TRANSAXLE ON CAR |
452 |
|
U. REMOVAL OF GEARSHIFT HOUSING, GEAR SHIFTER AND SELECTOR CABLE |
453 |
|
4.8 DRIVE SHAFT |
455 |
|
A. DRIVE SHAFT PARTS |
455 |
|
B. DISASSEMBLY AND ASSEMBLY PROCEDURE DRIVESHAFT TRIPOT JOINT |
456 |
|
C. DISASSEMBLY AND ASSEMBLY CV JOINT ASSEMBLY (OUTER) |
459 |
|
4B. DRIVETRAIN-AMT |
463 |
|
1. TRANSAXLE TA-65 STAR AMT |
467 |
|
1.1. PRECAUTION |
470 |
|
1.2. TRANSAXLE GENERAL INFORMATION |
471 |
|
1.3. TECHNICAL SPECIFCICATIONS |
472 |
|
1.4. TIGHTENING TORQUES |
473 |
|
1.5. SPECIAL TOOLS |
474 |
|
1.5.1. CLUTCH |
474 |
|
1.5.2. TRANSAXLE |
474 |
|
1.6. DIAGNOSIS OF TRANSAXLE |
479 |
|
1.7. SERVICE SCHEDULE OF TRANSAXLE |
479 |
|
1.8. CUT SECTION OF TRANSAXLE |
480 |
|
1.9. EXPLODED VIEWS OF TRANSAXLE |
481 |
|
1.10. REMOVAL OF TRANSAXLE FROM VEHICLE |
490 |
|
1.11. TRANSAXLE TA65 STAR AMT DISASSEMBLY (ON BENCH) |
493 |
|
1.12. SUB ASSEMBLIES |
499 |
|
1.13. TRANSAXLE TA65 STAR AMT ASSEMBLY |
511 |
|
2. CLUTCH |
514 |
|
2.1. GENERAL INFORMATION |
517 |
|
2.2. TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES |
517 |
|
2.3. DIAGNOSIS |
520 |
|
2.4. CLUTCH |
522 |
|
2.4.1. THEORY OF DIAPHRAGM SPRING CLUTCH |
522 |
|
2.4.2. CONSTRUCTIONAL DETAILS |
523 |
|
2.4.3. FACTOR AFFECTING CLUTCH WEAR |
525 |
|
2.4.4. REMOVAL OF CLUTCH FROM THE CAR |
525 |
|
2.4.5. INSTALLATION OF CLUTCH ON THE CAR |
525 |
|
2.5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE |
526 |
|
3. DRIVESHAFT |
527 |
|
3.1. GENERAL INFORMATION |
530 |
|
3.2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
531 |
|
3.3. TESTING FOR NOISE |
531 |
|
3.4. DRIVE SHAFT PARTS |
532 |
|
3.5. DISASSEMBLY PROCEDURE FOR TRIPOT JOINT |
533 |
|
3.6. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER) |
536 |
|
4. AMT KIT |
540 |
|
4.1. AMT-KIT LOCATION ON VEHICLE(LAYTOU) |
543 |
|
4.2. NOMENCLATURE FOR AMT KIT |
544 |
|
4.3. TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS |
545 |
|
4.4. SPECIAL TOOLS |
548 |
|
4.5. PRECAUTIONS |
551 |
|
4.6. ON VEHICLE PROCEDURES |
552 |
|
4.6.1. DEPRESSURIZATION OF AMT KIT |
552 |
|
4.6.2. AMT KIT REMOVAL (FROM TOP) |
555 |
|
4.7. ON BENCH PROCEDURES |
558 |
|
4.7.1. OIL TANK REMOVAL AND RE-FITMENT |
558 |
|
4.7.2. MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT |
560 |
|
4.7.3. TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT |
563 |
|
4.7.4. DC MOTOR REMOVAL AND RE-FITMENT |
566 |
|
4.7.5. HYDRAULIC OIL ACCUMLATOR REMOVAL AND RE-FITMENT |
567 |
|
4.7.6. CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT |
567 |
|
4.7.7. POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH |
568 |
|
5. CONSOLE |
569 |
|
5.1. AMT GEARBOX SHIFTER AND SHIFTING MECHANISM |
572 |
|
5.2. DRIVING MODES |
572 |
|
5.3. GEAR SHIFTER CENTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE |
574 |
|
5.4. GEAR SHIFTER PIN CONFIGURATION |
576 |
|
6. INSTRUMENT CLUSTER |
577 |
|
6.1. GENERAL INFORMATION |
580 |
|
6.2. BASIC FUNCTIONAL MATRIX |
582 |
|
6.3. TELL TALES MATRIX |
583 |
|
6.4. DRIVER INFORMATION SYSTEM |
589 |
|
6.5. REMINDER FEATURES |
594 |
|
6.6. MAIN CONNECTOR PIN-OUTS |
595 |
|
6.7. FUEL GAUGE DETAILS |
596 |
|
6.8. TEMPERATURE BAR GRAPH DETAILS |
597 |
|
6.9. CHIME TABLE |
598 |
|
6.10. DISPLAY SCREEN FLOW AND SETTINGS |
598 |
|
6.11. REMOVAL OF INSTRUMENT CLUSTER |
602 |
|
6.12. IMMOBILIZER SYSTEM |
604 |
|
6.13. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
609 |
|
6.14. .IMMOBILIZER SYSTEM STATUS IN EMS ECU |
610 |
|
7. COMPONENT REPLACEMENT MANUAL |
612 |
|
7.1. DOCUMENT SCOPE |
615 |
|
7.2. INTENDED AUDIENCE |
615 |
|
7.3. TERMINOLOGIES |
615 |
|
7.4. CONFIDENTIALITY |
615 |
|
7.5. CONTACTS AT TATA MOTORS |
615 |
|
7.6. ROUTINE PROCEDURE FOR COMPONENT REPLACEMENT |
616 |
|
7.6.1. MATRIX OF ROUTINE PROCEDURE FOR COMPONENT REPLACEMENT |
616 |
|
7.6.2. ROUTINE PROCEDURE FOR TCU REPLACEMENT |
617 |
|
7.6.3. ROUTINE PROCEDURE FOR ACTUATION SYSTEM REPLACEMENT |
618 |
|
7.6.4. ROUTINE PROCEDURE FOR GEAR BOX REPLACEMENT |
619 |
|
7.6.5. ROUTINE PROCEDURE FOR PUMP/ACCUMULATOR/CLUTCH ACTUATOR REPLACEMENT |
620 |
|
7.6.6. ROUTINE PROCEDURE FOR VALVE BOCK AND TCU REPLACEMENT |
621 |
|
7.6.7. ROUTINE PROCEDURE FOR CLUTCH SENSOR REPLACEMENT |
622 |
|
7.6.8. ROUTINE PROCEDURE FOR CLUTCH REPLACEMENT |
623 |
|
7.6.9. ROUTINE PROCEDURE FOR PRIMARY SHAFT SPEED SENSOR REPLACEMENT |
624 |
|
7.6.10. ROUTINE PROCEDURE FOR RUBBER BELLOW REPLACEMENT |
625 |
|
7.6.11. ROUTINE PROCEDURE FOR RESERVOIR REPLACEMENT |
625 |
|
7.6.12. ROUTINE PROCEDURE FOR GEAR SHIFT LEVER OR SPORTS/ECO REPLACEMENT |
626 |
|
7.6.13. ROUTINE PROCEDURE FOR ELECTRIC MOTOR REPLACEMENT |
626 |
|
7.6.14. TCU PROGRAMMING (FLASHING) |
627 |
|
7.6.15. ROUTINE PROCEDURE FOR AMT KIT REPLACEMENT |
628 |
|
8. DTC MANUAL |
630 |
|
8.1. P0914-02: GEAR POSITION SENSOR CIRCUIT FIXED SIGNAL HIGH LEVEL |
638 |
|
8.2. P0914-01: GEAR POSITION SENSOR CIRCUIT FIXED SIGNAL LOW LEVEL |
641 |
|
8.3. P0914-03: GEAR POSITION SENSOR CIRCUIT PERIOD ERROR |
644 |
|
8.4. P0914-05: GEAR POSITION SENSOR CIRCUIT PWM DUTY HIGH |
647 |
|
8.5. P0914-04: GEAR POSITION SENSOR CIRCUIT PWM DUTY LOW |
650 |
|
8.6. P1853-02: GEAR/SHIFT POSITION SENSOR WRONG SUPPLY VOLTAGE VBATT ERROR |
653 |
|
8.7. P1853-01: GEAR/SHIFT POSITION SENSOR WRONG SUPPLY VOLTAGE GND ERROR |
656 |
|
8.8. P0904-02: SHIFT POSITION SENSOR CIRCUIT FIXED SIGNAL HIGH LEVEL |
659 |
|
8.9. P0904-01: SHIFT POSITION SENSOR CIRCUIT FIXED SIGNAL LOW LEVEL |
662 |
|
8.10. P0904-03: SHIFT POSITION SENSOR CIRCUIT PERIOD ERROR |
665 |
|
8.11. P0904-05: SHIFT POSITION SENSOR CIRCUIT PWM DUTY HIGH |
668 |
|
8.12. P0904-04: SHIFT POSITION SENSOR CIRCUIT PWM DUTY LOW |
671 |
|
8.13. P0805-02: CLUTCH POSITION SENSOR CIRCUIT FIXED SIGNAL HIGH LEVEL |
674 |
|
8.14. P0805-01: CLUTCH POSITION SENSOR CIRCUIT FIXED SIGNAL LOW LEVEL |
677 |
|
8.15. P0805-03: CLUTCH POSITION SENSOR CIRCUIT PERIOD ERROR |
680 |
|
8.16. P0805-05: CLUTCH POSITION SENSOR CIRCUIT PWM DUTY HIGH |
683 |
|
8.17. P0805-04: CLUTCH POSITION SENSOR CIRCUIT PWM DUTY LOW |
686 |
|
8.18. P1852-02: CLUTCH POSITION/HYD PRESS SENSOR WRONG SUPPLY VOLTAGE VBATT ERROR |
689 |
|
8.19. P1852-01: CLUTCH POSITION/HYD PRESS SENSOR WRONG SUPPLY VOLTAGE GND ERROR |
692 |
|
8.20. P0932-02: HYDRAULIC PRESSURE SENSOR CIRCUIT SIGNAL OVER MAX THRESHOLD |
695 |
|
8.21. P0932-01: HYDRAULIC PRESSURE SENSOR CIRCUIT SIGNAL UNDER MIN THRESHOLD |
699 |
|
8.22. P0932-07: HYDRAULIC PRESSURE SENSOR CIRCUIT WRONG VALUE SENSOR |
702 |
|
8.23. P0932-03: HYDRAULIC PRESSURE SENSOR CIRCUIT WRONG SIGNAL SPIKES |
705 |
|
8.24. P0820/P0821/P0822/P0823-02: GEAR LEVER SENSOR CIRCUIT OVER MAX THRESHOLD |
708 |
|
8.25. P0820/P0821/P0822/P0823-01: GEAR LEVER SENSOR CIRCUIT UNDER MIN. THRESHOLD |
712 |
|
8.26. P0825 -02: GEAR LEVER SENSOR CIRCUIT SIGNAL NOT VALID |
716 |
|
8.27. P0825 -01: GEAR LEVER SENSOR CIRCUIT MISUSE |
720 |
|
8.28. P0715 -03: CLUTCH SPEED SENSOR CIRCUIT SIGNAL ABSENT |
725 |
|
8.29. P0715 -01: CLUTCH SPEED SENSOR CIRCUIT SIGNAL WRONG |
728 |
|
8.30. P0715 -02: CLUTCH SPEED SENSOR CIRCUIT SIGNAL WRONG SPIKES |
731 |
|
8.31. P2900 -01: SPORT SWITCH INPUT CIRCUIT SWITCH STUCK |
734 |
|
8.32. P0725-02: ENGINE SPEED INPUT CIRCUIT SIGNAL NOT VALID |
737 |
|
8.33. P0725-03: ENGINE SPEED INPUT CIRCUIT SIGNAL ABSENT |
740 |
|
8.34. P0725-01: ENGINE SPEED INPUT CIRCUIT SIGNAL WRONG |
743 |
|
8.35. P0505 -02: IDLE ENGINE SPEED INPUT SIGNAL IMPLAUSIBLE / SIGNAL WRONG |
746 |
|
8.36. P2903 -02: ACCELERATOR PEDAL POSITION SIGNAL NOT VALID |
749 |
|
8.37. P2906 -02: GENERATED ENGINE TORQUE SIGNAL NOT VALID |
752 |
|
8.38. P2906 -03: ENGINE LOSS TORQUE SIGNAL NOT VALID |
755 |
|
8.39. P1981 -02: DRIVER ENGINE TORQUE SIGNAL NOT VALID |
758 |
|
8.40. P2906 -04: ENGINE WISH TORQUE SIGNAL NOT VALID |
761 |
|
8.41. P2907 -02: ENGINE MAXIMUM TORQUE SIGNAL NOT VALID |
764 |
|
8.42. P0703 -02: BRAKE SWITCH INPUT CIRCUIT SIGNAL NOT VALID |
767 |
|
8.43. P0710 -02: ENGINE WATER TEMPERATURE SIGNAL NOT VALID |
770 |
|
8.44. P0716 -02: VEHICLE SPEED INPUT SIGNAL NOT VALID |
773 |
|
8.45. P0716 -03: VEHICLE SPEED INPUT SIGNAL ABSENT |
776 |
|
8.46. P0716 -01: VEHICLE SPEED INPUT SIGNAL WRONG |
779 |
|
8.47. P0710 -03: EXTERNAL TEMPERATURE SIGNAL NOT VALID |
782 |
|
8.48. P0900-04: CLUTCH ELECTROVALVE OPEN CIRCUIT |
785 |
|
8.49. P0900-02: CLUTCH ELECTROVALVE SHORT TO SUPPLY |
788 |
|
8.50. P0900-01: CLUTCH ELECTROVALVE SHORT TO GROUND |
791 |
|
8.51. P0900-05: CLUTCH ELECTROVALVE SHORT TO SUPPLY/OPEN CIRCUIT |
794 |
|
8.52. P0750-04: GEAR 1 ELECTROVALVE OPEN CIRCUIT |
797 |
|
8.53. P0750-02: GEAR 1 ELECTRO VALVE SHORT TO SUPPLY |
800 |
|
8.54. P0750-01: GEAR 1 ELECTROVALVE SHORT TO GROUND |
803 |
|
8.55. P0750-05: GEAR 1 ELECTROVALVE SHORT TO SUPPLY/OPEN CIRCUIT |
806 |
|
8.56. P0755-04: GEAR 2 ELECTROVALVE OPEN CIRCUIT |
809 |
|
8.57. P0755-02: GEAR 2 ELECTROVALVE SHORT TO SUPPLY |
812 |
|
8.58. P0755-01: GEAR 2 ELECTROVALVE SHORT TO GROUND |
815 |
|
8.59. P0755-05: GEAR 2 ELECTROVALVE SHORT TO SUPPLY/OPEN CIRCUIT |
818 |
|
8.60. P1889-04: SHIFT ELECTROVALVE OPEN CIRCUIT |
821 |
|
8.61. P1889-02: SHIFT ELECTROVALVE SHORT TO SUPPLY |
824 |
|
8.62. P1889-01: SHIFT ELECTROVALVE SHORT TO GROUND |
827 |
|
8.63. P1889-05: SHIFT ELECTROVALVE SHORT TO SUPPLY/OPEN CIRCUIT |
830 |
|
8.64. P185C-05: HYDRAULIC PUMP SUPPLY OPEN CIRCUIT /SHORT TO SUPPLY |
833 |
|
8.65. P185C-01: HYDRAULIC PUMP SUPPLY SHORT TO GROUND |
836 |
|
8.66. P185C-03: HYDRAULIC PUMP SUPPLY DEVICE CLOSED |
839 |
|
8.67. P185C-07: HYDRAULIC PUMP SUPPLY SHORT TO SUPPLY |
843 |
|
8.68. P081A-03: CRANKING ENABLE SHORT TO GROUND/OPEN CIRCUIT |
846 |
|
8.69. P081A-02: CRANKING ENABLE SHORT TO SUPPLY |
848 |
|
8.70. P1884-04: REVERSE LAMP RELAY OPEN CIRCUIT |
851 |
|
8.71. P1884-02: REVERSE LAMP RELAY SHORT TO SUPPLY |
854 |
|
8.72. P1884-01: REVERSE LAMP RELAY SHORT TO GROUND |
857 |
|
8.73. P2904-01: CLUTCH SYSTEM NOT OPENING BEFORE SHIFT |
860 |
|
8.74. P2904-02: CLUTCH SYSTEM CLOSING DURING ENGAGE+C8:C40 |
863 |
|
8.75. P2904-03: CLUTCH SYSTEM OVERHEAT |
866 |
|
8.76. P2908-01: CLUTCH SYSTEM CONTROL ERROR |
870 |
|
8.77. P1905-02: CLUTCH SYSTEM CLUTCH LOCKED |
872 |
|
8.78. P2905-01: GEARBOX SYSTEM DISENGAGE FAILED |
875 |
|
8.79. P2909-01: GEARBOX SYSTEM SHIFT FAILED |
879 |
|
8.80. P2905-02: GEARBOX SYSTEM ENGAGE FAILED |
883 |
|
8.81. P2905-03: GEARBOX SYSTEM UNINTENDED DISENGAGE |
887 |
|
8.82. P2909-02: GEARBOX SYSTEM SHIFT LOCKED |
891 |
|
8.83. P190B-01: GEARBOX SYSTEM UNINTENDED ENGAGE |
895 |
|
8.84. P190C-07: GEARBOX SYSTEM CONTROL ERROR |
898 |
|
8.85. P190D-01: GEARBOX SYSTEM CLUTCH OVER SPEED |
901 |
|
8.86. P0942- 01: HYDRAULIC CIRCUIT PRESSURE LOW |
904 |
|
8.87. P0942- 07: HYDRAULIC CIRCUIT PUMP OVERHEATING |
908 |
|
8.88. P2712- 07: HYDRAULIC CIRCUIT LEAKAGE TOO HIGH |
912 |
|
8.89. P2901- 01: HYDRAULIC CIRCUIT ACCUMULATOR DISCHARGED |
915 |
|
8.90. P0780- 07: HYDRAULIC CIRCUIT SYSTEM MISUSE |
918 |
|
8.91. P184A- 01: HYDRAULIC CIRCUIT PUMP TIMEOUT |
921 |
|
8.92. P0562-04: BATTERY SUPPLY 1 OPEN CIRCUIT |
924 |
|
8.93. P0560-01: BATTERY SUPPLY 1 WRONG VALUE |
927 |
|
8.94. P0560-02: IGNITION KEY VOLTAGE WRONG VALUE |
930 |
|
8.95. P0945-04: BATTERY SUPPLY 2 OPEN CIRCUIT |
933 |
|
8.96. P1711-01: BATTERY SUPPLY UNDER SHIFT THRESHOLD |
936 |
|
8.97. P1711-02: BATTERY SUPPLY OVER THRESHOLD |
938 |
|
8.98. P1711-07: BATTERY SUPPLY UNDER LOW THRESHOLD |
940 |
|
8.99. P0604- 08: TCU ROM CHECKSUM ERROR * |
942 |
|
8.100. P0604- 07: TCU RAM INTEGRITY ERROR * |
944 |
|
8.101. P062F- 07: TCU EEPROM TUNING DATA ALTERATION ERROR |
946 |
|
8.102. P062F- 08: TCU EEPROM Grid Data Alteration Error |
948 |
|
8.103. P1704- 07: TCU EEPROM System Data Alteration Error |
950 |
|
8.104. P060A- 07: Safety Microprocessor Integrity failure |
951 |
|
8.105. P060A- 08: Safety Microprocessor Output failure |
952 |
|
8.106. P0701- 02: Electro valves Driver 1 SPI Device fault |
953 |
|
8.107. P0701- 01: Electro valves Driver 1 Thermal warning |
955 |
|
8.108. P0701- 03: Electro valves Driver 1 Device closed |
957 |
|
8.109. P0701- 04: Electro valves Driver 1 Device open |
959 |
|
8.110. P184D- 02: Electro valves Driver 2 SPI Device fault |
961 |
|
8.111. P184D- 01: Electro valves Driver 2 Thermal warning |
963 |
|
8.112. P0881- 02: TCU 12V Internal Supply Device Open |
965 |
|
8.113. P0881- 03: TCU 12V Internal Supply Device closed* |
967 |
|
8.114. P0880- 04: SMP 5V power Supply under low threshold |
969 |
|
8.115. P0880- 06: SMP 5V power Supply under medium threshold |
971 |
|
8.116. P0880- 02: SMP 5V power Supply under low threshold |
973 |
|
8.117. P0880- 03: TCU 5V power Supply Device Closed |
975 |
|
8.118. P1401- 07: LEVEL 2 INTERVENTION-SAFETY INPUT FAILURE |
977 |
|
8.119. P1401- 08: LEVEL 2 INTERVENTION-SYSTEM PROBLEM |
979 |
|
8.120. P060C-07: LEVEL 3 INTERVENTION-SYSTEM PROBLEM |
981 |
|
8.121. P1844 -07: GRID SELF TUNING PROCEDURE ERROR |
983 |
|
8.122. P080A -07: KISS POINT SELFTUNING PROCEDURE ERROR |
986 |
|
8.123. P185B -07: CLUTCH STROKE SELFTUNING ERROR |
988 |
|
8.124. P1886-07:- DUAL PORT RAM CHECK |
990 |
|
8.125. U0001-01:- CAN EMS ERROR |
991 |
|
8.126. C0082-00:- ABS STATUS CAN SIGNAL INVALID |
992 |
|
8.127. U0001-88 - VEHICLE COMMUNICATION BUS A- BUS OFF |
994 |
|
8.128. U0121 -08:- LOST COMMUNICATION WITH ANTILOCK BRAKING SYSTEM MODULE- ABS/ESP BUS SIGNAL/ MESSAGE |
996 |
|
8.129. U0155-08:- LOST COMMUNICATION WITH INSTRUMENT PANEL CLUSTER MODULE- BUS SIGNAL/ MESSAGE FAILURE |
1002 |
|
8.130. U0100-08 LOSS OF COMMUNICATION WITH ENGINE CONTROL MODULE- BUS SIGNAL/ MESSAGE FAILURE |
1008 |
|
8.131. P1C10-01:- INVALID DATA RECEIVED FROM ECM (106 FRAME)-CYCLIC REDUNDANCY CHECK ERROR |
1018 |
|
8.132. P1C11-02:- INVALID DATA RECEIVED FROM ECM (106 FRAME) -MESSAGE ROLLING COUNTER ERROR |
1021 |
|
8.133. P1C12-01:- INVALID DATA RECEIVED FROM ECM (108 FRAME)-CYCLIC REDUNDANCY CHECK ERROR |
1023 |
|
8.134. P1C13-02:- INVALID DATA RECEIVED FROM ECM (108 FRAME)-MESSAGE ROLLING COUNTER ERROR |
1026 |
|
8.135. P1C14-01:- INVALID DATA RECEIVED FROM IPC (197 FRAME)-CYCLIC REDUNDANCY CHECK ERROR |
1028 |
|
8.136. P1C15-02:- INVALID DATA RECEIVED FROM IPC (197 FRAME)-MESSAGE ROLLING COUNTER ERROR |
1030 |
|
8.137. P1986-07 VARIANT CODE PROCEDURE NOT COMPLETED |
1032 |
|
8.138. U0001-02 ENGINE LIMP HOME SIGNAL-SIGNAL NOT VALID |
1034 |
|
GENERIC TROUBLESHOOTING GUIDELINES |
1035 |
|
CAN BUS ARCHITECTURE & NETWORK TOPOLOGY |
1036 |
|
IVN PRELIMINARY CHECK |
1037 |
|
ABBREVIATIONS |
1038 |
|
APPENDIX |
1039 |
|
DIAGNOSTIC TROUBLE CODES LIST |
1043 |
|
5. SUSPENSION |
1055 |
|
5.1 TECHNICAL SPECIFICATION AND TIGHTENING TORQUE |
1059 |
|
5.1.1 SPECIFCICATIONS |
1059 |
|
5.1.2 TIGHTENING TORQUES |
1060 |
|
5.2 SPECIAL TOOLS |
1062 |
|
5.3 DIAGNOSIS |
1068 |
|
5.4 PRECAUTION |
1069 |
|
5.5 SUSPENSION SYSTEM |
1070 |
|
5.6 EXPLODED VIEWS FRONT SUSPENSION SYSTEM |
1074 |
|
5.6.1. ASSEMBLY FRONT STRUT EXPLODED VIEW |
1074 |
|
5.6.2. LOWER ARM LINK EXPLODED VIEW |
1075 |
|
5.6.3. ANTI ROLL BAR MOUNTING EXPLODED VIEW |
1077 |
|
5.6.4. FRONT AXLE ASSEMBLY EXPLODED VIEW |
1078 |
|
5.7 ON VEHICLE REPAIRS FRONT SUSPENSION |
1079 |
|
5.7.1 REMOVAL AND INSTALLATION OF STRUT ASSEMBLY |
1079 |
|
5.7.2 DISASSEMBLY AND ASSEMBLY OF FRONT STRUT |
1080 |
|
5.7.3 REMOVAL AND INSTALLATION OF WHEEL HUB |
1083 |
|
5.7.4 REMOVAL AND INSTALLATION OF ANTI ROLL BAR |
1086 |
|
5.7.5 REMOVAL AND INSTALLATION OF LOWER ARM ASSEMBLY |
1088 |
|
5.7.6 REMOVAL AND INSTALLATION OF LOWER ARM BALL JOINT |
1089 |
|
5.7.7 REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES |
1091 |
|
5.7.8 PROCEDURE FOR CHECKING BALL JOINT PLAY ON LOWER ARM |
1092 |
|
5.8 EXPLODED VIEWS REAR SUSPENSION SYSTEM |
1093 |
|
5.8.1. REAR SHOCK ABSORBER EXPLODED VIEW |
1093 |
|
5.8.2. REAR HUB ASSEMBLY EXPLODED VIEW |
1094 |
|
5.8.3. PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW |
1095 |
|
5.9 ON VEHICLE REPAIRS REAR SUSPENSION |
1096 |
|
5.9.1. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER FROM VEHICLE |
1096 |
|
5.9.2. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER |
1096 |
|
5.9.3. REMOVAL AND INSTALLATION OF TORSION BEAM |
1099 |
|
5.9.4. TWIST BEAM BUSH REMOVAL |
1102 |
|
5.10 WHEELS AND TYRES |
1104 |
|
A. TYRE INSPECTION |
1104 |
|
B. PRLACEMENT OF TYRE |
1104 |
|
C. REPLACEMENT OF WHEELS |
1104 |
|
5.10.1. HOW TO MEASURE WHEEL RUNOUT |
1104 |
|
5.10.2. INFLATION OF TYRES |
1105 |
|
5.10.3. TYRE ROTATION |
1106 |
|
5.10.4. WHEEL REMOVAL |
1106 |
|
5.10.5. TYRE MOUNTING AND DEMOUNTING |
1106 |
|
5.10.6. BALANCING WHEELS |
1107 |
|
5.10.7. TYRE CARE |
1107 |
|
6. BRAKES |
1108 |
|
6.1 PRECAUTIONS |
1112 |
|
6.2 TECHNICAL SPECIFICATIONS |
1113 |
|
6.3 TIGHTENING TORQUES |
1115 |
|
6.4 DIAGNOSIS |
1116 |
|
6.5 NESSECITY OF ABS WITH EBD |
1119 |
|
6.6 BRAKE HYDRAULIC LINES |
1120 |
|
6.7 VACUUM BRAKE BOOSTER |
1122 |
|
6.8 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
1123 |
|
6.9 ABS COMPONENTS |
1127 |
|
6.9.1 ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
1127 |
|
6.9.2 HYDRAULIC CONTROL UNIT |
1129 |
|
6.9.3 WHEEL SPEED SENSOR: (MONITORS WHEEL SPEED) |
1130 |
|
6.9.4 ABS SYSTEM FAILURE WARNING LIGHT |
1131 |
|
6.10 MAINTENANCE, ADJUSTMENTS & TEST |
1132 |
|
6.10.1 FRONT BRAKE MAINTENANCE |
1132 |
|
6.10.2 REAR BRAKE MAINTENANCE |
1134 |
|
6.10.3 BRAKE TROUBLE SHOOTING |
1139 |
|
6.10.4 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
1140 |
|
6.11 BRAKE PEDAL ASSEMBLY |
1142 |
|
6.12 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE |
1143 |
|
6.13 REPAIRS |
1144 |
|
6.13.1 FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT |
1145 |
|
6.13.2 REMOVAL OF FRONT BRAKE DISC |
1151 |
|
6.13.3 REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
1152 |
|
6.13.4 REAR BRAKE ASSEMBLY |
1154 |
|
6.13.5 REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY |
1156 |
|
6.13.6 REMOVAL OF PARKING BRAKE LEVER |
1162 |
|
6.13.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE |
1163 |
|
6.13.8A PARKING BRAKE CABLE ADJUSTMENT |
1164 |
|
6.13.8B ARKING BRAKE LEVER PRIMARY CABLE GREASING |
1164 |
|
6.13.9 REMOVAL AND REFITMENT OF ABS ECU / HCU |
1165 |
|
6.13.10 REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR |
1166 |
|
6.13.11 REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR |
1167 |
|
6.14 TROUBLE SHOOTING & DIAGNOSIS |
1169 |
|
6.15 ABS ECU CONNECTOR |
1171 |
|
7. STEERING (ELECTRICAL POWER ASSIST SYSTEM-EPAS) |
1173 |
|
7.1. GENERAL INFORMATION |
1176 |
|
7.1.1. SPECIFICATIONS |
1176 |
|
7.1.2. SYSTEM LAYOUT |
1176 |
|
7.1.3. GENERAL DISCRIPTION |
1177 |
|
7.1.4. TIGHTENING TORQUES |
1178 |
|
7.1.5. SPECIAL TOOLS |
1180 |
|
7.2. MAINTENANCE, INSPECTION AND TEST |
1181 |
|
7.2.1. PRELIMINARY INSPECTION |
1181 |
|
7.2.2. REGULAR MAINTENANCE |
1182 |
|
7.2.3. ON VEHICLE REPAIRS |
1183 |
|
7.2.3.1. STEERING WHEEL REMOVAL |
1183 |
|
7.2.3.2. STEERING COLUMN REMOVAL |
1184 |
|
7.2.3.3. INTERMEDIATE SHAFT REMOVAL |
1186 |
|
7.2.3.4. ECU REMOVAL |
1186 |
|
7.2.3.5. RACK & PINION ASSEMBLY REMOVAL |
1188 |
|
7.3. OVERHAULING |
1190 |
|
7.3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY |
1190 |
|
7.3.2. PRECAUTIONS |
1191 |
|
7.3.3. DISMANTLING, INSPECTION & ASSEMBLY |
1191 |
|
7.3.3.1. DISASSEMBLY OF RACK & PINOIN |
1191 |
|
7.3.3.2. INSPECTION OF DISMANTLED PARTS |
1192 |
|
7.3.3.3. ASSEMBLY OF RACK & PINOIN |
1192 |
|
7.3.3.4. OBJ ON VEHICLE REMOVAL |
1193 |
|
7.3.3.5. DO'S & DON’T'S |
1193 |
|
7.3.3.6. WHEEL ALIGNMENT |
1194 |
|
7.4. TROUBLESHOOTING AND DIAGNOSIS |
1196 |
|
7.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS |
1200 |
|
7.6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
1203 |
|
8. ELECTRICAL |
1209 |
|
8.1 TECHNICAL SPECIFICATION |
1214 |
|
8.2 GENERAL PRECAUTIONS |
1216 |
|
8.3 FUSE BOX / RELAY LOCATIONS |
1220 |
|
8.4 BATTERY |
1221 |
|
8.5 ALTERNATOR |
1223 |
|
8.6 STARTER MOTOR |
1226 |
|
8.7 LIGHTING SYSTEM |
1233 |
|
8.7.1 BULB SPECIFICATIONS |
1233 |
|
8.7.2 FASTENERS TORQUE VALUE TABLE |
1234 |
|
8.7.3 GENERAL SYMPTOMS AND DIAGNOSTICS |
1234 |
|
8.7.4 HEAD LAMP |
1238 |
|
8.7.5 SIDE REPEATER LAMP |
1244 |
|
8.7.6 ROOF LAMP |
1245 |
|
8.7.7 HIGH MOUNTED STOP LAMP |
1246 |
|
8.7.8 TAIL LAMP |
1247 |
|
8.7.9 FRONT FOG LAMP |
1250 |
|
8.7.10 REGISTRATION PLATE LAMP |
1251 |
|
8.8 HORN |
1252 |
|
8.9 WIPER & WASHER SYSTEM |
1254 |
|
8.9.1 FRONT AND REARWIPER ANDWAHSER SYSTEM LAYOUT |
1255 |
|
8.9.2 FRONT AND REARWASH/WIPE SWITCH FUNCTIONALITY |
1256 |
|
8.9.3 WIPER ANDWIPER CARE |
1260 |
|
8.10 POWER SOCKETS |
1262 |
|
8.11 GLOW PLUG CONTROL UNIT |
1263 |
|
8.12 FUEL GAUGE AND FUEL LEVEL METER |
1265 |
|
8.13 COMBI-SWITCH |
1267 |
|
8.14 STEERING LOCK CUM IGNITION SWITCH |
1272 |
|
8.15 FASCIA SWITCHES |
1275 |
|
8.16 HAZARD SWITCH |
1279 |
|
8.17 MIRROR SWITCH |
1280 |
|
8.18 INFOTAINMENT SYSTEM |
1281 |
|
8.18.1 USB/AUX PORT |
1284 |
|
8.18.2 SPEAKERS |
1285 |
|
8.18.3 TWEETER |
1287 |
|
8.18.4 ANTENNA |
1288 |
|
8.18.5 MICROPHONE |
1289 |
|
8.18.6 DTC FOR INFOTAINMENT SYSTEM |
1290 |
|
8.19 WINDOW WINDING MODULE |
1291 |
|
8.20 POWER WINDOW SWITCHES |
1294 |
|
8.21 STEERING WHEEL SWITCHES |
1299 |
|
8.22 IGNITION E-KEY |
1302 |
|
8.23 INSTRUMENT CLUSTER |
1305 |
|
8.23.1 BASIC FUNCTIONALMATRIX |
1307 |
|
8.23.2 TELL TALESMATRIX |
1308 |
|
8.23.3 DRIVER INFORMATION SYSTEM |
1314 |
|
8.23.4 DTC FOR INSTRUMENT CLUSTER |
1319 |
|
8.23.5 CONNECTOR DETAILS |
1322 |
|
8.23.6 FUEL GAUGE DETAILS |
1324 |
|
8.23.7 TEMPERATURE BAR GRAPH DETAILS |
1325 |
|
8.23.8 CHIME TABLE |
1326 |
|
8.23.9 DISPLAY SCREEN FLOWAND SETTINGS |
1326 |
|
8.24 IMMOBILIZER SYSTEM |
1330 |
|
8.24.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
1335 |
|
8.24.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU |
1336 |
|
8.24.3 DTC FOR IMMOBILIZER |
1338 |
|
8.24.4 IGNITION KEYLEARNINGPROCEDURE |
1340 |
|
8.25 BODY CONTROL MODULE (BCM) |
1343 |
|
8.25.1 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
1349 |
|
8.25.2 BCM FUNCTIONS |
1361 |
|
8.25.3 DTC FOR BCM |
1399 |
|
8.26 CLUTCH PEDAL SENSOR |
1406 |
|
8.27 FUSE AND RELAY BOX DETAILS |
1409 |
|
8.27.1 BATTERY MOUNTED FUSE BOX (BDU) |
1411 |
|
8.27.2 ENGINE FUSE AND RELAY BOX |
1412 |
|
8.27.3 CABIN FUSE AND RELAY BOX |
1417 |
|
8.28 REVERSE PARK ASSIST SYSTEM |
1422 |
|
8.28.1 PARK ASSIST |
1422 |
|
8.28.2 PARK ASSIST FUNCTIONALITY OVERVIEW |
1422 |
|
8.28.3 PARK ASSIST ACTIVATION PROCEDURE |
1422 |
|
8.28.4 PARK ASSIST DEACTIVATION PROCEDURE |
1423 |
|
8.28.5 PARK ASSIST AUDIO SETTING |
1423 |
|
8.28.6 PARK ASSIST VOLUME |
1423 |
|
8.28.7 MIXWITH AUDIO |
1423 |
|
8.28.8 PARK ASSIST TONE |
1424 |
|
8.28.9 PARK ASSIST DELAY TIMER |
1424 |
|
8.28.10 PARK ASSIST HMI INDICATIONS |
1424 |
|
8.28.11 PARK ASSIST LIMITATIONS |
1425 |
|
8.28.12 PARK ASSIST SYSTEM MAINTENANCE |
1425 |
|
8.28.13 PARK ASSIST SYSTEM ARCHITECTURE |
1426 |
|
8.28.14 ECU TO SENSOR ELECTRICAL INTERFACE |
1427 |
|
8.28.15 ECU MOUNTING |
1427 |
|
8.28.16 PHYSICAL IMAGES |
1429 |
|
8.28.17 SENSOR FITMENT TO THE BUMPER |
1430 |
|
9. BODY |
1432 |
|
9.1 GENERAL INFORMATION |
1436 |
|
9.1.1 LAYOUT |
1436 |
|
9.1.2 TIGHTENING TORQUES |
1437 |
|
9.1.3 SPECIAL TOOLS |
1440 |
|
9.2 ON VEHICLE REPAIRS |
1441 |
|
9.2.1 BONNET |
1441 |
|
9.2.2 FLOOR CONSOLE |
1443 |
|
9.2.3 DASHBOARD |
1445 |
|
9.2.4 GLOVE BOX |
1454 |
|
9.2.5 SIDE AIR VENTS |
1455 |
|
9.2.6 FRONT BUMPER |
1455 |
|
9.2.7 REAR BUMPER |
1456 |
|
9.2.8 FRONT DOOR |
1458 |
|
9.2.9 FRONT DOOR TRIMS |
1459 |
|
9.2.10 DOOR INNER LOCK HANDLE |
1460 |
|
9.2.11 FRONT OUTER DOOR LOCK |
1461 |
|
9.2.12 FRONT DOOR LATCH |
1462 |
|
9.2.13 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
1464 |
|
9.2.14 REAR DOOR |
1465 |
|
9.2.15 REAR DOOR TRIM |
1466 |
|
9.2.16 REAR OUTER DOOR LOCK |
1468 |
|
9.2.17 DOOR LATCH REAR |
1469 |
|
9.2.18 TAIL GATE |
1470 |
|
9.2.19 TAIL GATE LATCH CABLE |
1473 |
|
9.2.20 TAILGATE TRIM |
1474 |
|
9.2.21 ORVM |
1475 |
|
9.2.22 INNER REAR VIEW MIRROR |
1476 |
|
9.2.23 FRONT ROW SEAT |
1476 |
|
9.2.24 REAR ROW SEAT |
1477 |
|
9.2.25 FRONT SEAT BELTS |
1480 |
|
9.2.26 REAR SEAT BELT |
1482 |
|
9.2.27 “A” PILLAR TRIM |
1483 |
|
9.2.28 FRONT SCUFF PLATE |
1485 |
|
9.2.29 “B" PILLAR TRIMS |
1485 |
|
9.2.30 “C” PILLAR TRIM |
1486 |
|
9.2.31 GRAB HANDLES |
1487 |
|
9.2.32 SUNVISOR |
1488 |
|
9.2.33 ROOF LINER |
1488 |
|
9.2.34 PLENUM COVER |
1489 |
|
9.2.35 GEAR LEVER BOOT |
1490 |
|
9.2.36 BONNET INSULATION |
1490 |
|
9.2.37 GLASS |
1491 |
|
9.2.38 FUEL FILLER ASSEMBLY |
1492 |
|
9.2.39 FRONT WHEEL ARCH LINER |
1494 |
|
9.2.40 REAR WHEEL ARCH LINER |
1495 |
|
9.2.41 FRONT FENDER |
1496 |
|
9.2.42 REAR WIPER MOTOR |
1498 |
|
9.2.43 FRONT WIPER |
1499 |
|
10. HVAC |
1500 |
|
10.1 GENERAL INFORMATION |
1503 |
|
10.1.1. SPECIFICATIONS |
1503 |
|
10.1.2. TIGHTENING TORQUES |
1505 |
|
10.1.3. PRECAUTIONS |
1513 |
|
10.1.4. HVAC SYSTEM LAYOUT & WORKING |
1515 |
|
10.1.5. COMPONENTS OF HVAC |
1517 |
|
10.1.5.1. CONTROL PANEL |
1517 |
|
10.1.5.2. HVAC UNIT |
1520 |
|
10.1.5.3. COMPRESSOR |
1523 |
|
10.1.5.4. CONDENSOR & RECEIVER DRIER |
1524 |
|
10.1.5.5. THERMISTOR / THERMO SENSOR |
1525 |
|
10.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR |
1527 |
|
10.1.5.7. AIR INLET ACTUATOR |
1528 |
|
10.1.6. TROUBLESHOOTING |
1529 |
|
10.2 MAINTAINANCE |
1543 |
|
10.2.1. PRELIMINARY INSPECTION |
1543 |
|
10.2.2. REGULAR MAINTENANCE |
1545 |
|
10.3 ON VEHICLE REPAIR |
1549 |
|
10.3.1. CONTROL PANEL ASSEMBLY |
1549 |
|
10.3.2. COMPRESSOR |
1554 |
|
10.3.3. BLOWER |
1554 |
|
10.3.4. BLOWER RESISTER |
1555 |
|
10.3.5. FILTER |
1555 |
|
10.3.6. TXV |
1556 |
|
10.3.7. PRESSURE SENSOR / SWITCH |
1556 |
|
10.3.8. HVAC UNIT |
1557 |
|
10.3.9. CONDENSOR SEALING DUCT |
1557 |
|
10.3.10. CONDENSOR |
1558 |
|
10.3.11. REFRIGERANT HOSES |
1559 |
|
10.3.12. DO'S & DON’TS |
1561 |
|
10.4 OVERHAULING HVAC UNIT |
1562 |
|
11. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) |
1569 |
|
11.1.1 TIGHTENING TORQUES |
1572 |
|
11.1.2 WORKING OF RESTRAINTS |
1574 |
|
A. RESTRAINTSWITHOUT AIRBAGS |
1574 |
|
B. RESTRAINTSWITH AIRBAGS |
1574 |
|
11.1.3 SYSTEM LAYOUT |
1575 |
|
11.1.3.1 RESTRAINTWITHOUT AIRBAG |
1575 |
|
11.1.3.2 RESTRAINTWITH AIRBAG |
1575 |
|
11.1.4 SAFETY PRECAUTIONS |
1576 |
|
11.1.5 DISPOSAL OF FAULTY AIR BAG UNIT |
1578 |
|
11.1.6 COMPONENTS |
1579 |
|
11.1.6.1 RESTRAINT WITHOUT AIRBAGS |
1579 |
|
A. SEAT BELT |
1579 |
|
B. EMERGENCY LOCKING RETRACTOR (ELR) |
1579 |
|
C. MICROSWITCH / SEAT BELT REMINDERWARNING LAMP |
1579 |
|
11.1.6.2 RESTRAINT WITH AIRBAGS |
1580 |
|
A. ECU |
1580 |
|
B. SENSORS |
1584 |
|
C. AIR BAGS |
1585 |
|
D. RPLL BELTS |
1588 |
|
E. CLOCK SPRING |
1590 |
|
12.1.7. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT |
1593 |