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1. GENERAL 		3
1.1. VEHICLE SPECIFICATION 		8
1.2. VEHICLE DIMENSIONS 		11
1.3. RECOMMENDATIONS 		12
1.3.1. REPAIRS AND REPLACEMENT 		12
1.4. GENERAL INFORMATION 		14
1.4.1. ABBREVIATIONS USED IN THIS MANUAL 		14
1.4.2. VEHICLE IDENTIFICATION NUMBER (VIN) 		14
1.5. VEHICLE JACKING AND LIFTING POINTS 		15
1.6. SPARE WHEEL REPLACEMENT 		16
1.7. EMERGENCY TOWING INFORMATION 		16
1.8. JUMP STARTING 		17
1.9. SERVICE AND MAINTENANCE SCHEDULE 		18
1.10. LUBRICANTS, FLUIDS AND CAPACITIES 		25
1.10.1. LUBRICANTS 		25
1.10.2. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 		25
1.10.3. RECOMMENDED FUEL 		27
1.11. GENERAL FITTING REMINDERS 		27
1.11.1. WORKSHOP SAFETY 		27
1.11.2. PREPARATION 		27
1.11.3. DISMANTLING 		27
1.11.4. GENERAL INSPECTION 		28
1.11.5. JOINTS AND JOINT FACES 		28
1.11.6. FLEXIBLE HYDRAULIC PIPES, HOSES 		28
2. ENGINE 320Nm 		29
2.1. GENERAL INFORMATION 		37
2.1.1. ENGINE INTRODUCTION 		37
2.1.2. TECHNICAL SPECIFICATION 		38
2.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 		39
2.1.4. SERVICE SCHEDULE 		40
2.1.5. ASSEMBLY CLEARANCES 		42
2.1.6. SPECIAL TOOLS 		43
2.2. GENERAL SYMPTOMS DIAGNOSIS 		44
2.3. CONSTRUCTIONAL AND SERVICE DETAILS 		47
2.3.1. ENGINE MOUNTING COMPONENTS 		47
2.3.2. CYLINDER HEAD AND COVER 		49
2.3.3. LUBRICATION SYSTEM COMPONENTS 		51
2.3.4. ENGINE 		53
2.3.5. OIL SUMP 		55
2.3.6. CYLINDER HEAD 		57
2.3.7. SPECIAL INSTALLATION 		59
2.3.8. EXHAUST SYSTEM COMPONENTS 		61
2.3.9. INTAKE SYSTEM COMPONENTS 		63
2.3.10. ENGINE SUSPENSION 		65
2.3.11. MOVING PARTS 		67
2.3.12. ENGINE TIMING 		69
2.3.13. FUEL INJECTION EQUIPMENT 		71
2.4. ENGINE TESTS AND MAINTENANCE 		73
2.4.1. PRELIMINARY INSPECTION 		73
2.4.2. ENGINE TESTS 		73
2.4.3. REGULAR MAINTENANCE 		76
2.4.3.1. ENGINE OIL REPLACEMENT 		76
2.4.3.2. OIL FILTER REPLACEMENT 		76
2.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		77
2.4.3.4. MAIN FUEL FILTER REPLACEMENT 		77
2.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR 		78
2.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT 		79
2.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT 		80
2.4.3.8. COOLANT REPLACEMENT 		84
2.5. REPAIR AND INSPECTION DETAILS 		85
2.5.1. TIMING BELT 		85
2.5.2. FUEL TANK 		85
2.5.3. CYLINDER HEAD 		86
2.5.4. VALVES 		87
2.5.5. VALVE SEATS 		88
2.5.6. CRANKCASE 		89
2.5.7. VALVE SEAT INSERT 		90
2.5.8. HYDRAULIC LASH ADJUSTER 		90
2.5.9. CYLINDER HEAD COVER 		90
2.5.10. VALVE GUIDES 		91
2.5.11. CAMSHAFT 		92
2.5.12. PISTON AND PISTON RINGS 		93
2.5.13. CONNECTING ROD 		94
2.5.14. CRANKSHAFT 		96
2.6. ENGINE SYSTEM 		98
2.6.1. AIR INTAKE SYSTEM 		98
2.6.2. BLOW BY SYSTEM 		100
2.6.3. VACUUM MANAGEMENT SYSTEM 		101
2.6.4. COOLING SYSTEM 		103
2.6.5. LUBRICATION SYSTEM 		106
2.6.6. FUEL SYSTEM 		110
2.6.7. EXHAUST SYSTEM 		119
2.6.8. EXHAUST GAS RECIRCULATION SYSTEM 		122
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE 		124
2.7.1. ENGINE REMOVAL 		124
2.7.2. AIR FILTER ASSEMBLY REMOVAL 		126
2.7.3. POWER STEERING PUMP BELT (STRETCH BELT) 		126
2.7.4. ALTERNATOR AND AC BELT 		127
2.7.5. INJECTOR REMOVAL 		128
2.7.6. TIMING BELT REMOVAL 		129
2.7.7. FITMENT OF TIMING BELT 		131
2.7.8. INTERCOOLER REMOVAL 		134
2.7.9. RADIATOR REMOVAL 		135
2.7.10. COOLANT TANK REMOVAL 		137
2.7.11. RADIATOR FAN SHROUD REMOVAL 		138
2.7.12. THERMOSTAT REMOVAL 		138
2.7.13. FUEL RAIL REMOVAL 		139
2.7.14. FUEL FILLER ASSEMBLY REMOVAL 		140
2.7.15. FUEL TANK 		141
2.7.16. TANK UNIT REMOVAL 		142
2.7.17. FUEL LEVEL SENSOR REMOVAL 		144
2.7.18. TANK PRESSURE VALVE REMOVAL 		145
2.7.19. FUEL TANK PURGING PROCEDURE 		146
2.7.20. POST SILENCER AND INTERMEDIATE PIPE 		147
2.7.21. PRE-SILENCER AND MAIN SILENCER 		147
2.7.22. FRONT EXHAUST PIPE 		148
2.7.23. CLOSE COUPLED CATALYTIC CONVERTER 		148
2.7.24. EGR COOLER MODULE 		149
2.7.25. TURBOCHARGER 		151
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 		154
2.8.1. ENGINE DIS-ASSEMBLY 		155
2.8.1.1. REMOVAL OF INTAKE MANIFOLD 		155
2.8.1.2. REMOVAL OF EXHAUST MANIFOLD 		160
2.8.1.3. REMOVAL OF OIL SUMP 		163
2.8.1.4. REMOVAL OF TIMING BELT 		164
2.8.1.5. REMOVAL OF CYLINDER HEAD 		166
2.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 		168
2.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 		171
2.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY 		172
2.8.2. ENGINE ASSEMBLY 		179
2.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 		179
2.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 		180
2.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 		181
2.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 		182
2.8.2.5. FITMENT OFTIMING BELT 		183
2.8.2.6. FITMENT OF OIL SUMP 		185
2.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 		186
2.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 		189
2.8.2.9. ON ENGINE SUPPORT STAND 		194
2.9. ENGINE MANAGEMENT SYSTEM (EMS) 		196
2.9.1. SYSTEM OVERVIEW 		197
2.9.2. BLOCK DIAGRAM 		198
2.9.3. CONNECTOR PIN ASSIGNMENT 		199
2.9.4. ANTI-CRANKING FUNCTION 		204
2.9.5. SENSORS AND ACTUATORS DETAILS 		205
2.9.5.1. CRANK ANGLE SENSOR 		205
2.9.5.2. CAM SENSOR 		206
2.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 		208
2.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 		209
2.9.5.5. COOLANT TEMPERATURE SENSOR 		211
2.9.5.6. FUEL TEMPERATURE SENSOR (FTS) 		212
2.9.5.7. INLET METERING VALVE (IMV) 		213
2.9.5.8. VENTURI 		213
2.9.5.9. RAIL PRESSURE SENSOR 		213
2.9.5.10. WATER IN FUEL SENSOR 		214
2.9.5.11. ACCELERATOR PEDAL SENSOR 		215
2.9.5.12. BRAKE SWITCH 		216
2.9.5.13. CLUTCH SWITCH 		218
2.9.5.14. GLOW PLUGS 		219
2.9.5.15. VTT ACTUATOR 		220
2.9.5.16. EGR VALVE ACTUATOR 		222
2.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 		224
2.9.5.18. INTAKE THROTTLE VALVE 		225
2.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 		226
3. ENGINE - 400Nm AUTOMATIC TRANSMISSION 		227
3.1. GENERAL INFORMATION 		235
3.1.1. ENGINE INTRODUCTION 		235
3.1.2. TECHNICAL SPECIFICATION 		236
3.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 		237
3.1.4. SERVICE SCHEDULE 		238
3.1.5. ASSEMBLY CLEARANCES 		240
3.1.6. SPECIAL TOOLS 		241
3.2. GENERAL SYMPTOMS DIAGNOSIS 		242
3.3. CONSTRUCTIONAL AND SERVICE DETAILS 		245
3.3.1. ENGINE MOUNTING COMPONENTS 		245
3.3.2. CYLINDER HEAD AND COVER 		247
3.3.3. LUBRICATION SYSTEM COMPONENTS 		249
3.3.4. ENGINE 		251
3.3.5. OIL SUMP 		253
3.3.6. CYLINDER HEAD 		255
3.3.7. SPECIAL INSTALLATION 		257
3.3.8. EXHAUST SYSTEM COMPONENTS 		259
3.3.9. INTAKE SYSTEM COMPONENTS 		261
3.3.10. ENGINE SUSPENSION 		263
3.3.11. MOVING PARTS 		265
3.3.12. ENGINE TIMING 		267
3.3.13. FUEL INJECTION EQUIPMENT 		269
3.4. ENGINE TESTS AND MAINTENANCE 		271
3.4.1. PRELIMINARY INSPECTION 		271
3.4.2. ENGINE TESTS 		271
3.4.3. REGULAR MAINTENANCE 		274
3.4.3.1. ENGINE OIL REPLACEMENT 		274
3.4.3.2. OIL FILTER REPLACEMENT 		274
3.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		275
3.4.3.4. MAIN FUEL FILTER REPLACEMENT 		275
3.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR 		276
3.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT 		277
3.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT 		278
3.4.3.8. COOLANT REPLACEMENT 		282
3.5. REPAIR AND INSPECTION DETAILS 		283
3.5.1. TIMING BELT 		283
3.5.2. FUEL TANK 		283
3.5.3. CYLINDER HEAD 		284
3.5.4. VALVES 		285
3.5.5. VALVE SEATS 		286
3.5.6. CRANKCASE 		287
3.5.7. VALVE SEAT INSERT 		288
3.5.8. HYDRAULIC LASH ADJUSTER 		288
3.5.9. CYLINDER HEAD COVER 		288
3.5.10. VALVE GUIDES 		289
3.5.11. CAMSHAFT 		290
3.5.12. PISTON AND PISTON RINGS 		291
3.5.13. CONNECTING ROD 		292
3.5.14. CRANKSHAFT 		294
3.6. ENGINE SYSTEM 		296
3.6.1. AIR INTAKE SYSTEM 		296
3.6.2. BLOW BY SYSTEM 		298
3.6.3. VACUUM MANAGEMENT SYSTEM 		299
3.6.4. COOLING SYSTEM 		301
3.6.5. LUBRICATION SYSTEM 		304
3.6.6. FUEL SYSTEM 		308
3.6.7. EXHAUST SYSTEM 		317
3.6.8. EXHAUST GAS RECIRCULATION SYSTEM 		320
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE 		322
3.7.1. ENGINE REMOVAL 		322
3.7.2. AIR FILTER ASSEMBLY REMOVAL 		324
3.7.3. POWER STEERING PUMP BELT (STRETCH BELT) 		324
3.7.4. ALTERNATOR AND AC BELT 		325
3.7.5. INJECTOR REMOVAL 		326
3.7.6. TIMING BELT REMOVAL 		327
3.7.7. FITMENT OF TIMING BELT 		329
3.7.8. INTERCOOLER REMOVAL 		332
3.7.9. RADIATOR REMOVAL 		333
3.7.10. COOLANT TANK REMOVAL 		335
3.7.11. RADIATOR FAN SHROUD REMOVAL 		336
3.7.12. THERMOSTAT REMOVAL 		336
3.7.13. FUEL RAIL REMOVAL 		337
3.7.14. FUEL FILLER ASSEMBLY REMOVAL 		338
3.7.15. FUEL TANK 		339
3.7.16. TANK UNIT REMOVAL 		340
3.7.17. FUEL LEVEL SENSOR REMOVAL 		342
3.7.18. TANK PRESSURE VALVE REMOVAL 		343
3.7.19. FUEL TANK PURGING PROCEDURE 		344
3.7.20. POST SILENCER AND INTERMEDIATE PIPE 		345
3.7.21. PRE-SILENCER AND MAIN SILENCER 		345
3.7.22. FRONT EXHAUST PIPE 		346
3.7.23. CLOSE COUPLED CATALYTIC CONVERTER 		346
3.7.24. EGR COOLER MODULE 		347
3.7.25. TURBOCHARGER 		349
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 		352
3.8.1. ENGINE DIS-ASSEMBLY 		353
3.8.1.1. REMOVAL OF INTAKE MANIFOLD 		353
3.8.1.2. REMOVAL OF EXHAUST MANIFOLD 		358
3.8.1.3. REMOVAL OF OIL SUMP 		361
3.8.1.4. REMOVAL OF TIMING BELT 		362
3.8.1.5. REMOVAL OF CYLINDER HEAD 		364
3.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 		366
3.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 		369
3.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY 		370
3.8.2. ENGINE ASSEMBLY 		377
3.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 		377
3.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 		378
3.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 		379
3.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 		380
3.8.2.5. FITMENT OF TIMING BELT 		381
3.8.2.6. FITMENT OF OIL SUMP 		383
3.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 		384
3.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 		387
3.8.2.9. ON ENGINE SUPPORT STAND 		392
3.9. ENGINE MANAGEMENT SYSTEM (EMS) 		394
3.9.1. SYSTEM OVERVIEW 		395
3.9.2. BLOCK DIAGRAM 		396
3.9.3. CONNECTOR PIN ASSIGNMENT 		397
3.9.4. ANTI-CRANKING FUNCTION 		402
3.9.5. SENSORS AND ACTUATORS DETAILS 		403
3.9.5.1. CRANK ANGLE SENSOR 		403
3.9.5.2. CAM SENSOR 		404
3.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 		406
3.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 		407
3.9.5.5. COOLANT TEMPERATURE SENSOR 		409
3.9.5.6. FUEL TEMPERATURE SENSOR (FTS) 		410
3.9.5.7. INLET METERING VALVE (IMV) 		411
3.9.5.8. VENTURI 		411
3.9.5.9. RAIL PRESSURE SENSOR 		411
3.9.5.10. WATER IN FUEL SENSOR 		412
3.9.5.11. ACCELERATOR PEDAL SENSOR 		413
3.9.5.12. BRAKE SWITCH 		414
3.9.5.13. CLUTCH SWITCH 		416
3.9.5.14. GLOW PLUGS 		417
3.9.5.15. VTT ACTUATOR 		418
3.9.5.16. EGR VALVE ACTUATOR 		420
3.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 		422
3.9.5.18. INTAKE THROTTLE VALVE 		423
3.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 		424
4. ENGINE - 400Nm MANUAL TRANSMISSION 		425
4.1. GENERAL INFORMATION 		433
4.1.1. ENGINE INTRODUCTION 		433
4.1.2. TECHNICAL SPECIFICATION 		434
4.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 		435
4.1.4. SERVICE SCHEDULE 		436
4.1.5. ASSEMBLY CLEARANCES 		438
4.1.6. SPECIAL TOOLS 		439
4.2. GENERAL SYMPTOMS DIAGNOSIS 		440
4.3. CONSTRUCTIONAL AND SERVICE DETAILS 		443
4.3.1. ENGINE MOUNTING COMPONENTS 		443
4.3.2. CYLINDER HEAD AND COVER 		445
4.3.3. LUBRICATION SYSTEM COMPONENTS 		447
4.3.4. ENGINE 		449
4.3.5. OIL SUMP 		451
4.3.6. CYLINDER HEAD 		453
4.3.7. SPECIAL INSTALLATION 		455
4.3.8. EXHAUST SYSTEM COMPONENTS 		457
4.3.9. INTAKE SYSTEM COMPONENTS 		459
4.3.10. ENGINE SUSPENSION 		461
4.3.11. MOVING PARTS 		463
4.3.12. ENGINE TIMING 		465
4.3.13. FUEL INJECTION EQUIPMENT 		467
4.4. ENGINE TESTS AND MAINTENANCE 		469
4.4.1. PRELIMINARY INSPECTION 		469
4.4.2. ENGINE TESTS 		469
4.4.3. REGULAR MAINTENANCE 		472
4.4.3.1. ENGINE OIL REPLACEMENT 		472
4.4.3.2. OIL FILTER REPLACEMENT 		472
4.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT 		473
4.4.3.4. MAIN FUEL FILTER REPLACEMENT 		473
4.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR 		474
4.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT 		475
4.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT 		476
4.4.3.8. COOLANT REPLACEMENT 		480
4.5. REPAIR AND INSPECTION DETAILS 		481
4.5.1. TIMING BELT 		481
4.5.2. FUEL TANK 		481
4.5.3. CYLINDER HEAD 		482
4.5.4. VALVES 		483
4.5.5. VALVE SEATS 		484
4.5.6. CRANKCASE 		485
4.5.7. VALVE SEAT INSERT 		486
4.5.8. HYDRAULIC LASH ADJUSTER 		486
4.5.9. CYLINDER HEAD COVER 		486
4.5.10. VALVE GUIDES 		487
4.5.11. CAMSHAFT 		488
4.5.12. PISTON AND PISTON RINGS 		489
4.5.13. CONNECTING ROD 		490
4.5.14. CRANKSHAFT 		492
4.6. ENGINE SYSTEM 		494
4.6.1. AIR INTAKE SYSTEM 		494
4.6.2. BLOW BY SYSTEM 		496
4.6.3. VACUUM MANAGEMENT SYSTEM 		497
4.6.4. COOLING SYSTEM 		499
4.6.5. LUBRICATION SYSTEM 		502
4.6.6. FUEL SYSTEM 		506
4.6.7. EXHAUST SYSTEM 		515
4.6.8. EXHAUST GAS RECIRCULATION SYSTEM 		518
4.7. ENGINE ON VEHICLE SERVICE PROCEDURE 		520
4.7.1. ENGINE REMOVAL 		520
4.7.2. AIR FILTER ASSEMBLY REMOVAL 		522
4.7.3. POWER STEERING PUMP BELT (STRETCH BELT) 		522
4.7.4. ALTERNATOR AND AC BELT 		523
4.7.5. INJECTOR REMOVAL 		524
4.7.6. TIMING BELT REMOVAL 		525
4.7.7. FITMENT OF TIMING BELT 		527
4.7.8. INTERCOOLER REMOVAL 		530
4.7.9. RADIATOR REMOVAL 		531
4.7.10. COOLANT TANK REMOVAL 		533
4.7.11. RADIATOR FAN SHROUD REMOVAL 		534
4.7.12. THERMOSTAT REMOVAL 		534
4.7.13. FUEL RAIL REMOVAL 		535
4.7.14. FUEL FILLER ASSEMBLY REMOVAL 		536
4.7.15. FUEL TANK 		537
4.7.16. TANK UNIT REMOVAL 		538
4.7.17. FUEL LEVEL SENSOR REMOVAL 		540
4.7.18. TANK PRESSURE VALVE REMOVAL 		541
4.7.19. FUEL TANK PURGING PROCEDURE 		542
4.7.20. POST SILENCER AND INTERMEDIATE PIPE 		543
4.7.21. PRE-SILENCER AND MAIN SILENCER 		543
4.7.22. FRONT EXHAUST PIPE 		544
4.7.23. CLOSE COUPLED CATALYTIC CONVERTER 		544
4.7.24. EGR COOLER MODULE 		545
4.7.25. TURBOCHARGER 		547
4.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 		550
4.8.1. ENGINE DIS-ASSEMBLY 		551
4.8.1.1. REMOVAL OF INTAKE MANIFOLD 		551
4.8.1.2. REMOVAL OF EXHAUST MANIFOLD 		556
4.8.1.3. REMOVAL OF OIL SUMP 		559
4.8.1.4. REMOVAL OF TIMING BELT 		560
4.8.1.5. REMOVAL OF CYLINDER HEAD 		562
4.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 		564
4.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 		567
4.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY 		568
4.8.2. ENGINE ASSEMBLY 		575
4.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 		575
4.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 		576
4.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 		577
4.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 		578
4.8.2.5. FITMENT OFTIMING BELT 		579
4.8.2.6. FITMENT OF OIL SUMP 		581
4.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 		582
4.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 		585
4.8.2.9. ON ENGINE SUPPORT STAND 		590
4.9. ENGINE MANAGEMENT SYSTEM (EMS) 		592
4.9.1. SYSTEM OVERVIEW 		593
4.9.2. BLOCK DIAGRAM 		594
4.9.3. CONNECTOR PIN ASSIGNMENT 		595
4.9.4. ANTI-CRANKING FUNCTION 		600
4.9.5. SENSORS AND ACTUATORS DETAILS 		601
4.9.5.1. CRANK ANGLE SENSOR 		601
4.9.5.2. CAM SENSOR 		602
4.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 		604
4.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 		605
4.9.5.5. COOLANT TEMPERATURE SENSOR 		607
4.9.5.6. FUEL TEMPERATURE SENSOR (FTS) 		608
4.9.5.7. INLET METERING VALVE (IMV) 		609
4.9.5.8. VENTURI 		609
4.9.5.9. RAIL PRESSURE SENSOR 		609
4.9.5.10. WATER IN FUEL SENSOR 		610
4.9.5.11. ACCELERATOR PEDAL SENSOR 		611
4.9.5.12. BRAKE SWITCH 		612
4.9.5.13. CLUTCH SWITCH 		614
4.9.5.14. GLOW PLUGS 		615
4.9.5.15. VTT ACTUATOR 		616
4.9.5.16. EGR VALVE ACTUATOR 		618
4.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 		620
4.9.5.18. INTAKE THROTTLE VALVE 		621
4.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 		622
5. CLUTCH - 320Nm 		623
5.1. GENERAL INFORMATION 		629
5.1.1. SPECIFICATIONS 		629
5.1.1.1. CLUTCH DISC ASSEMBLY 		629
5.1.1.2. SELF ADJUSTING CLUTCH COVER ASSEMBLY 		630
5.1.1.3. SINGLE MASS FLYWHEEL 		631
5.1.2. CLUTCH SYSTEM LAYOUT 		632
5.1.2.1. CLUTCH MASTER CYLINDER 		633
5.1.2.2. CONCENTRIC SLAVE CYLINDER 		633
5.1.2.3. PEAK TORQUE LIMITER 		633
5.1.2.4. HYDRAULIC ADAPTER 		634
5.1.2.5. SINGLE MASS FLYWHEEL 		634
5.1.2.6. SELF ADJUSTING CLUTCH 		634
5.1.3. TIGHTENING TORQUES 		635
5.1.4. SPECIAL TOOLS 		639
5.1.5. GENERAL SYMPTOMS DIAGNOSIS 		640
5.2. MAINTENANCE, INSPECTION AND TESTS 		642
5.2.1. PRELIMINARY INSPECTION 		642
5.2.2. REGULAR MAINTENANCE 		643
5.2.2.1. CLUTCH SWITCH ADJUSTMENT 		643
5.2.2.2. CLUTCH BLEEDING PROCEDURE 		643
5.2.2.3. CLUTCH FLUID DRAINING PROCEDURE 		644
5.2.3. REPAIRS 		645
5.2.3.1. CLUTCH PEDAL ASSEMBLY 		645
5.2.3.2. SELF ADJUSTING CLUTCH ASSEMBLY 		650
5.2.3.3. CLUTCH HYDRAULIC SYSTEM COMPONENTS 		655
5.2.3.4. SINGLE MASS FLYWHEEL (ON VEHICLE) 		660
6. CLUTCH - 400Nm 		661
6.1. GENERAL INFORMATION 		667
6.1.1. SPECIFICATIONS 		667
6.1.1.1. CLUTCH DISC ASSEMBLY 		667
6.1.1.2. SELF ADJUSTING CLUTCH COVER ASSEMBLY 		668
6.1.1.3. SINGLE MASS FLYWHEEL 		669
6.1.2. CLUTCH SYSTEM LAYOUT 		670
6.1.2.1. CLUTCH MASTER CYLINDER 		671
6.1.2.2. CONCENTRIC SLAVE CYLINDER 		671
6.1.2.3. PEAK TORQUE LIMITER 		671
6.1.2.4. HYDRAULIC ADAPTER 		672
6.1.2.5. SINGLE MASS FLYWHEEL 		672
6.1.2.6. SELF ADJUSTING CLUTCH 		672
6.1.3. TIGHTENING TORQUES 		673
6.1.4. SPECIAL TOOLS 		677
6.1.5. GENERAL SYMPTOMS DIAGNOSIS 		678
6.2. MAINTENANCE, INSPECTION AND TESTS 		680
6.2.1. PRELIMINARY INSPECTION 		680
6.2.2. REGULAR MAINTENANCE 		681
6.2.2.1. CLUTCH SWITCH ADJUSTMENT 		681
6.2.2.2. CLUTCH BLEEDING PROCEDURE 		681
6.2.2.3. CLUTCH FLUID DRAINING PROCEDURE 		682
6.2.3. REPAIRS 		683
6.2.3.1. CLUTCH PEDAL ASSEMBLY 		683
6.2.3.2. SELF ADJUSTING CLUTCH ASSEMBLY 		688
6.2.3.3. CLUTCH HYDRAULIC SYSTEM COMPONENTS 		693
6.2.3.4. SINGLE MASS FLYWHEEL (ON VEHICLE) 		698
7. GEAR BOX GBS-76 		699
7.1. GENERAL INFORMATION 		706
7.1.1. SPECIFICATIONS 		706
7.1.2. TIGHTENING TORQUES 		707
7.1.3. SPECIAL TOOLS 		711
7.1.4. GENERAL SYMPTOMS DIAGNOSIS 		715
7.2. MAINTENANCE, INSPECTION AND TEST 		716
7.2.1. PRELIMINARY INSPECTION 		716
7.2.2. REGULAR MAINTENANCE 		716
7.2.3. ON VEHICLE PROCEDURES 		717
7.2.3.1. GEARBOX REMOVAL 		717
7.3. OVERHAULING 		719
7.3.1. INFORMATION FOR OVERHAULING 		719
7.3.1.1. COMPONENT INDENTIFICATION 		719
7.3.1.2. PRECAUTIONS 		722
7.3.1.3. CONSTRUCTIONAL DETAILS 		723
7.3.2. GEARBOX DISMANTLING (ON BENCH) 		726
7.3.3. DISMANTLING OF SUB-ASSEMBLIES 		733
7.3.3.1. MAIN SHAFT 		733
7.3.3.2. DRIVE SHAFT 		744
7.3.3.3. REVERSE IDLER SHAFT 		745
7.3.3.4. COUNTER SHAFT 		747
7.3.3.5. FRONT COVER 		750
7.3.3.6. TOP COVER 		751
7.3.3.7. REAR COVER (4X2) 		752
7.3.3.8. ADAPTOR (4X4) 		753
7.3.3.9. SHIFTER SHAFTS & FORKS 		754
7.3.3.10. NON-ADJUSTABLE SHIFTER LINKAGE 		756
7.3.4. GEAR BOX ASSEMBLY 		759
8. GEAR BOX G-6450 		768
8.1. GENERAL INFORMATION 		769
8.1.1. SPECIFICATIONS 		769
8.1.2. TIGHTENING TORQUE 		770
8.1.3. SPECIAL TOOLS 		775
8.1.4. GENERAL SYMPTOMS DIAGNOSIS 		779
8.2. MAINTENANCE, INSPECTION, AND TEST 		780
8.2.1. PRELIMINARY INSPECTION 		780
8.2.2. REGULAR MAINTENANCE 		780
8.2.3. ON VEHICLE PROCEDURE 		781
8.2.3.1. GEARBOX REMOVAL 		781
8.2.4. CONSTRUCTION OF GEAR BOX 		783
8.3. OVERHAULING 		785
8.3.1. INFORMATION FOR OVERHAULING 		785
8.3.1.1. COMPONENT INDENTIFICATION 		785
8.3.2. GEAR BOX DISMANTLING ON BENCH PROCEDURE 		788
8.3.3. INSPECTION 		798
8.3.4. GEAR BOX ASSEMBLY ON BENCH PROCEDURE 		800
9. AUTOMATIC TRANSMISSION 		816
9.1. TRANSMISSION BASE SPECIFICATION 		820
9.2. TRANSMISSION SYSTEM OVERVIEW 		821
9.3. EXPLANATION OF THE SELECTOR LEVER POSITIONS 		822
9.4. PRINCIPLE OF OPERATIONS 		824
9.5. EXPLODED VIEW OF TRANSMISSION 		831
9.6. MAINTENANCE AND SERVICE / FREQUENCY 		833
9.7. FLUID DRAIN AND OIL PAN REMOVING PROCEDURE 		834
9.8. OIL PAN INSTALLATION PROCEDURE 		835
9.9. TRANSMISSION FLUID FILL TUBE REMOVING AND INSTALLATION PROCEDURE 		835
9.10. TRANSMISSION FLUID LEVEL AFTER REPAIRS PROCEDURE 		836
9.11. TRANSMISSION FLUID LEVEL CHECKING PROCEDURE 		837
9.12. ESD (ELECTROSTATIC DISCHARGE) NOTICE 		838
9.13. REAR WHEEL DRIVE TRANSMISSION REMOVING PROCEDURE 		839
9.14. REAR WHEEL DRIVE TRANSMISSION INSTALLING PROCEDURE 		844
9.15. ALL-WHEEL DRIVE TRANSMISSION REMOVING PROCEDURE 		850
9.16. ALL-WHEEL DRIVE TRANSMISSION INSTALLING PROCEDURE 		857
9.17. TORQUE CONVERTER REMOVING PROCEDURE 		863
9.18. TORQUE CONVERTER INSTALLING PROCEDURE 		864
9.19. OIL FILTER-LIP SEAL REMOVING & INSTALLING PROCEDURE 		865
9.20. MECHATRONIC REMOVING PROCEDURE 		866
9.21. MECHATRONIC INSTALLING PROCEDURE 		868
9.22. SELECTOR SHAFT & LIP SEAL REMOVING PROCEDURE 		870
9.23. SELECTOR SHAFT & LIP SEAL INSTALLING PROCEDURE 		871
9.24. SHIFT LINKAGE ADJUSTMENT PROCEDURE 		872
9.25. TRANSMISSION AIR OIL COOLER REMOVAL WITHOUT HOSES AND TUBES 		874
9.26. TRANSMISSION WATER OIL COOLER REMOVAL PROCEDURE 		877
10. TORQUE ON DEMAND (TOD) 		879
10.1. GENERAL INFORMATION 		881
10.1.1. SPECIFICATIONS 		881
10.1.2. LAYOUT 		882
10.2. COMPONENTS OF TOD 		883
10.2.1. ECU 		883
10.2.1.1. GENERAL 		883
10.2.1.2. LOCATION 		883
10.2.1.3. ECU INPUT/ OUTPUT BLOCK DIAGRAM 		884
10.2.1.4. PINOUT 		885
10.2.2. MOMENTARY SWITCH 		886
10.2.3. WARNING LAMP 		886
10.2.4. CLUTCH COIL 		887
10.3. WORKING OF TOD 		887
10.4. TIGHTENING TORQUES 		892
10.5. SPECIAL TOOLS 		894
10.6. GENERAL SYMPTOMS AND DIAGNOSIS 		897
10.7. MAINTENANCE 		898
10.8. ON VEHICLE REPAIRS 		899
10.8.1. TRANSFER CASE 		899
10.8.2. TOD ELECTRONIC CONTROL UNIT (ECU) 		900
10.9. OVERHAULING 		901
10.9.1. DISMANTLING 		901
10.9.1.1. REAR YOKE 		901
10.9.1.2. REAR COVER ASSEMBLY 		901
10.9.1.3. CLUTCH PACK ASSEMBLY 		903
10.9.1.4. CHAIN DRIVE 		905
10.9.1.5. GEROTOR PUMP 		906
10.9.1.6. FRONT OUTPUT SHAFT AND YOKE 		908
10.9.1.7. ADAPTER, INPUT SHAFT AND CARRIER ASSEMBLY 		909
10.10. INSPECTION AND CLEANING 		910
10.10.1. ASSEMBLY 		910
10.10.1.1. ADAPTER AND INPUT SHAFT 		910
10.10.1.2. FRONT OUTPUT SHAggFT AND YOKE 		911
10.10.1.3. ASSEMBLY OF OUTPUT SHAFT AND GEROTOR PUMP 		912
10.10.1.4. CHAIN DRIVE 		914
10.10.1.5. CLUTCH PACK 		915
10.10.1.6. COVER ASSEMBLY 		919
10.10.1.7. REAR OUTPUT YOKE 		921
11. FRONT SUSPENSION 		922
11.1. GENERAL INFORMATION 		928
11.1.1. SPECIFICATIONS 		928
11.1.2. CONSTRUCTION 		929
11.1.3. TIGHTENING TORQUES 		930
11.1.4. SPECIAL TOOLS 		935
11.2. GENERAL SYMPTOMS AND DIAGNOSIS 		939
11.3. MAINTENANCE 		940
11.3.1. PRELIMINARY INSPECTION 		940
11.3.2. REGULAR MAINTENANCE 		940
11.4. ON VEHICLE REPAIRS 		942
11.4.1. ANTI ROLL BAR (ARB) REMOVAL 		942
11.4.2. FRONT STRUT ASSEMBLY REMOVAL 		943
11.4.3. LOWER WISHBONE REMOVAL 		944
11.4.4. UPPER WISHBONE REMOVAL 		945
11.4.5. BUMP STOPPER 		946
11.5. OVERHAULING 		947
11.5.1. PRECAUTIONS 		947
11.5.2. DISMANTLING, INSPECTION AND ASSEMBLY 		947
11.5.2.1. FRONT STRUT DISMANTLING./ DAMPER REPLACEMENT 		947
11.5.2.2. FRONT DAMPER BOTTOM BUSH 		950
11.5.2.3. UPPER WISHBONE BUSH 		950
11.5.2.4. UPPER WISHBONE BALL JOINT 		952
11.5.2.5. LOWER WISHBONE BALL JOINT REMOVAL 		952
12. REAR SUSPENSION 		953
12.1. GENERAL INFORMATION 		957
12.1.1. SPECIFICATIONS 		957
12.1.2. CONSTRUCTION 		958
12.1.3. TIGHTENING TORQUES 		959
12.1.4. SPECIAL TOOLS 		962
12.2. MAINTENANCE 		966
12.2.1. ON VEHICLE REPAIRS 		966
12.2.1.1. ANTIROLL BAR 		966
12.2.1.2. REAR SUSPENSION LINKS TIGHTENING PROCEDURE 		967
12.2.1.3. UPPER LINK REMOVAL 		968
12.2.1.4. LOWER LINK REMOVAL 		968
12.2.1.5. PAN HARD ROD REMOVAL 		969
12.2.1.6. REAR SHOCK ABSORBER REMOVAL 		969
12.2.1.7. REAR COIL SPRING REMOVAL 		970
12.3. OVERHAULING 		971
12.3.1. PRECAUTIONS 		971
12.3.2. DISMANTLING, INSPECTION AND ASSEMBLY 		971
12.3.2.1. UPPER LINK BUSH REMOVAL 		971
12.3.2.2. LOWER LINK BUSH REMOVAL 		972
12.3.2.3. PAN HARD ROD BUSH REMOVAL 		973
12.3.2.4. SHOCK ABSORBER BOTTOM BUSH REMOVAL 		975
12.3.2.5. SHOCK ABSORBER TOP REPLACEMENT 		976
13. FRONT AXLE 4X2 		977
13.1. GENERAL INFORMATION 		983
13.1.1. TECHNICAL SPECIFICATION 		983
13.1.2. CONSTRUCTION AND LAYOUT 		983
13.1.3. TIGHTENING TORQUES 		984
13.1.4. SPECIAL TOOLS 		985
13.2. MAINTENANCE 		986
13.2.1. ON VEHICLE PROCEUDRE 		986
13.2.1.1. FRONT STUB AXLE ASSEMBLY 		986
13.2.1.2. HUB REPLACEMENT 		989
13.2.1.3. TONER RING REPLACEMENT 		991
14. FRONT AXLE 4X4 		993
14.1. GENERAL INFORMATION 		999
14.1.1. SPECIFICATION 		999
14.1.2. CONSTRUCTION 		1000
14.1.3. TIGHTENING TORQUES 		1001
14.1.4. SPECIAL TOOLS 		1005
14.2. GENERAL SYMPTOMS AND DIAGNOSIS 		1010
14.3. MAINTENANCE 		1011
14.3.1. PRELIMINARY INSPECTION 		1011
14.3.2. REGULAR MAINTENANCE 		1011
14.4. ON VEHICLE REPAIRS 		1012
14.4.1. FRONT AXLE ASSEMBLY 		1012
14.4.2. ELECTRICAL DISCONNECT ASSEMBLY 		1015
14.4.3. TONER RING 		1016
14.5. OVERHAULING 		1018
14.5.1. PRECAUTIONS 		1018
14.5.2. DISMANTLING INSPECTION AND ASSEMBLY 		1018
14.5.2.1. DIFFERENTIAL CASING 		1018
14.5.2.2. PINION POSITION SHIM SELECTION 		1023
14.5.2.3. WHEEL END ASSEMBLY 		1031
14.5.2.4. FRONT AXLE DISCONNECT (FAD) 		1035
14.5.2.5. CONSTANT VELOCITY SHAFT 		1040
15. REAR AXLE 		1044
15.1. GENERAL INFORMATION 		1050
15.1.1. SPECIFICATION 		1050
15.1.2. SYSTEM LAYOUT 		1051
15.1.3. TIGHTENING TORQUE 		1052
15.1.4. SPECIAL TOOLS 		1055
15.2. GENERAL SYMPTOMS AND DIAGNOSIS 		1059
15.3. MAINTENANCE 		1061
15.3.1. PRELIMINARY INSPECTION 		1061
15.3.2. REGULAR MAINTENANCE 		1061
15.4. ON VEHICLE REPAIRS 		1062
15.4.1. REAR AXLE 		1062
15.4.2. AXLE SHAFT 		1064
15.4.3. DIFFERENTIAL CASE 		1065
15.5. OVERHAULING 		1067
15.5.1. PRECAUTIONS 		1067
15.5.2. DISMANTLING INSPECTION AND ASSEMBLY 		1067
15.5.2.1. AXLE SHAFT 		1067
15.5.2.2. DIFFERENTIAL CASING 		1070
15.5.2.3. PINION POSITION SHIM SELECTION 		1077
15.5.2.4. DIFFERENTIAL SHIM SELECTION 		1080
15.5.2.5. LIMITED SLIP DIFFERENTIAL 		1085
16. WHEELS AND TYRES 		1090
16.1. GENERAL INFORMATION 		1093
16.1.1. SPECIFICATIONS 		1093
16.1.2. CONSTRUCTION 		1094
16.1.3. TIGHTENING TORQUES 		1096
16.2. GENERAL SYMPTOMS DIAGNOSIS 		1097
16.2.1. DIAGNOSIS CHART 		1097
16.2.2. TYRE WEAR PATTERN 		1100
16.2.3. WEAR CAUSES 		1102
16.2.4. TYRE VIBRATION DIAGNOSIS 		1104
16.3. MAINTENANCE, INSPECTION AND TESTS 		1105
16.3.1. PRELIMINARY INSPECTION 		1105
16.3.2. REGULAR MAINTENANCE 		1106
16.3.2.1. INFLATION 		1106
16.3.2.2. WHEEL BALANCING 		1106
16.3.2.3. TYRE ROTATION 		1107
16.3.2.4. WHEEL RUN OUT 		1108
16.3.2.5. DO'S AND DON’TS 		1109
16.4. WHEEL AND TYRE REPLACEMENT 		1110
16.4.1. PRECAUTIONS DURING TYRE REPLACEMENT 		1110
16.4.2. TYRE REPLACEMENT 		1111
16.4.3. WHEEL ASSEMBLY REPLACEMENT 		1111
17. PROPELLER SHAFT 		1112
17.1. GENERAL INFORMATION 		1118
17.1.1. ADJUSTMENT / REPAIR DATA 		1118
17.2. SYSTEM DESCRIPTION 		1119
17.2.1. FOR 4X2 DRIVE 		1119
17.2.2. FOR 4X4 DRIVE 		1120
17.3. TIGHTENING TORQUE 		1121
17.4. SPECIAL TOOLS 		1122
17.5. GENERAL SYMPTOMS DIAGNOSIS 		1123
17.6. MAINTENANCE, INSPECTION AND TESTS 		1124
17.7. REGULAR MAINTENANCET 		1124
17.8. ON VEHICLE REPAIRS 		1125
17.8.1. PROPELLER SHAFT 4X2 		1126
17.8.2. PROPELLER SHAFT 4X4 		1127
17.9. OVERHAULING 		1128
18. BRAKES 		1133
18.1. GENERAL INFORMATION 		1138
18.1.1. SPECIFICATIONS 		1138
18.1.2. SYSTEM SCHEMATICS 		1139
18.1.3. SYSTEM LAYOUT 		1140
18.1.4. TIGHTENING TORQUES 		1141
18.2. GENERAL SYMTOMS DIAGNOSIS 		1143
18.3. MAINTENANCE, INSPECTION AND TEST 		1144
18.3.1. PRELIMINARY INSPECTION 		1145
18.3.1.1. FRONT BRAKE AND REAR BRAKE 		1145
18.3.1.2. PARKING BRAKE 		1145
18.3.1.3. BRAKE HOSES AND LINES 		1145
18.3.1.4. ROAD TEST 		1145
18.3.2. REGULAR MAINTAENANCE 		1146
18.3.2.1. BRAKE BLEEDING PROCEDURE 		1146
18.3.2.2. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) 		1147
18.3.2.3. CALIPER PAD REPLACEMENT 		1152
18.3.2.4. PARKING BRAKE ADJUSTMENT 		1153
18.3.2.5. BRAKE FLUID DRAINING PROCEDURE 		1154
18.3.2.6. BRAKE LIGHT SWITCH ADJUSTMENT 		1155
18.3.2.7. BOOSTER FILTER REPLACEMENT 		1156
18.3.2.8. GREASING 		1157
18.3.2.9. DISC RUN-OUT MEASUREMENT PROCEDURE 		1158
18.3.3. ON VEHICLE REPAIRS 		1158
18.3.3.1. CALIPER ASSEMBLY WITH CARRIER 		1158
18.3.3.2. BRAKE DISC 		1159
18.3.3.3. PARKING BRAKE 		1162
18.3.3.4. BRAKE PEDAL 		1165
18.3.3.5. VACUUM TANK AND VACUUM LINES 		1168
18.3.3.6. BOOSTER ASSEMBLY 		1170
18.3.3.7. PARKING BRAKE (DRUM IN HAT) 		1174
18.4. OVERHAULING 		1176
18.4.1. PRECAUTIONS 		1176
18.4.2. DISMANTLING, INSPECTION AND ASSEMBLY 		1177
18.4.2.1. FRONT CALIPER ASSEMBLY 		1177
18.4.2.2. REAR CALIPER ASSEMBLY 		1181
19. ANTI-LOCK BRAKING SYSTEM (ABS) 		1185
19.1. GENERAL INFORMATION 		1191
19.1.1. NECCESITY OF ABS WITH EBD 		1191
19.1.2. TECHNICAL SPECIFICATIONS 		1192
19.1.3. TIGHTENING TORQUES 		1193
19.1.4. SCHEMATIC OF HYDRAULIC CIRCUIT 		1195
19.1.5. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 		1196
19.2. COMPONENTS 		1200
19.2.1. ABS ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 		1201
19.2.2. WHEEL SPEED SENSOR 		1204
19.2.3. ABS SYSTEM FAILURE WARNING LIGHT 		1205
19.3. REPAIRS 		1207
19.3.1. ABS ECU/HCU REMOVAL 		1207
19.3.2. FRONT WHEEL SPEED SENSOR 		1210
19.3.3. FRONT TONER RING 		1211
19.3.4. REAR WHEEL SPEED SENSOR 		1212
19.3.5. REAR TONER RING 		1213
19.4. TROUBLE SHOOTING AND DIAGNOSIS 		1214
19.4.1. ROAD TEST 		1214
19.4.2. TABLE OF ABS 8.1 - FALL-BACK LEVEL 		1214
19.5. ABS DIAGNOSTIC USER MANUAL 		1215
20. ELECTRONIC STABILITY PROGRAM (ESP) 		1228
20.1. GENERAL INFORMATION 		1234
20.1.1. NECESSITY OF ESP AND TCS 		1234
20.1.2. SPECIFICATIONS 		1235
20.1.3. TIGHTENING TORQUES 		1236
20.1.4. SYSTEM LAYOUT 		1237
20.2. WORKING OF ESP 		1238
20.3. COMPONENTS 		1240
20.3.1. ESP ECU AND HYDRAULIC UNIT 		1240
20.3.2. YAW RATE SENSOR (YRS) 		1242
20.3.3. STEERING ANGLE SENSOR (SAS) 		1243
20.3.4. ESP SYSTEM FAILURE WARNING LIGHT 		1244
20.4. ON VEHICLE REPAIRS 		1245
20.4.1. YAW RATE SENSOR REMOVAL 		1245
20.4.2. STEERING ANGLE SENSOR REMOVAL 		1246
20.4.3. STEERING ANGLE SENSOR CALIBRATION USING DIAGNOSTIC TOOL 		1248
20.5. TROUBLESHOOTING 		1256
21. STEERING 		1257
21.1. GENERAL INFORMATION 		1259
21.1.1. SPECIFICATIONS 		1259
21.1.2. SYSTEM LAYOUT 		1260
21.1.3. TIGHTENING TORQUES 		1261
21.1.4. SPECIAL TOOLS 		1265
21.2. GENERAL SYMPTOMS DIAGNOSIS 		1266
21.3. MAINTENANCE, INSPECTION AND TEST 		1273
21.3.1. PRELIMINARY INSPECTION 		1273
21.3.1.1. INSPECTION OF TYRE 		1273
21.3.1.2. STEERING WHEEL FREE PLAY 		1273
21.3.1.3. LEAKAGES IN THE HYDRAULIC SYSTEM 		1273
21.3.1.4. TEST DRIVE 		1273
21.3.1.5. ROAD TEST 		1273
21.3.2. REGULAR MAINTENANCE 		1274
21.3.2.1. POWER STEERING OIL REPLACEMENT 		1274
21.3.2.2. POWER STEERING RESERVOIR ASSY 		1275
21.3.2.3. HYDRAULIC SYSTEM AIR BLEEDING 		1276
21.3.2.4. TOE IN ADJSUTMENT 		1277
21.3.2.5. STEERING WHEEL ALIGNMENT/CENTRALISING 		1278
21.3.2.6. STEERING WHEEL PLAY 		1278
21.3.2.7. POWER STEERING OIL FLUSHING PROCEDURE 		1279
21.3.3. REPAIRS 		1280
21.3.3.1. STEERING WHEEL 		1280
21.3.3.2. STEERING COLUMN 		1283
21.3.3.3. STEERING RESERVOIR AND POWER STEERING PUMP 		1286
21.3.3.4. RACK AND PINION ASSEMBLY 		1288
21.4. OVERHAULING 		1289
21.4.1. PRECAUTIONS 		1289
21.4.2. RACK AND PINION ASSEMBLY 		1290
21.4.3. DISMANTLING, INSPECTION AND ASSEMBLY 		1291
21.4.3.1. OUTER BALL JOINT (OBJ) 		1291
21.4.3.2. BELLOW KIT 		1292
21.4.3.3. INNER BALL JOINT (IBJ) 		1293
21.4.3.4. FEED PIPE 		1294
21.4.3.5. DO’S & DON’TS 		1295
21.4.4. STEERING PUMP 		1298
21.4.4.1. PRESSURE PORT CONNECTOR 		1298
21.4.4.2. SUCTION PORT CONNETOR 		1300
22. ELECTRICAL 		1301
22.1. TECHNICAL SPECIFICATIONS 		1303
22.2. GENERAL ELECTRCIAL PRECAUTIONS 		1307
22.3. CHARGING & STARTING SYSTEM 		1310
22.3.1. BATTERY 		1310
22.3.2. ALTERNATOR 		1320
22.3.3. STARTER MOTOR 		1337
22.4. LIGHTING SYSTEM 		1354
22.4.1. BULB SPECIFICATIONS 		1354
22.4.2. TORQUE VALUE TABLE 		1355
22.4.3. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS 		1356
22.4.4. HEAD LAMP 		1360
22.4.5. FRONT FOG LAMP WITH DRL 		1365
22.4.6. FIRST and SECOND ROOF LAMP 		1366
22.4.7. THIRD ROOF LAMP 		1367
22.4.8. REGISTRATION PLATE LAMP 		1368
22.4.9. HIGH MOUNTED STOP LAMP 		1368
22.4.10. DOOR AJAR CUM PUDDLE LAMP 		1369
22.4.11. GLOVE BOX LAMP 		1370
22.4.12. LOAD AREA LAMP 		1371
22.4.13. TAIL LAMP 		1371
22.4.14. SUNVISOR MIRROR LAMP 		1374
22.4.15. MOOD LAMP 		1374
22.5. HORN 		1375
22.6. POWER SOCKET 		1380
22.7. WIPER AND WASHER SYSTEM 		1383
22.7.1. FRONT AND REAR WIPER AND WASHER SYSTEM COMPONENT LOCATIONS 		1383
22.7.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 		1385
22.7.3. FRONT WIPER MOTOR 		1386
22.7.4. FRONT WIPER ARM AND BLADE 		1388
22.7.5. REAR WIPER ARM AND BLADE 		1390
22.7.6. REAR WIPER MOTOR 		1392
22.7.7. WIPER CARE 		1394
22.7.8. WASHER BOTTLE 		1395
22.7.9. WASHER PUMP 		1397
22.7.10. FRONT WASHER NOZZLE 		1398
22.7.11. REAR WASHER NOZZLE 		1399
22.7.12. FLOAT LEVEL SENSOR 		1400
22.7.13. DIAGNOSTIC INFORMATION AND PROCEDURES 		1401
22.8. ELECTRICAL SWITCHES 		1402
22.8.1. COMBINATION - SWITCH 		1402
22.8.2. IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION 		1415
22.8.3. MASTER LIGHT SWITCH 		1417
22.8.4. FASCIA SWITCH 		1423
22.8.5. WINDOW WINDING SWITCHES 		1427
22.8.6. STEERING WHEEL SWITCHES 		1433
22.8.7. BONNET SWITCH 		1437
22.8.8. TAILGATE SWITCH 		1438
22.8.9. DOOR SWITCHES (FRONT & REAR) 		1439
22.8.10. GLOVE BOX SWITCH 		1440
22.8.11. REVERSE LIGHT SWITCH 		1441
22.8.12. HAND BRAKE SWITCH 		1442
22.8.13. INERTIA SWITCH 		1443
22.8.14. DRIVE CONTROL SWITCH (DCS) 		1444
22.9. IN VEHICLE NETWORKING (IVN) 		1453
22.10. WINDOW WINDING CONTROLLER 		1461
22.11. BODY CONTROL MODULE (BCM) 		1469
22.11.1. BCM CONNECTOR PIN SIGNALS APLICABILITY MATRIX 		1471
22.11.2. BCM FUNCTIONS 		1488
22.11.2.1. EXTERIOR LIGHTS 		1489
22.11.2.2. INTERIOR LIGHTS 		1501
22.11.2.3. WIPER WASHER 		1507
22.11.2.4. VEHICLE POWER MODE 		1513
22.11.2.5. CENTRAL LOCKING & RKE 		1520
22.11.2.6. PERIMETRIC ALARM 		1526
22.11.2.7. USER CUSTOMIZATION SETTINGS 		1527
22.11.2.8. ORVM FOLD/UNFOLD 		1529
22.12. IMMOBILIZER SYSTEM 		1535
22.12.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 		1301
22.12.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU 		1539
22.12.3. IGNITION SWITCH_AT WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION (XMA, XTA) 		1540
22.13. INSTRUMENT CLUSTER (XE VARIANT) 		1541
22.13.1. TACHOMETER 		1543
22.13.2. SPEEDOMETER 		1543
22.13.3. TEMPERATURE GAUGE 		1543
22.13.4. FUEL GAUGE 		1543
22.13.5. TELLTALES 		1544
22.13.6. DRIVER INFORMATION CENTER 		1548
22.13.7. FUEL COMPUTER 		1549
22.13.8. DIC SWITCH FUNCTIONS 		1551
22.13.9. CONNECTION BLOCK DIAGRAM 		1555
22.13.10. CONNECTOR DETAILS 		1557
22.13.11. DIAGNOSTICS BRIEF 		1559
22.14. INSTRUMENT CLUSTER - XM, XMA, XTA (4X2), XT (4X4) 		1565
22.14.1. TACHOMETER 		1567
22.14.2. FUEL GAUGE 		1567
22.14.3. SPEEDOMETER 		1568
22.14.4. TEMPERATURE GAUGE 		1568
22.14.5. DRIVER INFORMATION SYSTEM 		1569
22.14.6. XM, XT, XT (4X4) DRIVE MODE AND GEAR DISPLAY 		1578
22.14.7. XMA, XMA (4X4) DRIVE MODE AND GEAR DISPLAY 		1581
22.14.8. DISPLAY MESSAGES 		1583
22.14.9. WARNING LAMPS 		1587
22.14.10. CONNECTOR DETAILS OF XT, XM & XMA VARIANTS INSTRUMENT CLUSTER 		1590
22.15. ULTRASONIC PARK ASSIST SYSTEM 		1591
22.15.1. ULTRASONIC PARK ASSIST SYSTEM ARCHITECTURE 		1591
22.15.2. ULTRASONIC PARK ASSIST 		1592
22.15.3. ULTRASONIC PARK ASSIST OVERVIEW 		1592
22.15.4. ULTRASONIC PARK ASSIST ACTIVATION PROCEDURE 		1592
22.15.5. ULTRASONIC PARK ASSIST DEACTIVATION PROCEDURE 		1593
22.15.6. PARK ASSIST BUTTON LED INDICATIONS (IF EQUIPPED) 		1593
22.15.7. PARK ASSIST AUDIO SETTINGS 		1593
22.15.8. PARK ASSIST VOLUME 		1593
22.15.9. MIX WITH AUDIO 		1594
22.15.10. PARK ASSIST TONE 		1594
22.15.11. PARK ASSIST DELAY TIMER 		1594
22.15.12. ULTRA PARK ASSIST HMI INDICATIONS 		1594
22.15.13. ULTRASONIC PARK ASSIST SYSTEM LIMITATIONS 		1595
22.15.14. ULTRASONIC PARK ASSIST SYSTEM MAINTENANCE 		1595
22.15.15. PARK DISTANCE CONTROLLER LOCATION 		1595
22.15.16. PHYSICAL IMAGES 		1597
22.15.17. SENSOR FITMENT TO THE BUMPER 		1598
22.15.18. PARKING DISTANCE CONTROL WITH REAR VIEW CAMERA ( IF EQUIPPED ) 		1602
22.16. INFOTAINMENT SYSTEM: (If fitted) 		1608
22.16.1. USB/AUX PORT 		1612
22.16.2. SPEAKERS 		1613
22.16.3. TWEETER 		1616
22.16.4. AUDIO AMPLIFIER 		1618
22.16.5. MICROPHONE 		1620
22.16.6. ANTENNA 		1621
22.17. GENERAL ELECTRICAL INFORMATION 		1622
22.17.1. INTRODUCTION 		1623
22.17.2. FUSE & RELAY BOX DETAILS 		1627
22.18. CLUTCH PEDAL SENSOR 		1639
23A. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) - AUTOLIV 		1643
23A.1. TIGHTENING TORQUES 		1649
23A.2. WORKING OF RESTRAINTS 		1651
A. RESTRAINTS WITHOUT AIRBAGS 		1651
B. RESTRAINTS WITH AIRBAGS 		1651
23A.3. WORKING OF SRS 		1651
23A.4. SYSTEM LAYOUT 		1652
A. RESTRAINT WITHOUT AIRBAG 		1652
B. RESTRAINT WITH AIRBAG 		1652
C. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 		1654
23A.5. SAFETY PRECAUTIONS 		1655
23A.6. DISPOSAL OF FAULTY AIR BAG UNIT 		1657
23A.7. COMPONENTS 		1659
A. RESTRAINT WITHOUT AIRBAGS 		1659
I. SEAT BELT 		1659
II. EMERGENCY LOCKING RETRACTOR (ELR) 		1659
III. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP 		1659
B. RESTRAINT WITH AIRBAGS 		1659
I. ECU 		1659
II. SENSORS 		1666
III. AIR BAGS 		1668
IV. RPLL BELTS 		1674
V. CLOCK SPRING 		1676
VI. SRS WARNING LAMP 		1679
VII. PAB DECACTIVATION SWITCH 		1679
VIII. PAB INDICATOR 		1681
23B. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) - BOSCH 		1685
23B.0. ABBREVIATIONS 		1692
23B.1. TIGHTENING TORQUES 		1693
23B.2. WORKING OF RESTRAINTS 		1695
A. RESTRAINTSWITHOUT AIRBAGS 		1695
B. RESTRAINTSWITH AIRBAGS 		1695
23B.3. WORKING OF SRS 		1695
23B.4. SYSTEM LAYOUT 		1696
A. RESTRAINTWITHOUT AIRBAG 		1696
B. RESTRAINTWITH AIRBAG 		1696
C. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 		1698
23B.5. SAFETY PRECAUTIONS 		1699
23B.6. DISPOSAL OF FAULTY AIR BAG UNIT 		1701
23B.7. COMPONENTS 		1703
A. RESTRAINTWITHOUT AIRBAGS 		1703
I. SEAT BELT 		1703
II. EMERGENCY LOCKING RETRACTOR (ELR) 		1703
III. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP 		1703
B. RESTRAINTWITH AIRBAGS 		1703
I. ECU 		1703
II. SENSORS 		1709
III. AIR BAGS 		1711
IV. RPLL BELTS 		1717
V. CLOCK SPRING 		1719
VI. SRS WARNING LAMP 		1722
VII. PAB DECACTIVATION SWITCH 		1722
VIII. PAB INDICATOR 		1722
24. BODY 		1728
24.1. GENERAL INFORMATION 		1737
24.1.1. SPECIFICATIONS 		1737
24.1.2. CONSTRUCTION 		1741
24.1.3. TIGHTENING TORQUES 		1742
24.2. ON VEHICLE REPAIRS 		1748
24.2.1. BONNET 		1748
24.2.2. FLOOR CONSOLE 		1752
24.2.3. AC DUCTS IN FLOOR CONSOLE 		1755
24.2.4. DASHBOARD 		1756
24.2.5. FRONT BUMPER 		1762
24.2.6. REAR BUMPER 		1765
24.2.7. DOOR 		1766
24.2.8. TAIL GATE 		1775
24.2.9. MIRROR 		1780
24.2.10. SEATS 		1781
24.2.11. TRIMS 		1787
24.2.12. LEAF SCREEN 		1792
24.2.13. PANEL ASSEMBLY 		1792
24.2.14. STONE GUARD 		1793
24.2.15. FRONT WHEEL ARCH LINER 		1793
24.2.16. FUEL FLAP MECHANISM 		1794
24.2.17. GLASS 		1795
24.2.18. ROOF LINER ASSEMBLY 		1798
24.2.19. FRONT FENDER 		1799
24.2.20. FRONT WHEEL ARCH COVER 		1799
24.2.21. VALANCE COVER 		1800
24.2.22. REAR DOOR CLADDING 		1800
24.2.23. REAR WHEEL ARCH COVER 		1801
24.2.24. LOAD FLOOR 		1802
24.2.25. ROOF RAIL ASSEMBLY 		1803
24.2.26. "D" PILLAR MOULDING 		1803
24.3. BODY REPAIR 		1804
25. HVAC 		1813
25.1. GENERAL INFORMATION 		1815
25.2. TIGHTENING TORQUES 		1817
25.3. PRECAUTIONS 		1820
25.4. HVAC SYSTEM LAYOUT AND WORKING 		1822
25.5. COMPONENTS OF HVAC 		1826
25.5.1. CONTROL PANEL 		1827
25.5.2. FRONT HVAC UNIT 		1831
25.5.3. REAR AC UNIT 		1834
25.5.4. COMPRESSOR 		1834
25.5.5. CONDENSER AND RECEIVER DRIER CONDENSER 		1836
25.5.6. THERMISTER OR THERMO SENSOR 		1836
25.5.7. TRINARY PRESSURE SWITCH 		1838
25.5.8. TEMPERATURE AND MODE ACTUATOR 		1839
25.5.9. AIR INLET ACTUATOR 		1840
25.5.10. REAR BLOWER CONTROLLER 		1842
25.6. TROUBLESHOOTING 		1844
25.7. MAINTENANCE 		1857
25.7.1. PRELIMINARY INSPECTION 		1857
25.7.2. REGULAR MAINTENANCE 		1859
25.8. ON VEHICLE REPAIRS 		1865
25.8.1. CONTROL PANEL ASSEMBLY 		1865
25.8.2. COMPRESSOR REMOVAL 		1865
25.8.3. FRONT HVAC UNIT 		1866
25.8.4. REAR AC UNIT 		1867
25.8.5. BLOWER (FRONT HVAC UNIT) 		1868
25.8.6. BLOWER RESISTER 		1868
25.8.7. LPM (LINEAR POWER MODULE) 		1869
25.8.8. WIRE MESH 		1869
25.8.9. TXV (THERMAL EVAPORATION VALVE) 		1870
25.8.10. PRESSURE SWITCH 		1870
25.8.11. CONDENSER 		1871
25.8.12. REFRIGERANT HOSES/PIPES 		1872
25.8.13. REAR AC DUCTING 		1874
25.8.14. CONDENSER SEALING DUCT 		1877
25.9. OVERHAULING 		1878
25.9.1. FRONT HVAC UNIT 		1878
25.9.2. REAR AC 		1882
25.9.3. COMPRESSOR 		1883
25.10. DIAGNOSTICS USING BLINK CODES 		1886
25.10.1. ACTIVATING DIAGNOSTICS MODE 		1886
25.10.2. DISPLAYING BLINK CODES 		1887
25.10.3. READING BLINK CODES 		1887
25.10.4. ERASING ACTIVE FAULTS 		1888
25.10.5. EXITING DIAGNOSTIC MODE 		1888
25.11. FULLY AUTOMATIC TEMPERATURE CONTROL (FATC) 		1889
25.11.1. INTRODUCTION 		1889
25.11.2. TECHNICAL SPECIFICATION 		1890
25.11.3. FATC CONTROL SCHEMATICS 		1892
25.12. COMPONENTS 		1893
25.12.1. FATC CONTROL PANEL DETAILS 		1893
25.12.2. CONTROLS 		1895
25.12.3. VF DISPLAY (VACUUM FLUORESCENT DISPLAY) 		1898
25.12.4. SOLAR LOAD SENSOR 		1900
25.12.5. INCAR TEMPERATURE SENSOR WITH INTEGRATED ASPIRATOR 		1901
25.12.6. OUTSIDE AIR TEMPERATURE SENSOR 		1904
25.12.7. LPM (LINEAR POWER MODULE) 		1905
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