Nexon Service Manual
|
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 |
33 |
|
1.1. GENERAL INFORMATION |
39 |
|
A. ENGINE INTRODUCTION |
39 |
|
B. ELECTRONIC CONTROL UNIT |
40 |
|
C. TECHNICAL SPECIFICATION |
41 |
|
D. SPECIAL TOOLS |
42 |
|
E. ASSEMBLY CLEARANCES |
45 |
|
F. SEALANTS |
45 |
|
G. LEAKAGE RATES |
46 |
|
H. RECOMMENDED LUBRICANTS & COOLANTS |
46 |
|
I. SERVICE SCHEDULE |
47 |
|
1.2. TROUBLESHOOTING |
48 |
|
1.3. CONSTRUCTIONAL AND SERVICE DETAILS |
56 |
|
A. ENGINE LIFTING HOOKS |
56 |
|
B. INTAKE MANIFOLD |
58 |
|
C. CYLINDER HEAD COVER |
60 |
|
D. CYLINDER HEAD-A |
62 |
|
E. CYLINDER HEAD-B |
64 |
|
F. CYLINDER BLOCK |
66 |
|
G. LUBRICATION PUMP AND COMPONENTS |
68 |
|
H. PISTON, CRANKSHAFT AND COMPONENTS |
71 |
|
I. ENGINE TIMING |
74 |
|
J. TURBOCHARGER, CATCON AND COMPONENTS |
76 |
|
K. FUEL INJECTION EQUIPMENT |
79 |
|
L. AIR FILTER, SNORKEL AND BLOW-BY PIPE |
81 |
|
M. WATER PUMP, THERMOSTAT AND COMPONENTS |
83 |
|
N. STARTER MOTOR AND ALTERNATOR |
86 |
|
O. COMPRESSOR, AUTO-TENSIONER AND BELT |
88 |
|
P. ENGINE SUSPENSION |
90 |
|
Q. INTERCOOLER AND HOSES |
93 |
|
1.4. ENGINE TESTS AND MAINTENANCE |
95 |
|
A. PRELIMINARY INSPECTION |
95 |
|
B. ENGINE TESTS |
96 |
|
I. ENGINE COMPRESSION TEST |
96 |
|
II. ENGINE OIL CONSUMPTION TEST |
97 |
|
III. ENGINE OIL PRESSURE TEST |
98 |
|
C. REGULAR MAINTENANCE |
99 |
|
I. ENGINE OIL AND FILTER CHANGE |
99 |
|
II. ENGINE COOLANT REPLACEMENT |
101 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
102 |
|
IV. SPARK PLUG REPLACEMENT |
103 |
|
V. AIR CONDITIONER COMPRESSOR AND ALTERNATOR BELT REPLACEMENT |
106 |
|
1.5. REPAIR AND INSPECTION DETAILS |
107 |
|
A. ACCESSORY DRIVING BELT |
107 |
|
B. TIMING CHAIN |
107 |
|
C. CYLINDER HEAD |
107 |
|
D. VALVES |
108 |
|
E. CYLINDER HEAD VALVE SEATS |
110 |
|
F. ROCKER ARM AND SHAFTS |
111 |
|
G. HYDRAULIC LASH ADJUSTER |
111 |
|
H. CAMSHAFT |
112 |
|
I. PISTON AND PISTON RINGS |
113 |
|
J. CONNECTING RODS |
114 |
|
K. CRANKSHAFT |
116 |
|
L. CRANK CASE |
118 |
|
M. FUEL TANK |
119 |
|
N. CANISTER PURGE VALVE |
119 |
|
O. CANISTER |
120 |
|
1.6. ENGINE SYSTEM |
121 |
|
A. AIR INTAKE SYSTEM |
121 |
|
B. BLOW BY SYSTEM |
124 |
|
C. LUBRICATION SYSTEM |
125 |
|
D. EXHAUST SYSTEM |
129 |
|
E. COOLING SYSTEM |
132 |
|
F. FUEL SYSTEM |
135 |
|
1.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
138 |
|
A. ENGINE REMOVAL AND INSTALLATION |
138 |
|
B. AIR FILTER ASSEMBLY |
144 |
|
C. INJECTION SYSTEM |
145 |
|
D. SPARK PLUG |
146 |
|
E. EXHAUST SYSTEM |
147 |
|
F. FUEL SYSTEM |
153 |
|
G. COOLING SYSTEM |
159 |
|
H. REMOVAL OF ACCESSORIES |
165 |
|
1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
166 |
|
A. ENGINE DIS-ASSEMBLY |
166 |
|
I. REMOVAL OF INTAKE MANIFOLD |
166 |
|
II. REMOVAL OF EXHAUST MANIFOLD |
168 |
|
III. REMOVAL OF OIL SUMP |
172 |
|
IV. REMOVAL OF SENSORS |
173 |
|
V. REMOVAL OF ACCESSORIES |
174 |
|
VI. REMOVAL OF TIMING CHAIN |
178 |
|
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
181 |
|
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
183 |
|
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
185 |
|
B. ENGINE ASSEMBLY |
190 |
|
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
190 |
|
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
194 |
|
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES |
197 |
|
IV. ASSEMBLY OF CYLINDER HEAD ON CYLINDER BLOCK |
199 |
|
V. ASSEMBLY OF TIMING CHAIN |
201 |
|
VI. FITMENT OF CYLINDERHEAD COVER AND PERIPHERALS |
205 |
|
VII. ASSEMBLY OF SENSORS |
208 |
|
VIII. ASSEMBLY OF OIL SUMP |
209 |
|
IX. ASSEMBLY OF EXHAUST MANIFOLD |
210 |
|
X. ASSEMBLY OF INTAKE MANIFOLD |
213 |
|
1.9. ENGINE MANAGEMENT SYSTEM |
215 |
|
A. ABBREVIATIONS |
215 |
|
B. AN OVERVIEW |
216 |
|
C. ELECTRONIC CONTROL UNIT |
217 |
|
D. SENSORS |
224 |
|
I. T-MAP SENSOR |
225 |
|
II. LAMBDA SENSOR |
226 |
|
III. CAMSHAFT POSITION SENSOR |
228 |
|
IV. KNOCK SENSOR |
229 |
|
V. CRANKSHAFT POSITION SENSOR |
231 |
|
VI. COOLANT TEMPERATURE SENSOR |
232 |
|
E. ACTUATORS |
234 |
|
I. IGNITION COIL |
235 |
|
II. PURGE CONTROL VALVE |
236 |
|
III. SOLENOID VALVE (OCV) |
237 |
|
IV. FUEL INJECTOR |
238 |
|
V. ELECTRONIC THROTTLE BODY |
239 |
|
F. SWITCH |
241 |
|
I. OIL PRESSURE SWITCH |
241 |
|
II. THROTTLE PEDAL SENSOR |
242 |
|
III. CLUTCH SWITCH |
243 |
|
IV. BRAKE SWITCH |
244 |
|
V. WHEEL SPEED SENSOR |
245 |
|
VI. ELECTRONIC VACUUM REGULATING VALVE |
246 |
|
VII. START STOP SWITCH |
247 |
|
VIII. AC PRESSURE SENSOR |
248 |
|
3. 1.5L REVOTORQ ENGINE |
250 |
|
1.1. GENERAL INFORMATION |
256 |
|
A. ENGINE INTRODUCTION |
256 |
|
B. TECHNICAL SPECIFICATION |
257 |
|
C. SPECIAL TOOLS |
258 |
|
D. ASSEMBLY CLEARANCES |
262 |
|
E. LEAKAGE RATES |
263 |
|
F. RECOMMENDED LUBRICANTS AND COOLANTS |
263 |
|
G. SERVICE SCHEDULE |
264 |
|
1.2. TROUBLESHOOTING |
265 |
|
1.3. CONSTRUCTIONAL AND SERVICE DETAILS |
269 |
|
A. ENGINE LIFTING HOOK |
269 |
|
B. INTAKE MANIFOLD AND FUEL INJECTION SYSTEM |
271 |
|
C. LUBRICATION SYSTEM |
274 |
|
D. AIR FILTER, SNORKEL, BLOW BY PIPE |
277 |
|
E. STARTER MOTOR, COMPRESSOR AND ALTERNATOR |
280 |
|
F. TIMING BELT, AUTO TENSIONER, WATER PUMP |
283 |
|
G. EXHAUST MANIFOLD, CATCON, TURBOCHARGER |
286 |
|
H. CYLINDER HEAD AND COMPONENTS |
288 |
|
I. PISTON, CRANKSHAFT AND COMPONENTS |
291 |
|
J. ENGINE SUSPENSION |
293 |
|
K. EGR VALVE, THERMOSTAT AND COMPONENTS |
296 |
|
L. CRANKCASE AND COMPONENTS |
300 |
|
1.4. ENGINE TESTS AND MAINTENANCE |
302 |
|
A. PRELIMINARY INSPECTION |
302 |
|
B. ENGINE TESTS |
302 |
|
C. REGULAR MAINTENANCE |
307 |
|
I. ENGINE OIL AND FILTER CHANGE |
307 |
|
II. ENGINE COOLANT REPLACEMENT |
308 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
309 |
|
IV. FUEL FILTER REPLACEMENT |
310 |
|
V. DRAINING WATER FROM PRE-FILTER |
311 |
|
VI. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
312 |
|
1.5. REPAIR AND INSPECTION DETAILS |
314 |
|
A. TIMING BELT |
314 |
|
B. FUEL TANK |
314 |
|
C. CYLINDER HEAD |
315 |
|
D. VALVES |
315 |
|
E. VALVE SEATS |
317 |
|
F. CRANKCASE |
318 |
|
G. VALVE SEAT INSERT |
319 |
|
H. HYDRAULIC LASH ADJUSTER |
319 |
|
I. VALVE GUIDES |
320 |
|
J. CAMSHAFT |
321 |
|
K. PISTON AND PISTON RINGS |
322 |
|
L. CONNECTING ROD |
323 |
|
M. CRANKSHAFT |
325 |
|
1.6. ENGINE SYSTEM |
327 |
|
A. AIR INTAKE SYSTEM |
327 |
|
B. EXHAUST SYSTEM |
330 |
|
C. COOLING SYSTEM |
334 |
|
D. LUBRICATION SYSTEM |
337 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM |
341 |
|
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM |
343 |
|
G. VACUUM MANAGEMENT SYSTEM |
344 |
|
H. FUEL SYSTEM |
345 |
|
1.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
351 |
|
A. ENGINE REMOVAL |
351 |
|
B. ENGINE INSTALLATION |
359 |
|
C. EXHAUST SYSTEM |
360 |
|
D. COOLING SYSTEM |
364 |
|
E. FUEL SYSTEM |
370 |
|
F. TURBOCHARGER REMOVAL AND REFITMENT |
379 |
|
G. TIMING BELT REMOVAL AND REFITMENT |
381 |
|
H. STARTER MOTOR REMOVAL AND REFITMENT |
383 |
|
I. ALTERNATOR MOTOR REMOVAL AND REFITMENT |
385 |
|
J. COMPRESSOR MOTOR REMOVAL AND REFITMENT |
386 |
|
K. HIGH PRESSURE PUMP REMOVAL AND REFITMENT |
387 |
|
1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
390 |
|
A. ENGINE DIS-ASSEMBLY |
390 |
|
I. ON OVERHAUL STAND |
390 |
|
II. REMOVAL OF INTAKE MANIFOLD |
394 |
|
III. REMOVAL OF EGR VALVE & OIL COOLER |
396 |
|
IV. REMOVAL OF EXHAUST MANIFOLD |
397 |
|
V. REMOVAL OF EVRV AND THERMOSTAT |
398 |
|
VI. REMOVAL OF OIL SUMP |
400 |
|
VII. REMOVAL OF TIMING BELT |
401 |
|
VIII. REMOVAL OF CYLINDER HEAD |
406 |
|
IX. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
407 |
|
X. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
410 |
|
XI. PISTON CONNECTING ROD DIS-ASSEMBLY |
413 |
|
B. ENGINE ASSEMBLY |
419 |
|
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
419 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
420 |
|
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
421 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
423 |
|
V. FITMENT OF TIMING BELT |
425 |
|
VI. FITMENT OF ENGINE SUPPORT |
430 |
|
VII. FITMENT OF OIL SUMP |
430 |
|
VIII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
432 |
|
IX. FITMENT OF INTAKE MANIFOLD |
436 |
|
X. FITMENT OF PERIPHERALS |
438 |
|
1.9. ENGINE MANAGEMENT SYSTEM |
441 |
|
A. ABBREVIATIONS |
441 |
|
B. AN OVERVIEW |
442 |
|
C. ELECTRONIC CONTROL UNIT (ECU) |
443 |
|
D. EMS SENSORS |
448 |
|
I. CRANK POSITION SENSOR |
448 |
|
II. WHEEL SPEED SENSOR |
449 |
|
III. CAMSHAFT POSITION SENSOR |
450 |
|
IV. AIR MASS FLOW SENSOR |
451 |
|
V. VENTURI |
452 |
|
VI. RAIL PRESSURE SENSOR |
453 |
|
VII. THROTTLE PEDAL SENSOR |
454 |
|
VIII. WATER IN FUEL SENSOR |
455 |
|
IX. CLUTCH SWITCH |
455 |
|
X. OIL PRESSURE SWITCH |
456 |
|
XI. BRAKE SWITCH |
458 |
|
XII. COOLANT TEMPERATURE SENSOR |
459 |
|
XIII. GLOW PLUG |
460 |
|
XIV. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
461 |
|
XV. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) |
462 |
|
XVI. START STOP SWITCH |
463 |
|
XVII. AC PRESSURE SENSOR |
464 |
|
4. CLUTCH |
466 |
|
1.1. GENERAL INFORMATION |
469 |
|
1.2. TECHNICAL SPECIFICATIONS |
472 |
|
A. CLUTCH DISC ASSEMBLY |
472 |
|
B. SELF ADJUSTING CLUTCH COVER ASSEMBLY |
473 |
|
C. SINGLE MASS FLYWHEEL |
474 |
|
1.3. TIGHTENING TORQUES |
476 |
|
1.4. SPECIAL TOOLS |
478 |
|
1.5. MAINTENANCE, INSPECTION AND TESTS |
479 |
|
1.5.1. PRELIMINARY MAINTENANCE |
479 |
|
1.5.2. REULAR MAINTENANCE |
480 |
|
1.6. GENERAL SYMPTOMS DIAGNOSIS |
482 |
|
1.7. TROUBLE SHOOTING FOR SAC ASSEMBLY |
484 |
|
1.8. PRECAUTION FOR SAC ASEMBLY |
485 |
|
1.9. EXPLODED VIEWS |
488 |
|
1.10. ON VEHICLE PROCEDURES |
491 |
|
A. CLUTCH PEDAL ASSEMBLY REMOVAL |
491 |
|
B. CONTROL BRACKET ASSEMBLY REMOVAL |
492 |
|
C. SELF ADJUSTING CLUTCH ASSEMBLY REMOVAL |
493 |
|
D. CLUTCH MASTER CYLINDER REMOVAL |
494 |
|
E. FLYWHEEL REMOVAL |
496 |
|
5. TRANSAXLE-MT |
497 |
|
1.1. GENERAL INFORMATION |
500 |
|
1.2. TECHNICAL SPECIFICATIONS |
501 |
|
1.3. PRECAUTIONS |
501 |
|
1.4. TIGHTENING TORQUES |
502 |
|
1.5. SPECIAL TOOLS |
508 |
|
1.6. DIAGNOSIS |
512 |
|
1.7. SECTION VIEWS |
513 |
|
1.8. EXPLODED VIEWS |
516 |
|
1.9. REMOVAL OF TRANSAXLE FROM VEHICLE |
523 |
|
1.10. INSTALLATION OF TRANSAXLE ON VEHICLE |
524 |
|
1.11. TRANSAXLE DISASSEMBLY ON BENCH |
525 |
|
A. INPUT SHAFT DISASSEMBLY & ASSEMBLY |
529 |
|
B. LAY SHAFT DISASSEMBLY & ASSEMBLY |
533 |
|
C. DIFFERENTIAL DISASSEMBLY & ASSEMBLY |
537 |
|
D. SHIFTER SHAFTS |
540 |
|
E. INDENTIFICATION OF ENGAGING GEARS |
540 |
|
1.12. TRANSAXLE ASSEMBLY ON BENCH |
541 |
|
1.13. INSTRUCTION FOR ASSEMBLY & DISASSEMBLY OF CABLE ON TRANSAXLE |
546 |
|
1.14. REMOVAL OF GEAR SHIFTER HOUSING, GEAR SHIFTER & SELECTOR CABLE |
547 |
|
6. TRANSAXLE-AMT |
549 |
|
1. TRANSAXLE |
553 |
|
1. GENERAL INFORMATION |
556 |
|
2. TECHNICAL SPECIFICATIONS |
557 |
|
3. PRECAUTIONS |
558 |
|
4. TIGHTENING TORQUES |
559 |
|
5. SPECIAL TOOL |
565 |
|
6. DIAGNOSIS |
569 |
|
7. SECTION VIEWS |
570 |
|
8. EXPLODED VIEW TRANSAXLE |
572 |
|
9. REMOVAL OF TRANSAXLE FROMVEHICLE (FOR PETROL VERSION) |
583 |
|
10. INSTALLATION OF TRANSAXLE ONVEHICLE (FOR PETROL VERSION) |
586 |
|
11. REMOVAL OF TRANSAXLE FROMVEHICLE (FOR DIESEL VERSION) |
586 |
|
12. INSTALLATION OF TRANSAXLE ONVEHICLE (FOR DIESEL VERSION) |
590 |
|
13. TRANSAXLE DISASSEMBLY ON BENCH |
590 |
|
14. TRANSAXLE ASSEMBLY ON BENCH |
606 |
|
2. CLUTCH |
611 |
|
1. GENERAL INFORMATION |
614 |
|
2 TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES |
614 |
|
3. DIAGNOSIS |
617 |
|
4. CLUTCH |
619 |
|
5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE |
622 |
|
3. DRIVESHAFT |
623 |
|
1. GENERAL INFORMATION |
626 |
|
2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
628 |
|
3. DRIVESHAFT PARTS |
629 |
|
4. TIGHTENING TORQUES |
630 |
|
5. ON BENCH PROCEDURE |
632 |
|
A. TRIPOT JOINT DISASSEMBLY |
632 |
|
B. TRIPOT JOINT ASSEMBLY |
633 |
|
C. CV JOINT OUTER DISASSEMBLY |
634 |
|
6. ON VEHICLE PROCEDURE |
635 |
|
A. DRIVE SHAFT REMOVAL |
635 |
|
B. INTERMEDIATE DRIVE SHAFT REMOVAL |
636 |
|
4. AMT KIT |
637 |
|
1. AMT-KIT LOCATION ON VEHICLE(LAYTOUT) |
640 |
|
2. NOMENCLATURE FOR AMT KIT |
641 |
|
3. TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS |
642 |
|
4. EXPLODED VIEW AMT KIT |
643 |
|
5. GEAR SHIFT PIN CONFIGURATION |
645 |
|
6. PRECAUTIONS |
646 |
|
7. MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT ON BENCH |
647 |
|
8. TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT ON BENCH |
649 |
|
9. DC MOTOR REMOVAL AND RE-FITMENT ON BENCH |
653 |
|
10. CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT ON BENCH |
654 |
|
11. HYDRAULIC OIL ACCUMLATOR REMOVAL AND RE-FITMENT ON BENCH |
654 |
|
12. POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH |
654 |
|
13. SPECIAL TOOLS |
656 |
|
5. CONSOLE |
658 |
|
1. AUTOMATED MANUAL TRANSMISSION(AMT) GEARBOX SHIFTER AND SHIFTINGMECHANISM |
658 |
|
2. DRIVING MODES |
658 |
|
3. GEAR SHIFTER CENTER CONSOLEREMOVAL AND RE-FITMENT ON VEHICLE |
660 |
|
6. COMPONENT REPLACEMENT MANUAL |
663 |
|
1. Document Scope |
666 |
|
2. Intended Audience |
666 |
|
3. Terminologies |
666 |
|
4. Confidentiality |
666 |
|
5. Contacts at Tata Motors |
666 |
|
6. Routine Procedure for Component Replacement |
667 |
|
6.1 Matrix of Routine Procedure for Component Replacement |
667 |
|
6.2 Routine Procedure for TCU replacement |
668 |
|
6.3 Routine Procedure for Actuation system replacement |
669 |
|
6.4 Routine Procedure for Gear Box replacement |
670 |
|
6.5 Routine Procedure for Pump/Accumulator/Clutch Actuator Replacement |
671 |
|
6.6 Routine Procedure for Valve bock and TCU replacement |
672 |
|
6.7 Routine Procedure for Clutch Sensor replacement |
673 |
|
6.8 Routine Procedure for Clutch replacement |
675 |
|
6.9 Routine Procedure for Primary shaft speed sensor replacement |
675 |
|
6.10 Routine Procedure for Rubber Bellow replacement |
676 |
|
6.11 Routine Procedure for Reservoir replacement |
676 |
|
6.12 Routine Procedure for Gear Shift Lever replacement |
677 |
|
6.13 Routine Procedure for Electric Motor replacement |
677 |
|
6.14 TCU programming (Flashing) |
678 |
|
6.15 Routine Procedure for AMT Kit replacement |
679 |
|
7. DRIVESHAFT |
681 |
|
1.1. GENERAL INFORMATION |
684 |
|
1.2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
686 |
|
1.3. DRIVESHAFT PARTS |
687 |
|
1.4. TIGHTENING TORQUES |
688 |
|
1.5. ON BENCH PROCEDURE |
690 |
|
A. TRIPOT JOINT DISASSEMBLY |
690 |
|
B. TRIPOT JOINT ASSEMBLY |
691 |
|
C. CV JOINT OUTER DISASSEMBLY |
692 |
|
1.6. ON VEHICLE PROCEDURE |
693 |
|
A. DRIVE SHAFT REMOVAL |
693 |
|
B. INTERMEDIATE DRIVE SHAFT REMOVAL |
694 |
|
C. TURNING NOISE REPAIR (1.5CRAIL) PROCEDURE |
695 |
|
8. SUSPENSION |
697 |
|
1.1. GENERAL INFORMATION |
700 |
|
1.2. TECHNICAL SPECIFICATION |
704 |
|
1.3. TIGHTENING TORQUES |
705 |
|
1.4. SPECIAL TOOLS |
710 |
|
1.5. DIAGNOSIS |
716 |
|
1.6. PRECAUTIONS |
717 |
|
1.7. EXPLODED VIEWS FRONT SUSPENSION |
718 |
|
1.8. EXPLODED VIEWS REAR SUSPENSION |
722 |
|
1.9. ON VEHICLE PROCEDURE |
725 |
|
1.9.1. REMOVAL OF FRONT STRUT ASSEMBLY |
725 |
|
1.9.2. DISASSEMBLY OF FRONT STRUT |
726 |
|
1.9.3. REMOVAL OF WHEEL HUB |
727 |
|
1.9.4. REMOVAL OF SUBFRAME ASSEMBLY |
730 |
|
1.9.5. REMOVAL OF REAR SHOCK ABSORBER AND COIL SPRINGS |
734 |
|
1.9.6. REMOVAL OF TORSION BEAM |
737 |
|
1.10. WHEELS AND TYRES |
741 |
|
1.10.1. HOW TO MEASURE WHEEL RUNOUT |
741 |
|
1.10.2. INFLATION OF TYRES |
742 |
|
1.10.3. TYRE ROTATION |
743 |
|
1.10.4. WHEEL REMOVAL |
743 |
|
1.10.5. TYRE MOUNTING AND DEMOUNTING |
743 |
|
1.10.6. BALANCING WHEELS |
744 |
|
1.10.7. TYRE CARE. |
744 |
|
9. STEERING |
745 |
|
1.1. GENERAL INFORMATION |
748 |
|
1.1.1. SPECIFICATIONS |
748 |
|
1.1.2. SYSTEM LAYOUT |
748 |
|
1.1.3. GENERAL DISCRIPTION |
749 |
|
1.1.4. TIGHTENING TORQUES |
750 |
|
1.1.5. SPECIAL TOOLS |
752 |
|
1.2. MAINTENANCE, INSPECTION AND TEST |
753 |
|
1.2.1. PRELIMINARY INSPECTION |
753 |
|
1.2.2. REGULAR MAINTENANCE |
754 |
|
1.2.3. ON VEHICLE REPAIRS |
756 |
|
1.2.3.1. STEERING WHEEL REMOVAL |
756 |
|
1.2.3.2. STEERING COLUMN REMOVAL |
757 |
|
1.2.3.3. INTERMEDIATE SHAFT REMOVAL |
758 |
|
1.2.3.4. RACK & PINION ASSEMBLY REMOVAL |
758 |
|
1.3. OVERHAULING |
760 |
|
1.3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY |
760 |
|
1.3.2. PRECAUTIONS |
761 |
|
1.3.3. DISMANTLING, INSPECTION & ASSEMBLY |
761 |
|
1.3.3.1. DISASSEMBLY OF RACK & PINOIN |
761 |
|
1.3.3.2. INSPECTION OF DISMANTLED PARTS |
762 |
|
1.3.3.3. ASSEMBLY OF RACK & PINOIN |
762 |
|
1.3.3.4. OBJ ON VEHICLE REMOVAL |
764 |
|
1.3.3.5. DO'S & DON’T'S |
764 |
|
1.3.3.6. WHEEL ALIGNMENT |
765 |
|
1.4. TROUBLESHOOTING AND DIAGNOSIS |
767 |
|
1.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS |
771 |
|
1.6. TUNING DATA SELECTION FOR ECU-TML EOL PROCEDURE |
774 |
|
1.7. CONFIGURATION SELECTION |
774 |
|
10. BRAKE |
776 |
|
1.1 PRECAUTIONS |
780 |
|
1.2 TECHNICAL SPECIFICATIONS |
781 |
|
1.3 TIGHTENING TORQUES |
783 |
|
1.4 DIAGNOSIS |
784 |
|
1.5 NESSECITY OF ABS WITH EBD |
787 |
|
1.6 BRAKE HYDRAULIC LINES |
788 |
|
1.7 VACUUM BRAKE BOOSTER |
789 |
|
1.8 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
790 |
|
1.9 ABS COMPONENTS |
794 |
|
1.9.1 ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
795 |
|
1.9.2 HYDRAULIC CONTROL UNIT |
796 |
|
1.9.3 WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED) |
797 |
|
1.9.4 ABS SYSTEM FAILUREWARNING LIGHT |
798 |
|
1.10 MAINTENANCE, ADJUSTMENTS & TEST |
799 |
|
1.10.1 FRONT BRAKE MAINTENANCE |
799 |
|
1.10.2 REAR BRAKE MAINTENANCE |
801 |
|
1.10.3 BRAKE TROUBLE SHOOTING |
806 |
|
1.10.4 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
807 |
|
1.11 BRAKE PEDAL ASSEMBLY |
809 |
|
1.12 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE |
810 |
|
1.13 REPAIRS |
811 |
|
1.13.1 FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT |
812 |
|
1.13.2 REMOVAL OF FRONT BRAKE DISC |
817 |
|
1.13.3 REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
818 |
|
1.13.4 REAR BRAKE ASSEMBLY |
820 |
|
1.13.5 REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY |
821 |
|
1.13.6 REMOVAL OF PARKING BRAKE LEVER |
827 |
|
1.13.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE |
828 |
|
1.13.8 PARKING BRAKE CABLE ADJUSTMENT |
830 |
|
1.13.9 REMOVAL AND REFITMENT OF ABS ECU / HCU |
831 |
|
1.13.10 REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR |
832 |
|
1.13.11 REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR |
833 |
|
1.14 TROUBLE SHOOTING & DIAGNOSIS |
834 |
|
1.15 ABS ECU CONNECTOR |
836 |
|
11. BODY |
838 |
|
1.1. GENERAL INFORMATION |
842 |
|
1.2. TIGHTENING TORQUES |
843 |
|
1.3. SOECIAL TOOLS |
846 |
|
1.4. ON VEHICLE PROCEDURES |
847 |
|
1.4.1. BONNET |
847 |
|
1.4.2. FLOOR CONSOLE |
849 |
|
1.4.3. DASHBOARD SKIN |
851 |
|
1.4.4. GLOVE BOX |
859 |
|
1.4.5. SIDE AIR VENTS |
860 |
|
1.4.6. FRONT BUMPER |
861 |
|
1.4.7. REAR BUMPER |
862 |
|
1.4.8. FRONT DOOR |
863 |
|
1.4.9. FRONT DOOR TRIMS |
865 |
|
1.4.10. DOOR INNER LOCK HANDLE |
866 |
|
1.4.11. FRONT OUTER DOOR LOCK |
867 |
|
1.4.12. FRONT DOOR LATCH |
868 |
|
1.4.13. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
870 |
|
1.4.14. REAR DOOR |
871 |
|
1.4.15. REAR DOOR TRIM |
872 |
|
1.4.16. REAR OUTER DOOR LOCK |
873 |
|
1.4.17. DOOR LATCH REAR |
874 |
|
1.4.18. TAIL GATE |
875 |
|
1.4.19. TAIL GATE LATCH CABLE |
877 |
|
1.4.20. TAIL GATE TRIM |
878 |
|
1.4.21. ORVM |
879 |
|
1.4.22. INNER REAR VIEW MIRROR |
879 |
|
1.4.23. FRONT ROW SEAT |
880 |
|
1.4.24. REAR ROW SEAT |
881 |
|
1.4.25. FRONT SEAT BELT |
882 |
|
1.4.26. REAR SEAT BELT |
884 |
|
1.4.27. “A” PILLAR TRIMS |
885 |
|
1.4.28. FRONT SCUFF PLATE |
886 |
|
1.4.29. “B” PILLAR TRIMS |
886 |
|
1.4.30. “C” PILLAR TRIMS |
887 |
|
1.4.31. GRAB HANDLE |
888 |
|
1.4.32. SUNVISOR |
889 |
|
1.4.33. ROOF LINER |
889 |
|
1.4.34. PLENUM COVER |
890 |
|
1.4.35. GEAR LEVER BOOT |
890 |
|
1.4.36. BONNET INSULATION |
890 |
|
1.4.37. GLASS |
891 |
|
1.4.38. FUEL FILLER ASSEMBLY |
892 |
|
1.4.39. FRONT WHEEL ARCH LINER |
893 |
|
1.4.40. REAR WHEEL ARCH LINER |
894 |
|
1.4.41. FRONT FENDER |
895 |
|
1.4.42. REAR WIPER MOTOR |
897 |
|
1.4.43. FRONT WIPER |
898 |
|
12. ELECTRICAL |
899 |
|
1.1 TECHNICAL SPECIFICATION |
905 |
|
1.2 GENERAL PRECAUTIONS |
907 |
|
1.3 FUSE BOX / RELAY LOCATIONS |
911 |
|
1.4 BATTERY |
912 |
|
1.5 ALTERNATOR |
914 |
|
1.6 STARTER MOTOR |
917 |
|
1.7 LIGHTING SYSTEM |
924 |
|
1.7.1 BULB SPECIFICATIONS |
924 |
|
1.7.2 FASTENERS TORQUE VALUE TABLE |
925 |
|
1.7.3 GENERAL SYMPTOMS AND DIAGNOSTICS |
926 |
|
1.7.4 HEAD LAMP |
930 |
|
1.7.5 SIDE REPEATER LAMP |
936 |
|
1.7.6 ROOF LAMP |
936 |
|
1.7.7 HIGH MOUNTED STOP LAMP |
937 |
|
1.7.8 TAIL LAMP |
939 |
|
1.7.9 REAR FOG LAMP |
942 |
|
1.7.10. FRONT FOG LAMP |
943 |
|
1.7.11. REGISTRATION PLATE LAMP |
944 |
|
1.7.12. REVERSE LAMP |
945 |
|
1.8 HORN |
946 |
|
1.9 WIPER & WASHER SYSTEM |
948 |
|
1.9.1 FRONT AND REAR WIPER AND WAHSER SYSTEM LAYOUT |
949 |
|
1.9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
950 |
|
1.9.3 WIPER AND WIPER CARE |
955 |
|
1.10. POWER SOCKETS |
958 |
|
1.11. GLOW PLUG CONTROL UNIT |
959 |
|
1.12. FUEL GAUGE AND FUEL LEVEL METER |
962 |
|
1.13. COMBI-SWITCH |
965 |
|
1.14. STEERING LOCK CUM IGNITION SWITCH |
971 |
|
1.15. FASCIA SWITCHES |
974 |
|
1.16. HAZARD SWITCH |
982 |
|
1.17. MIRROR SWITCH |
983 |
|
1.18. INFOTAINMENT SYSTEM |
986 |
|
1.18.1. USB/AUX PORT |
990 |
|
1.18.2. SPEAKERS |
991 |
|
1.18.3. ANTENNA |
993 |
|
1.18.4. MICROPHONE |
994 |
|
1.18.5. SILVER BOX |
995 |
|
1.18.6. TWEETER |
1001 |
|
1.19. WINDOW WINDING MODULE |
1003 |
|
1.20. POWER WINDOW SWITCHES |
1006 |
|
1.21. STEERING WHEEL SWITCHES |
1011 |
|
1.22. DOOR HANDLE SWITCH |
1014 |
|
1.23. TAILGATE HANDLE SWITCH |
1015 |
|
1.24. IGNITION KEY |
1016 |
|
1.25. INSTRUMENT CLUSTER |
1023 |
|
1.25.1. BASIC FUNCTIONAL MATRIX |
1026 |
|
1.25.2. TELL TALES MATRIX |
1027 |
|
1.25.3. DRIVER INFORMATION SYSTEM |
1033 |
|
1.25.4. REMINDER FEATURES |
1038 |
|
1.25.5. FUEL GAUGE DETAILS |
1040 |
|
1.25.6. TEMPERATURE BAR GRAPH DETAILS |
1041 |
|
1.25.7. CHIME TABLE |
1042 |
|
1.25.8. DISPLAY SCREEN FLOW AND SETTINGS |
1042 |
|
1.26. IMMOBILIZER SYSTEM (IF APPLICABLE) |
1048 |
|
1.26.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
1052 |
|
1.26.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
1053 |
|
1.26.3. IGNITION KEY LEARNING PROCEDURE |
1056 |
|
1.27. BODY CONTROL MODULE (BCM) |
1059 |
|
1.27.1. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
1065 |
|
1.27.2. BCM FUNCTIONS |
1075 |
|
1.28. CLUTCH PEDAL SENSOR |
1111 |
|
1.29. FUSE AND RELAY BOX DETAILS |
1114 |
|
1.29.1. BATTERY MOUNTED FUSE BOX (BDU) |
1117 |
|
1.29.2. ENGINE FUSE AND RELAY BOX |
1117 |
|
1.29.3. CABIN FUSE AND RELAY BOX |
1121 |
|
1.29.4. CIRCUIT SCHMATICS |
1122 |
|
1.29.5. DTCs |
1122 |
|
1.30. REVERSE PARK ASSIST SYSTEM |
1123 |
|
1.30.1. REAR VIEW CAMERA |
1126 |
|
1.30.2. ECU TO SENSOR ELECTRICAL INTERFACE |
1129 |
|
1.30.3. ECU MOUNTING |
1130 |
|
1.30.4. PHYSICAL IMAGES |
1131 |
|
1.30.5. SENSOR FITMENT TO THE BUMPER |
1132 |
|
1.31. PASSIVE ENTRY PASSIVE START (PEPS) |
1134 |
|
1.31.1. PEPS ECU |
1135 |
|
1.31.2. START STOP SWITCH |
1137 |
|
1.31.3. ELECTRONIC STEERING COLUMN LOCK (ESCL) |
1139 |
|
1.31.4. DOOR HANDLE SWITCHES WITH HARNESS |
1140 |
|
1.31.5. LF ANTENNAS |
1141 |
|
13. HVAC |
1143 |
|
1.1 GENERAL INFORMATION |
1146 |
|
1.1.1. SPECIFICATIONS |
1146 |
|
1.1.2. TIGHTENING TORQUES |
1148 |
|
1.1.3. PRECAUTIONS |
1154 |
|
1.1.4. HVAC SYSTEM LAYOUT & WORKING |
1155 |
|
1.1.5. COMPONENTS OF HVAC |
1158 |
|
1.1.5.1. CONTROL PANEL |
1158 |
|
1.1.5.2. HVAC UNIT |
1160 |
|
1.1.5.3. COMPRESSOR |
1163 |
|
1.1.5.4. CONDENSOR & RECEIVER DRIER |
1164 |
|
1.1.5.5. THERMISTOR / THERMO SENSOR |
1164 |
|
1.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR |
1167 |
|
1.1.5.7. AIR INLET ACTUATOR |
1168 |
|
1.1.6. TROUBLESHOOTING |
1169 |
|
1.2 MAINTAINANCE |
1183 |
|
1.2.1. PRELIMINARY INSPECTION |
1183 |
|
1.2.2. REGULAR MAINTENANCE |
1185 |
|
1.3 ON VEHICLE REPAIR |
1191 |
|
1.3.1. CONTROL PANEL ASSEMBLY |
1191 |
|
1.3.2. COMPRESSOR |
1196 |
|
1.3.3. BLOWER |
1196 |
|
1.3.4. BLOWER RESISTER |
1197 |
|
1.3.5. FILTER |
1197 |
|
1.3.6. TXV |
1200 |
|
1.3.7. PRESSURE SENSOR / SWITCH |
1200 |
|
1.3.8. HVAC UNIT |
1201 |
|
1.3.9. CONDENSOR SEALING DUCT |
1201 |
|
1.3.10. CONDENSOR |
1202 |
|
1.3.11. REFRIGERANT HOSES |
1203 |
|
1.3.12. DO's & DON’T's |
1204 |
|
14. FATC |
1205 |
|
1.1. GENERAL INFORMATION |
1208 |
|
1.2. TECHNICAL SPECIFICATIONS |
1210 |
|
1.3. TIGHTENING TORQUES |
1212 |
|
A. FOR PETROL VERIENT |
1212 |
|
B. FOR DIESEL VERIENT |
1215 |
|
1.4. FRONT HVAC UNIT |
1218 |
|
1.5. COMPRESSOR |
1220 |
|
1.6. CONDENSER AND RECEIVER DRIER |
1221 |
|
1.7. FATC CONTROL PANEL |
1222 |
|
1.8. HMI CLIMATE CONTROL DISPLAY |
1226 |
|
1.9. CONTROL PANEL CONNECTOR DETAILS |
1227 |
|
1.10. FATC SENSOR & ACTUATOR |
1229 |
|
A. SOLAR LOAD SENSOR |
1229 |
|
B. OAT SENSOR |
1230 |
|
C. INCAR SENSOR |
1230 |
|
D. EVAPORATOR SENSOR |
1231 |
|
E. MODE ACTUATOR |
1231 |
|
F. BLOWER CONTROL MODULE |
1232 |
|
1.11. FRONT HVAC BLOWER ASSEMBLY |
1234 |
|
1.12. REAR BLOWER SWITCH |
1234 |
|
1.13. REAR BLOWER ASSEMBLY |
1235 |
|
1.14. OVERHAULING FRONT FATC UNIT |
1237 |
|
15. SRS |
1242 |
|
1.1. WORKING OF RESTRAINTS |
1245 |
|
1.2. SYSTEM LAYOUT |
1246 |
|
1.3. SAFETY PRECAUTIONS |
1247 |
|
1.4. DISPOSAL OF FAULTY AIR BAG UNIT |
1249 |
|
1.5. SRS POST ACCIDENT PROCEDURE |
1250 |
|
1.6. TIGHTENING TORQUES |
1251 |
|
1.7. COMPONENTS |
1252 |
|
1.7.1. RESTRAINT WITHOUT AIRBAGS |
1252 |
|
1.7.2. RESTRAINT WITH AIRBAGS |
1252 |
|
1.7.2.1. ECU |
1252 |
|
1.7.2.2. SENSORS |
1255 |
|
1.7.2.3. AIRBAGS |
1257 |
|
1.7.2.4. RPLL BELTS |
1259 |
|
1.7.2.5. CLOCK SPRING |
1261 |