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0. MAIN
1

INTRODUCTION
3

1. ENGINE
5

1. ENGINE INDEX
6

1. GENERAL INFORMATION
10

A. ENGINE INTRODUCTION
10

B. TECHNICAL SPECIFICATION
11

C. SPECIAL TOOLS
12

D. ASSEMBLY CLEARANCES
17

E. LEAKAGE RATES
18

F. RECOMMENDED LUBRICANTS & COOLANTS
18

G. SERVICE SCHEDULE
19

2. TROUBLESHOOTING
20

3. CONSTRUCTIONAL AND SERVICE DETAILS
28

4. ENGINE TESTS AND MAINTENANCE
31

A. PRELIMINARY INSPECTION
31

B. ENGINE TESTS
31

C. REGULAR MAINTENANCE
37

i. ENGINE OIL AND FILTER CHANGE
37

ii. ENGINE COOLANT REPLACEMENT
38

iii. AIR FILTER ELEMENT REPLACEMENT
39

iv. FUEL FILTER REPLACEMENT
40

v. DRAINING WATER FROM FUEL FILTER
41

vi. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT
41

vii. DIESEL PARTICULATE FILTER (DPF) REGENERATION / CLEANING
42

5. REPAIR AND INSPECTION DETAILS
43

A. TIMING BELT
43

B. FUEL TANK
44

C. CYLINDER HEAD
44

D. VALVES
45

E. CRANK CASE
46

F. HYDRAULIC LASH ADJUSTER
47

G. VALVE GUIDES
47

H. CAMSHAFT
48

I. PISTON AND PISTON RINGS
49

J. CONNECTING ROD
50

K. CRANK SHAFT
52

L. EXHAUST PIPE
56

6. ENGINE ON VEHICLE SERVICE
57

A. ENGINE REMOVAL
57

B. ENGINE INSTALLATION
66

C. EXHAUST SYSTEM
66

D. COOLING SYSTEM
74

E. FUEL SYSTEM
77

F. TURBOCHARGER REMOVAL AND REFITMENT
77

G. TIMING BELT REMOVAL AND REFITMENT
83

H. STARTER MOTOR REMOVAL AND REFITMENT
86

I. ALTERNATOR REMOVAL AND REFITMENT
87

J. COMPRESSOR REMOVAL AND REFITMENT
87

K. HIGH PRESSURE PUMP REMOVAL AND REFITMENT
88

7. ENGINE OVERHAULING
91

A. ENGINE DIS-ASSEMBLY
91

i. ON OVERHAUL STAND
91

ii. REMOVAL OF FUEL INJECTOR AND PERIPHERAL
94

iii. REMOVAL OF EXHAUST MANIFOLD AND OTHER COMPONENTS
95

iv. REMOVAL OF ENGINE PERIPHERALS
99

v. REMOVAL OF TIMING BELT
101

vi. REMOVAL OF INTAKE MANIFOLD
105

vii. REMOVAL OF CYLINDER HEAD
106

viii. REMOVAL OF OIL SUMP
108

ix. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES
108

x. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES
110

xi. REMOVAL OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES
111

B. ENGINE ASSEMBLY
112

i. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES
112

ii. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES
113

iii. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES
114

iv. FITMENT OF OIL SUMP
116

v. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK
117

vi. FITMENT OF INTAKE MANIFOLD
120

vii. FITMENT OF TIMING BELT
121

viii. FITMENT OF ENGINE PERIPHERALS
125

ix. FITMENT OF EXHAUST MANIFOLD AND OTHER COMPONENTS
127

x. FITMENT OF FUEL INJECTOR AND PERIPHERALS
131

xi. ON SUPPORT STAND
133

2. TRANSAXLE
135

2. TRANSAXLE INDEX
137

1. TECHNICAL SPECIFICATION
138

2. PRECAUTIONS
138

3. COMMON PROBLEM CAUSES OR PRE-DIAGNOSTIC INSPECTION
139

4. TIGHTENING TORQUES
145

5. SPECIAL TOOLS
151

6. REMOVAL OF TRANSAXLE FROM VEHICLE
153

7. INSTALLATION OF TRANSAXLE ON VEHICLE
156

8. FLUID
160

9. TRANSAXLE DISASSEMBLY ON BENCH
161

10. TRANSAXLE ASSEMBLY ON BENCH
166

11. DIFFERENTIAL BEARING REMOVAL
173

12. DIFFERENTIAL BEARING ASSEMBLY
173

13. DISASSEMBLY GEARSHIFT CONTROL CABLE
174

14.ASSEMBLY GEARSHIFT CONTROL CABLE
176

15. REMOVAL GEARSHIFT MECHANISM
176

16.ASSEMBLY GEARSHIFT MECHANISM
178

17. ASSEMBLY DIFFERENTIAL OIL SEAL
178

18. INPUT SHAFT DISASSEMBLY
179

19. INPUT SHAFT ASSEMBLY
180

20. DISASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th)
182

21. ASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th)
185

22. DISASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.)
188

23. ASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.)
191

24. REMOVAL BACKUP (REVERSE) LAMP SWITCH
194

25. ASSEMBLY BACKUP (REVERSE) LAMP SWITCH
194

3. DRIVESHAFT
195

3. DRIVESHAFT INDEX
197

1.1. GENERAL INFORMATION
199

1.2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE
200

1.3. DRIVE SHAFT PARTS
201

1.4. TIGHTENING OF TORQUES
202

1.5. SPECIAL TOOLS
204

1.6. ON BENCH PROCEDURE
205

1.7. ON VEHICLE PROCEDURE
207

A. DRIVE SHAFT LH
207

B. DRIVE SHAFT RH
211

4. CLUTCH RELEASE SYSTEM
215

4. CLUTCH RELEASE SYSTEM INDEX
217

1. CLUTCH SYSTEM LAYOUT
219

2. CLUTCH SYSTEM COMPONENTS
220

3. REGULAR MAINTENANCE
221

4. CLUTCH PEDAL ASSEMBLY
222

5. BRAKE PEDAL ASSEMBLY
223

6. REMOVAL OF ACCELERATOR PEDAL
224

7. REMOVAL OF CLUTCH CONTROL BRACKET
225

8. ASSEMBLY OF CLUTCH CONTROL BRACKET
227

9. BRAKE SWITCH INSTALLATION PROCEDURE
229

5. STEERING
230

5. STEERING INDEX
232

1.1 GENERAL INFORMATION
234

A. SPECIFICATIONS
234

B. SYSTEM LAYOUT
235

C. TIGHTENING OF TORQUES
236

D. SPECIAL TOOLS
239

1.2 GENERAL SYMPTOMS DIAGNOSIS
240

1.3 MAINTENANCE, INSPECTION AND TEST
247

A. PRELIMINARY INSPECTION
247

B. REGULAR MAINTENANCE
248

C. REPAIRS
253

1.4 OVERHAULING
262

A. PRECAUTIONS
262

B. RACK AND PINION ASSEMBLY
262

C. FEED PIPE
263

D. DO'S & DONT'S
263

E. STEERING PUMP
264

6. SUSPENSION
265

6. SUSPENSION INDEX
267

1. GENERAL INFORMATION
268

2. TECHNICAL SPECIFICATIONS
271

3. TIGHTENING TORQUES
272

4. SPECIAL TOOLS
276

5. DIAGNOSIS
279

6. PRECAUTIONS
280

7. EXPLODED VIEWS OF FRONT SUSPENSION
281

8. EXPLODED VIEWS OF REAR SUSPENSION
284

9. ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY
285

10. ON BENCH FRONT SUSPENSION DISASSEMBLY
288

11. ON BENCH FRONT SUSPENSION ASSEMBLY
290

12. REMOVAL AND ASSEMBLY OF WHEEL DISC
292

13. ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB
293

14. REMOVAL OF SUBFRAME ASSEMBLY
294

15. INSTALLATION OF SUBFRAME ASSEMBLY
295

16. LCA REAR HYDRA-BUSH INSTALLATION
296

17. REMOVAL OF ANTI ROLL BAR
297

18. REMOVAL AND ASSEMBLY OF REAR DAMPER ASSEMBLY AND COIL SPRINGS
298

19. ECIE CONDITION
298

20. INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS
299

21. REAR SUSPENSION DISMANTLING OR INSTALLATION PROCESS
300

22. RTB BUSH INSTALLATION
303

23. PAN HARD ROD BUSH INSTALLATION AND REMOVAL
304

24. INSTALLATION AND REMOVAL OF DAMPER BOTTOM BUSH
305

7. WHEELS & TYRES
306

7. WHEELS & TYRES INDEX
308

1. GENERAL INFORMATION
310

A. SPECIFICATIONS - FOR XZ & XT VARIANTS
310

B. SPECIFICATIONS - FOR XM & XE VARIANTS
311

C. TIGHTENING OF TORQUES
312

2. GENERAL SYMPTOMS DIAGNOSIS
313

A. DIAGNOSIS CHART
313

B. TYRE WEAR PATTERN
315

C. WEAR CAUSES
316

D. TYRE VIBRATION DIAGNOSIS
317

3. MAINTENANCE, INSPECTION AND TEST
318

A. PRELIMINARY INSPECTION
318

B. REGULAR MAINTENANCE
319

4. WHEEL AND TYRE REPLACEMENT
322

A. PRECAUTIONS DURING TYRE REPLACEMENT
322

B. TYRE REPLACEMENT
323

C. WHEEL ASSEMBLY REPLACEMENT
323

D. WHEEL REMOVAL
323

E. BALANCING WHEELS
324

F. TYRE CARE
324

8. BRAKES
325

8. BRAKES INDEX
327

1. GENERAL INFORMATION
331

2. SPECIFICATOIN
331

3. SYSTEM DETAILS
332

A. SYSTEM SCHEMATIC FOR ABS & ESP VERSION
332

B. SYSTEM LAYOUT FOR ABS & ESP VERSION
333

4. TIGHTENING TORQUES
334

5. GENERAL SYMPTOMS DIAGNOSIS
339

6. NESSECITY OF ABS WITH EBD
341

7. VACUUM BRAKE BOOSTER
341

8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS)
343

A. BRAKING WITHOUT ABS IN OPERATION
343

B. BRAKING WITH EBD INTO OPERATION
343

9. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU/HCU)
346

10. WHEEL SPEED SENSOR: (MONITOR SPEED)
348

11. ABS SYSTEM FAILURE WARNING LIGHT
349

12. MAINTENANCE, INSPECTION AND TEST
350

13. REAR DRUM BRAKES
351

14. REMOVAL OF SHOES
354

15. WHEEL CYLINDER SERVICING
357

16. REGULAR MAINTENANCE
359

A. BRAKE BLEEDING PROCEDURE
359

B. ABS SECONDAY CIRCUIT BLEEDING PROCEDURE(USING DIAGNOSTIC TOOL)
360

C. CALIPER PAD REPLACEMENT
361

D. PARKING BRAKE ADJUSTMENT
363

E. BRAKE FLUID DRAINING PROCEDURE
364

F. BRAKE LIGHT SWITCH ADJUSTMENT
364

G. CALIPER GREASING
365

H. DISC RUN-OUT MEASUREMENT PROCEDURE
365

17. ON VEHICLE REPAIRS
366

A. CALIPER ASSEMBLY WITH CARRIER REMOVAL
366

B. BRAKE DISC REMOVAL
367

C. PARKING BRAKE
368

D. BRAKE PEDAL
372

E. VACUUM LINES
377

F. BOOSTER ASSEMBLY
378

18. DISMANTLING, INSPECTION AND ASSEMBLY
384

A. FRONT CALIPER ASSEMBLY
384

9. ABS
389

9. ABS INDEX
391

1. GENERAL INFORMATION
393

2. COMPONENTS LAYOUT
401

3. REPAIRS
408

4. TROUBLE SHOOTING AND DIAGNOSIS
413

10. ESP
416

10. ESP INDEX
418

1. ELECTRONIC STABILITY PROGRAM(ESP)
420

1.1 GENERAL INFORMATION
420

A. NECESSITY OF ESP AND TCS
420

B. SPECIFICATIONS
421

C. TIGHTENING OF TORQUES
422

D. SYSTEM LAYOUT
423

1.2 WORKING OF ESP
424

1.3 COMPONENTS
426

1.4 ON VEHICLE REPAIRS
431

1.5 TROUBLESHOOTING
432

11. HVAC
433

11. HVAC INDEX
435

1. HVAC SYSTEM LAYOUT
436

2. TECHNICAL SPECIFICATIONS
437

3. TIGHTENING OF TORQUES
441

4. PRECAUTIONS
445

5. HVAC SYSTEM LAYOUT AND WORKING
446

6. CONTROL PANEL
449

7. HVAC UNIT COMPONENTS
451

8. COMPRESSOR
453

9. CONDENSER
454

10. RECEIVER DRIER(R.D)
454

11. ON VEHICLE INSPECTION(WITHOUT DISMANTLING HVAC UNIT
455

12. TRINARY PRESSURE SWITCH
456

13. MODE & TEMPERATURE CONTROL ACTUATOR
457

14. INSPECTION OF MODE AND TEMPERATURE ACTUATOR
458

15. TROUBLESHOOTING
460

16. MAINTENANCE
470

17. ON VEHICLE REPAIRS
476

A. AC FILTER REMOVAL AND ASSEMBLY
476

B. COMPRESSOR REMOVAL AND ASSEMBLY
476

C. CONTROL PANEL REMOVAL AND ASSEMBLY
477

D. BLOWER MOTOR REMOVAL AND ASSEMBLY
478

E. FRONT HVAC UNIT REMOVAL AND ASSEMBLY
479

F. B-PILLAR VENT REMOVAL AND ASSEMBLY
480

G. HEATER HOSE REMOVAL AND ASSEMBLY
481

H. PRESSURE SWITCH REMOVAL AND ASSEMBLY
482

I. CONDENSER REMOVAL AND ASSEMBLY
483

J. CONDENSER SEALING DUCT REMOVAL AND ASSEMBLY
483

18. DO’S AND DONT’S FOR A/C SYSTEM
484

12. FATC
486

12. FATC INDEX
488

1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM
489

2. TECHNICAL SPECIFICATIONS
491

3. TIGHTENING TORQUES
497

4. PRECAUTIONS
501

5. HMI CLIMATE CONTRL DISPLAY
502

6. CONTROL PANEL
503

7. CONTROL PANEL MODULE CONNECTOR DETAILS
508

8. FATC UNIT
510

9. FATC SENSOR & ACTUATOR
512

10. COMPRESSOR
518

11. CONDENSER AND RECEIVER DRIER
519

12. TROUBLESHOOTING
520

13. MAINTENANCE
531

14. ON VEHICLE REPAIR
539

A. AC FILTER REMOVAL AND ASSEMBLY
539

B. CONTROL PANEL REMOVAL AND ASSEMBLY
539

C. BLOWER MOTOR REMOVAL AND ASSEMBLY
540

D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY
542

E. B-PILLAR VENT REMOVAL AND ASSEMBLY
543

F. COMPRESSOR REMOVAL AND ASEMBLY
544

G. HEATER HOSE REMOVAL AND ASSEMBLY
545

H. PRESSURE SWITCH REMOVAL AND ASSEMBLY
546

I. CONDENSER REMOVAL AND ASSEMBLY
546

J. CONDENSER SEALING DUCT REMOVAL AND ASSEMBLY
547

15. DO’S AND DONT’S FOR A/C SYSTEM
548

13. BODY
549

13. BODY INDEX
555

1. GENERAL INFORMATION
559

1.1 LAYOUT
559

1.2 TIGHTENING TORQUES
560

1.3 SPECIAL TOOL
563

2. ON VEHICLE REPAIRS
564

2.1 BONNET
564

2.2 ARM REST
567

2.3 FLOOR CONSOLE
567

2.4 DASHBOARD SKIN
569

2.5 GLOVE BOX
577

2.6 SIDE AIR VENTS
577

2.7 FRONT BUMPER
579

2.8 REAR BUMPER
581

2.9 FRONT DOOR
583

2.10 FRONT DOOR TRIMS
585

2.11 DOOR INNER LOCK HANDLE
587

2.12 FRONT OUTER DOOR LOCK
588

2.13 FRONT DOOR LATCH
589

2.14 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM
590

2.15 REAR DOOR
591

2.16 REAR DOOR TRIM
593

2.17 REAR OUTER DOOR LOCK
594

2.18 DOOR LATCH REAR
595

2.19 TAIL GATE
596

2.20 TAIL GATE TRIM
598

2.21 ORVM
599

2.22 INNER REAR VIEW MIRROR
600

2.23 FRONT ROW SEAT
600

2.24 REAR ROW SEAT
601

2.25 FRONT SEAT BELT
603

2.26 REAR SEAT BELT
605

2.27 “A” PILLAR TRIM
606

2.28 FRONT SCUFF PLATE
607

2.29 “B” PILLAR TRIMS
607

2.30 REAR SCUFF PLATE
608

2.31 REAR QUARTER TRIM
609

2.32 “C” PILLAR TRIMS
610

2.33 GRAB HANDLE
610

2.34 SUNVISOR
611

2.35 ROOF LINEAR
611

2.42 REAR WHEEL ARCH LINER
612

2.43 FRONT FENDER
614

2.44 REAR WIPER MOTOR
615

2.45 FRONT WIPER
616

14. ELECTRICAL
617

14. ELECTRICAL INDEX
623

1. TECHNICAL SPECIFICATION
626

2. GENERAL PRECAUTIONS
629

3. FUSE BOX / RELAY LOCATIONS
633

4. BATTERY
634

5. ALTERNATOR
636

6. STARTER MOTOR
637

7. LIGHTING SYSTEM
644

7.1 BULB SPECIFICATIONS
644

7.2 FASTENERS TORQUE VALUE TABLE
645

7.3 GENERAL SYMPTOMS AND DIAGNOSTICS
646

7.4 HEAD LAMP
650

7.5 DRL Assembly
654

7.6 SIDE REPEATER LAMP (LH/RH)
655

7.7 ROOF LAMP
655

7.8 HIGH MOUNTED STOP LAMP
656

7.9 TAIL LAMP
657

7.10 REAR FOG LAMP (HIGH VERSION ONLY)
660

7.11 FRONT FOG LAMP
661

7.12 REGISTRATION PLATE LAMP
662

8. HORN
663

9 WIPER & WASHER SYSTEM
665

9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT
666

9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY
667

9.3 WIPER AND WIPER CARE
673

10 POWER SOCKETS
676

11 GLOW PLUG CONTROL UNIT
677

12 FUEL GAUGE AND FUEL LEVEL METER
679

13 COMBI-SWITCH
682

14. STEERING LOCK CUM IGNITION SWITCH
688

15. FASCIA SWITCHES
691

16. MIRROR SWITCH
698

17. INFOTAINMENT SYSTEM
701

17.1 USB/AUX PORT
705

17.2 SPEAKERS
707

17.3 ANTENNA
709

17.4 MICROPHONE
710

17.5 SILVER BOX
712

17.6 TWEETERS
717

18. WINDOW WINDING MODULE
720

19. POWER WINDOW SWITCHES & INHIBIT SWITCH
723

20. STEERING WHEEL SWITCHES
729

21. DOOR HANDLE SWITCH
732

22. TAILGATE HANDLE SWITCH
733

23. IGNITION KEY
734

24. INSTRUMENT CLUSTER
741

24.1 BASIC FUNCTIONAL MATRIX
746

24.2 TELL TALES MATRIX
747

24.3 DRIVER INFORMATION SYSTEM
753

24.4 REMINDER FEATURES
768

24.5 FUEL GAUGE DETAILS
771

24.6 TEMPERATURE BAR GRAPH DETAILS
772

24.7 CHIME TABLE
773

25. IMMOBILIZER SYSTEM
776

25.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB
780

25.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU
781

25.3 REMINDER FEATURES
783

25.4 FUEL GAUGE DETAILS
785

25.5 TEMPERATURE BAR GRAPH DETAILS
786

25.6 CHIME TABLE
787

25.7 DISPLAY SCREEN FLOW AND SETTINGS
787

26 IMMOBILIZER SYSTEM
794

26.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB
799

26.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU
800

26.3 IGNITION KEY LEARNING PROCEDURE
803

27. BODY CONTROL MODULE (BCM)
806

27.1 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX
813

27.2 BCM FUNCTIONS
824

28. FUSE AND RELAY BOX DETAILS
884

28.1 BATTERY MOUNTED FUSE BOX
887

28.2 ENGINE FUSE AND RELAY BOX
887

28.3 CABIN FUSE AND RELAY BOX
890

29. REVERSE PARK ASSIST SYSTEM
893

29.1 REAR VIEW CAMERA
897

30. PASSIVE ENTRY PASSIVE START (PEPS)
909

30.1 PEPS ECU
910

30.2 START STOP SWITCH
912

30.3 ELECTRONIC STEERING COLUMN LOCK (ESCL)
914

30.4 DOOR AND TAILGATE HANDLE SWITCHES WITH HARNESS
915

30.5 LF ANTENNAS
916

15. SRS
919

15. SRS INDEX
921

1.1. WORKING OF RESTRAINTS
923

1.2. SYSTEM LAYOUT
925

1.3. SAFETY PRECAUTIONS
926

1.4. DISPOSAL OF FAULTY AIR BAG UNIT
928

1.5. SRS POST ACCIDENT PROCEDURE
929

1.6. TIGHTENING TORQUES
930

1.7. COMPONENTS
934

1.7.1. RESTRAINT WITHOUT AIRBAGS
934

1.7.2. RESTRAINT WITH AIRBAGS
934

1.7.2.1. ECU
934

1.7.2.2. SENSORS
937

1.7.2.3. AIR BAGS
940

1.7.2.4. RPLL BELTS
944

1.7.2.5. CLOCK SPRING
946