TIGOR - 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. PETROL ENGINE |
30 |
|
2.1. GENERAL INFORMATION |
36 |
|
A. ENGINE INTRODUCTION |
36 |
|
B. ELECTRONIC FUEL INJECTION CONTROL |
37 |
|
C. TECHNICAL SPECIFICATION |
38 |
|
D. SPECIAL TOOLS |
39 |
|
E. ASSEMBLY CLEARANCES |
42 |
|
F. SEALANTS |
42 |
|
G. LEAKAGE RATES |
42 |
|
H. RECOMMENDED LUBRICANTS & COOLANTS |
42 |
|
I. SERVICE SCHEDULE |
43 |
|
2.2. TROUBLESHOOTING |
44 |
|
2.3. CONSTRUCTIONAL AND SERVICE DETAILS |
51 |
|
A. ENGINE LIFTING |
51 |
|
B. INTAKE MANIFOLD |
52 |
|
C.CYLINDER HEAD AND COVER |
54 |
|
D. CYLINDER HEAD-A |
56 |
|
E. CYLINDER HEAD-B |
58 |
|
F. CYLINDER BLOCK |
60 |
|
G. OIL SUMP |
62 |
|
H. MOVING PARTS |
64 |
|
I. ENGINE TIMING |
67 |
|
J. EXHAUST MANIFOLD |
69 |
|
K. FUEL INJECTION EQUIPMENT |
71 |
|
L. LUBRICATION PUMP AND COMPONENTS |
73 |
|
M. AIR INTAKE SYSTEM |
75 |
|
N. SPECIAL INSTALLATION |
77 |
|
O. ENGINE SUSPENSION |
80 |
|
2.4. ENGINE TESTS AND MAINTENANCE |
83 |
|
A. PRELIMINARY INSPECTION |
83 |
|
B. ENGINE TESTS |
84 |
|
I. ENGINE COMPRESSION TEST |
84 |
|
II. ENGINE OIL CONSUMPTION TEST |
85 |
|
III. ENGINE OIL PRESSURE TEST |
86 |
|
C. REGULAR MAINTENANCE |
87 |
|
I. ENGINE OIL AND FILTER CHANGE |
87 |
|
II. ENGINE COOLANT REPLACEMENT |
88 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
89 |
|
IV. SPARK PLUG REPLACEMENT |
90 |
|
V. FUEL FILTER REPLACEMENT |
93 |
|
VI. AIR CONDITIONER COMPRESSOR BELT REPLACEMENT |
94 |
|
2.5. REPAIR AND INSPECTION DETAILS |
95 |
|
A. ACCESSORY DRIVING BELT |
95 |
|
B. TIMING CHAIN |
95 |
|
C. CYLINDER HEAD |
95 |
|
D. VALVES |
96 |
|
E. CYLINDER HEAD VALVE SEATS |
98 |
|
F. ROCKER ARM AND SHAFTS |
99 |
|
G. HYDRAULIC LASH ADJUSTER |
99 |
|
H. CAMSHAFT |
99 |
|
I. PISTON AND PISTON RINGS |
101 |
|
J. CONNECTING RODS |
102 |
|
K. CRANKSHAFT |
104 |
|
L. CRANK CASE |
106 |
|
M. FUEL TANK |
107 |
|
N. CANISTER PURGE VALVE |
107 |
|
O. CANISTER |
108 |
|
2.6. ENGINE SYSTEM |
109 |
|
A. AIR INTAKE SYSTEM |
109 |
|
B. BLOW BY SYSTEM |
111 |
|
C. LUBRICATION SYSTEM |
112 |
|
D. EXHAUST SYSTEM |
116 |
|
E. COOLING SYSTEM |
119 |
|
F. FUEL SYSTEM |
122 |
|
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
125 |
|
A. ENGINE REMOVAL AND INSTALLATION |
125 |
|
B. AIR FILTER ASSY |
130 |
|
C. INJECTION SYSTEM |
131 |
|
D. SPARK PLUG |
132 |
|
E. EXHAUST SYSTEM |
132 |
|
F. FUEL SYSTEM |
135 |
|
G. COOLING SYSTEM |
141 |
|
H. REMOVAL OF ACCESSORIES |
144 |
|
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
145 |
|
A. ENGINE DIS-ASSEMBLY |
145 |
|
I. REMOVAL OF INTAKE MANIFOLD |
145 |
|
II. REMOVAL OF EXHAUST MANIFOLD |
146 |
|
III. REMOVAL OF OIL SUMP |
148 |
|
IV. REMOVAL OF SENSORS |
148 |
|
V. REMOVAL OF ACCESSORIES |
149 |
|
VI. REMOVAL OF TIMING CHAIN |
152 |
|
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 |
161 |
|
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
161 |
|
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
165 |
|
III. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
167 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
169 |
|
V. ASSEMBLY OF TIMING CHAIN |
170 |
|
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
174 |
|
VII. FITMENT OF ENGINE SENSORS AND PERIPHERALS |
175 |
|
VIII. FITMENT OF OIL SUMP |
176 |
|
IX. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
177 |
|
X. ASSEMBLY OF INTAKE MANIFOLD |
179 |
|
2.9. ENGINE MANAGEMENT SYSTEM |
181 |
|
A. ABBREVIATIONS |
181 |
|
B. AN OVERVIEW |
182 |
|
C. ELECTRONIC CONTROL UNIT |
183 |
|
D. SENSORS |
188 |
|
I. T-MAP SENSOR |
189 |
|
II. LAMBDA SENSOR |
190 |
|
III. CAMSHAFT POSITION SENSOR |
192 |
|
IV. KNOCK SENSOR |
193 |
|
V. CRANKSHAFT POSITION SENSOR |
194 |
|
VI. COOLANT TEMPERATURE SENSOR |
195 |
|
E. ACTUATORS |
197 |
|
I. IGNITION COIL |
198 |
|
II. PURGE CONTROL VALVE |
199 |
|
III. SOLENOID VALVE (OCV) |
200 |
|
IV. FUEL INJECTOR |
201 |
|
V. ELECTRONIC THROTTLE BODY |
202 |
|
F. SWITCH |
204 |
|
I. OIL PRESSURE SWITCH |
204 |
|
II. THROTTLE PEDAL SENSOR |
205 |
|
III. CLUTCH SWITCH |
206 |
|
IV. BRAKE SWITCH |
207 |
|
V. VEHICLE SPEED SENSOR |
208 |
|
VI. WHEEL SPEED SENSOR |
209 |
|
3. DIESEL ENGINE |
210 |
|
3.1. GENERAL INFORMATION |
215 |
|
A. ENGINE INTRODUCTION |
215 |
|
B. TECHNICAL SPECIFICATION |
216 |
|
C. SPECIAL TOOLS |
217 |
|
D.ASSEMBLY CLEARANCES |
221 |
|
E. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
222 |
|
F. SERVICE SCHEDULE |
223 |
|
3.2. TROUBLESHOOTING |
224 |
|
3.3. CONSTRUCTIONAL AND SERVICE DETAILS |
232 |
|
A. ENGINE MOUNTING SYSTEM |
232 |
|
B. CYLINDER HEAD AND COVER |
234 |
|
C. LUBRICATION SYSTEM |
236 |
|
D. ENGINE |
238 |
|
E. OIL SUMP |
240 |
|
F. CYLINDER HEAD |
242 |
|
G. SPECIAL INSTALLATION |
244 |
|
H. EXHAUST SYSTEM |
246 |
|
I. INTAKE SYSTEM |
248 |
|
J. ENGINE SUSPENSION |
250 |
|
K. MOVING PARTS |
252 |
|
L. ENGINE TIMING |
254 |
|
M. FUEL INJECTION EQUIPMENT |
256 |
|
3.4. ENGINE TESTS AND MAINTENANCE |
258 |
|
A. PRELIMINARY INSPECTION |
258 |
|
B. ENGINE TESTS |
258 |
|
C. REGULAR MAINTENANCE |
262 |
|
I. ENGINE OIL AND FILTER CHANGE |
262 |
|
II.ENGINE COOLANT REPLACEMENT |
263 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
264 |
|
IV. FUEL FILTER REPLACEMENT |
265 |
|
V. DRAINING WATER FROM PRE-FILTER |
266 |
|
VI. PRE-FILTER REPLACEMENT |
266 |
|
VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
267 |
|
3.5. REPAIR AND INSPECTION DETAILS |
268 |
|
A. TIMING BELT |
268 |
|
B. FUEL TANK |
268 |
|
C. CYLINDER HEAD |
269 |
|
D. VALVES |
270 |
|
E. VALVE SEATS |
271 |
|
F. CRANKCASE |
272 |
|
G. VALVE SEAT INSERT |
273 |
|
H. HYDRAULIC LASH ADJUSTER |
273 |
|
I. VALVE GUIDES |
274 |
|
J. CAMSHAFT |
275 |
|
K. PISTON AND PISTON RINGS |
276 |
|
L. CONNECTING ROD |
277 |
|
M. CRANKSHAFT |
279 |
|
3.6. ENGINE SYSTEM |
281 |
|
A. AIR INTAKE SYSTEM |
281 |
|
B. EXHAUST SYSTEM |
283 |
|
C. COOLING SYSTEM |
287 |
|
D. LUBRICATION SYSTEM |
290 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM |
293 |
|
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM |
295 |
|
G. VACUUM MANAGEMENT SYSTEM |
296 |
|
H. FUEL SYSTEM |
297 |
|
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
303 |
|
A. ENGINE REMOVAL |
303 |
|
B. ENGINE INSTALLATION |
307 |
|
C. EXHAUST SYSTEM |
308 |
|
D. COOLING SYSTEM |
310 |
|
E. FUEL SYSTEM |
312 |
|
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
319 |
|
A. ENGINE DIS-ASSEMBLY |
319 |
|
I ON OVERHAUL STAND |
319 |
|
II. REMOVAL OF INTAKE MANIFOLD |
322 |
|
III. REMOVAL OF EXHAUST MANIFOLD |
324 |
|
IV. REMOVAL OF OIL SUMP |
328 |
|
V. REMOVAL OF TIMING BELT |
329 |
|
VI. REMOVAL OF CYLINDER HEAD |
332 |
|
VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
333 |
|
VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
335 |
|
IX. PISTON CONNECTING ROD DIS-ASSEMBLY |
337 |
|
B. ENGINE ASSEMBLY |
343 |
|
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
343 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
344 |
|
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
345 |
|
IV.FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
346 |
|
V. FITMENT OFTIMING BELT |
347 |
|
VI. FITMENT OF OIL SUMP |
350 |
|
VII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
352 |
|
VIII. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
356 |
|
IX. ON ENGINE SUPPORT STAND |
358 |
|
3.9. ENGINE MANAGEMENT SYSTEM |
362 |
|
A. ABBREVIATIONS |
362 |
|
B. AN OVERVIEW |
363 |
|
C. ELECTRONIC CONTROL UNIT (ECU) |
364 |
|
D. EMS SENSORS |
368 |
|
I. CRANK POSITION SENSOR |
368 |
|
II. VEHICLE SPEED SENSOR |
369 |
|
III. WHEEL SPEED SENSOR |
370 |
|
IV. CAMSHAFT POSITION SENSOR |
371 |
|
V. AIR MASS FLOW SENSOR |
372 |
|
VI. INLET METERING VALVE |
373 |
|
VII. VENTURI |
373 |
|
VIII. RAIL PRESSURE SENSOR |
373 |
|
IX. THROTTLE PEDAL SENSOR |
374 |
|
X. WATER IN FUEL SENSOR |
375 |
|
XI. CLUTCH SWITCH |
375 |
|
XII. OIL PRESSURE SWITCH |
376 |
|
XIII. BRAKE SWITCH |
378 |
|
XIV. COOLANT TEMPERATURE SENSOR |
379 |
|
XV. GLOW PLUG |
380 |
|
XVI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
381 |
|
4. DRIVETRAIN |
382 |
|
4.1. PRECAUTION |
386 |
|
4.2. SPECIFCICATIONS & TIGHTENING TORQUES |
387 |
|
A. CLUTCH |
387 |
|
B. TRANSAXLE |
392 |
|
C. TIGHTENING TORQUES |
393 |
|
4.3. SPECIAL TOOLS |
394 |
|
A. CLUTCH |
394 |
|
B. TRANSAXLE |
394 |
|
4.4. DIAGNOSIS |
399 |
|
A. CLUTCH |
399 |
|
B. TRANSAXLE |
402 |
|
4.5. MAINTENANCE, ADJUSTMENT & TEST |
403 |
|
A. PRELIMINARY INSPECTION OF CLUTCH |
403 |
|
B. DRIVESHAFT |
404 |
|
4.6. CLUTCH |
406 |
|
A. THEORY OF DIAPHRAGM SPRING CLUTCH |
406 |
|
B. CONSTRUCTIONAL DETAILS |
407 |
|
C. FACTOR AFFECTING CLUTCH WEAR |
409 |
|
D. CLUTCH CABLE – REMOVAL AND INSPECTION |
410 |
|
E. REMOVAL OF CLUTCH FROM THE CAR |
411 |
|
F. INSTALLATION OF CLUTCH ON THE CAR |
411 |
|
G. PROCEDURE FOR CLUTCH ADJUSTMENT |
412 |
|
4.7. TRANSAXLE |
413 |
|
A. GENERAL DISCRIPTION |
413 |
|
B. CUT SECTION OF TRANSAXLE TA 65 STAR |
415 |
|
C. CUT SECTION OF TOP COVER ASSEMBLY |
416 |
|
D. EXPLODED VIEW OF TRANSAXLE |
417 |
|
E. EXPLODED VIEWS OF DIFFERENTIAL |
419 |
|
F. EXPLODED VIEW OF SHIFTER FORK |
421 |
|
G. EXPLODED VIEWS OF GEAR SHIFT LINKAGE ASSSEMBLY |
423 |
|
H. EXPLODED VIEWS OF LAY SHAFT AND INPUT SHAFT |
424 |
|
I. REMOVAL OF TRANSAXLE FROM THE VEHICLE |
427 |
|
J. TRANSAXLE TA65 STAR (ON BENCH) DISASSSEMBLY |
429 |
|
K. INPUT SHAFT SUB- ASSEMBLY |
435 |
|
L. INPUT SHAFT ASSEMBLY |
435 |
|
M. DISASSEMBLY OF LAY SHAFT |
436 |
|
N. IDENTIFICATION OF COMPONENTS |
438 |
|
O. SUBASSEMBLIE |
441 |
|
P. LAY SHAFT ASSEMBLY |
443 |
|
Q. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL |
446 |
|
R. ASSEMBLY OF TRANSAXLE |
448 |
|
S. ASSEMBLY OF TOP COVER |
451 |
|
T. INSTALLATION OF TRANSAXLE ON CAR |
455 |
|
U. REMOVAL OF GEARSHIFT HOUSING, GEAR SHIFTER AND SELECTOR CABLE |
456 |
|
4.8. DRIVE SHAFT |
458 |
|
A. DRIVE SHAFT PARTS |
458 |
|
B. DISASSEMBLY AND ASSEMBLY PROCEDURE DRIVESHAFT TRIPOT JOINT |
459 |
|
C. DISASSEMBLY AND ASSEMBLY CV JOINT ASSEMBLY (OUTER) |
462 |
|
5. SUSPENSION |
466 |
|
5.1. TECHNICAL SPECIFICATION AND TIGHTENING TORQUE |
470 |
|
5.1.1. SPECIFCICATIONS |
470 |
|
5.1.2. TIGHTENING TORQUES |
471 |
|
5.2. SPECIAL TOOLS |
472 |
|
5.3. DIAGNOSIS |
478 |
|
5.4. PRECAUTION |
479 |
|
5.5. SUSPENSION SYSTEM |
480 |
|
5.6. EXPLODED VIEWS FRONT SUSPENSION SYSTEM |
483 |
|
5.6.1. ASSEMBLY FRONT STRUT EXPLODED VIEW |
483 |
|
5.6.2. LOWER ARM LINK EXPLODED VIEW |
484 |
|
5.6.3. ANTI ROLL BAR MOUNTING EXPLODED VIEW |
485 |
|
5.6.4. FRONT AXLE ASSEMBLY EXPLODED VIEW |
486 |
|
5.7. ON VEHICLE REPAIRS FRONT SUSPENSION |
487 |
|
5.7.1. REMOVAL AND INSTALLATION OF STRUT ASSEMBLY |
487 |
|
5.7.2. DISASSEMBLY AND ASSEMBLY OF FRONT STRUT |
488 |
|
5.7.3. REMOVAL AND INSTALLATION OF WHEEL HUB |
491 |
|
5.7.4. REMOVAL AND INSTALLATION OF ANTI ROLL BAR |
494 |
|
5.7.5. REMOVAL AND INSTALLATION OF LOWER ARM ASSEMBLY |
496 |
|
5.7.6. REMOVAL AND INSTALLATION OF LOWER ARM BALL JOINT |
497 |
|
5.7.7. REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES |
499 |
|
5.7.8. PROCEDURE FOR CHECKING BALL JOINT PLAY ON LOWER ARM |
500 |
|
5.8. EXPLODED VIEWS REAR SUSPENSION SYSTEM |
501 |
|
5.8.1. REAR SHOCK ABSORBER EXPLODED VIEW |
501 |
|
5.8.2. REAR HUB ASSEMBLY EXPLODED VIEW |
502 |
|
5.8.3. PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW |
503 |
|
5.9. ON VEHICLE REPAIRS REAR SUSPENSION |
504 |
|
5.9.1. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER FROM VEHICLE |
504 |
|
5.9.2. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER |
504 |
|
5.9.3. REMOVAL AND INSTALLATION OF TORSION BEAM |
507 |
|
5.9.4. TWIST BEAM BUSH REMOVAL |
510 |
|
5.10. WHEELS AND TYRES |
512 |
|
A. TYRE INSPECTION |
512 |
|
B. PRLACEMENT OF TYRE |
512 |
|
C. TYRE INSPECTION |
512 |
|
5.10.1. HOW TO MEASURE WHEEL RUNOUT |
512 |
|
5.10.2. INFLATION OF TYRES |
513 |
|
5.10.3. TYRE ROTATION |
514 |
|
5.10.4. WHEEL REMOVAL |
514 |
|
5.10.5. TYRE MOUNTING AND DEMOUNTING |
514 |
|
5.10.6. WHEEL ALIGNMENT |
515 |
|
5.10.7. BALANCING WHEELS |
515 |
|
5.10.8. TYRE CARE |
515 |
|
6.BRAKE |
516 |
|
6.1. PRECAUTIONS |
520 |
|
6.2. TECHNICAL SPECIFICATIONS |
521 |
|
6.3. TIGHTENING TORQUES |
523 |
|
6.4. DIAGNOSIS |
524 |
|
6.5. NESSECITY OF ABS WITH EBD |
527 |
|
6.6. BRAKE HYDRAULIC LINES |
528 |
|
6.7. VACUUM BRAKE BOOSTER |
530 |
|
6.8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
531 |
|
6.9. ABS COMPONENTS |
535 |
|
6.9.1. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
535 |
|
6.9.2. HYDRAULIC CONTROL UNIT |
537 |
|
6.9.3. WHEEL SPEED SENSOR (MONITORS WHEEL SPEED) |
538 |
|
6.9.4. ABS SYSTEM FAILURE WARNING LIGHT |
539 |
|
6.10. MAINTENANCE, ADJUSTMENTS & TEST |
540 |
|
6.10.1. FRONT BRAKE MAINTENANCE |
540 |
|
6.10.2. REAR BRAKE MAINTENANCE |
542 |
|
6.10.3. BRAKE TROUBLE SHOOTING |
547 |
|
6.10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
548 |
|
6.11. BRAKE PEDAL ASSEMBLY |
550 |
|
6.12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE |
551 |
|
6.13. REPAIRS |
552 |
|
6.13.1. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT |
553 |
|
6.13.2. REMOVAL OF FRONT BRAKE DISC |
559 |
|
6.13.3. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
560 |
|
6.13.4. REAR BRAKE ASSEMBLY |
562 |
|
6.13.5. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY |
564 |
|
6.13.6. REMOVAL OF PARKING BRAKE LEVER |
570 |
|
6.13.7. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE |
571 |
|
6.13.8A PARKING BRAKE CABLE ADJUSTMENT |
572 |
|
6.13.8B PARKING BRAKE CABLE ADJUSTMENT |
572 |
|
6.13.9. REMOVAL AND REFITMENT OF ABS ECU / HCU |
573 |
|
6.13.10. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR |
574 |
|
6.13.11. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR |
575 |
|
6.14. TROUBLE SHOOTING & DIAGNOSIS |
577 |
|
6.15. ABS ECU CONNECTOR |
579 |
|
7A. STEERING (BOSCH) |
581 |
|
7.1. GENERAL INFORMATION |
584 |
|
7.1.1. SPECIFICATIONS |
584 |
|
7.1.2. SYSTEM LAYOUT |
584 |
|
7.1.3. GENERAL DISCRIPTION |
585 |
|
7.1.4. TIGHTENING TORQUES |
586 |
|
7.1.5. SPECIAL TOOLS |
588 |
|
7.2. MAINTENANCE, INSPECTION AND TEST |
589 |
|
7.2.1. PRELIMINARY INSPECTION |
589 |
|
7.2.2. REGULAR MAINTENANCE |
590 |
|
7.2.3. ON VEHICLE REPAIRS |
591 |
|
7.2.3.1. STEERING WHEEL REMOVAL |
591 |
|
7.2.3.2. STEERING COLUMN REMOVAL |
592 |
|
7.2.3.3. INTERMEDIATE SHAFT REMOVAL |
594 |
|
7.2.3.4. ECU REMOVAL |
594 |
|
7.2.3.5. RACK & PINION ASSEMBLY REMOVAL |
596 |
|
7.3. OVERHAULING |
598 |
|
7.3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY |
598 |
|
7.3.2. PRECAUTIONS |
599 |
|
7.3.3. DISMANTLING, INSPECTION & ASSEMBLY |
599 |
|
7.3.3.1. DISASSEMBLY OF RACK & PINOIN |
599 |
|
7.3.3.2. INSPECTION OF DISMANTLED PARTS |
600 |
|
7.3.3.3. ASSEMBLY OF RACK & PINOIN |
600 |
|
7.3.3.4. OBJ ON VEHICLE REMOVAL |
601 |
|
7.3.3.5. DO'S & DON’T'S |
601 |
|
7.3.3.6. WHEEL ALIGNMENT |
602 |
|
7.4. TROUBLESHOOTING AND DIAGNOSIS |
605 |
|
7.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS |
609 |
|
7.6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
611 |
|
7B. STEERING (MANDO) |
617 |
|
1 GENERAL INFORMATION |
623 |
|
1.1 SPECIFICATIONS |
623 |
|
1.2 SYSTEM LAYOUT |
623 |
|
1.3 GENERAL DESCRIPTION |
624 |
|
1.4 TIGHTENING TORQUES |
625 |
|
2. MAINTENANCE, INSPECTION AND TEST |
628 |
|
2.1 PRELIMINARY INSPECTION |
628 |
|
2.2 REGULAR MAINTENANCE |
629 |
|
2.3 ON VEHICLE REPAIRS |
630 |
|
2.3.1 STEERING WHEEL REMOVAL |
630 |
|
2.3.2 STEERING COLUMN REMOVAL |
632 |
|
2.3.3 INTERMEDIATE SHAFT REMOVAL |
634 |
|
2.3.4 ECU REMOVAL |
634 |
|
2.3.5 MOTOR REMOVAL |
635 |
|
2.3.6 RACK & PINION ASSEMBLY REMOVAL |
636 |
|
3. OVERHAULING |
638 |
|
3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
638 |
|
3.2 PRECAUTIONS |
639 |
|
3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
639 |
|
3.3.1 DISASSEMBLY OF RACK & PINON |
639 |
|
3.3.2 INSPECTION OF DISMANTLED PARTS |
640 |
|
3.3.3 ASSEMBLY OF RACK & PINON |
640 |
|
3.3.4 OBJ ON-VEHICLE REMOVAL NOTE |
641 |
|
3.3.5 DO’S & DON’TSDON’TS |
641 |
|
3.3.6 WHEEL ALIGNMENT |
645 |
|
4. TROUBLESHOOTING AND DIAGNOSIS |
647 |
|
5. STEERING ANGLE CALIBRATION PROCESS |
651 |
|
6. Electric Power Assisted Steering (EPAS) ECU replacement and software update procedure in fieldGeneral |
658 |
|
7. CIRCUIT SCHEMATICS OF MANDO EPAS |
662-663 |
|
8.ELECTRICAL |
664 |
|
8.1. TECHNICAL SPECIFICATION |
669 |
|
8.2. GENERAL PRECAUTIONS |
671 |
|
8.3. FUSE BOX / RELAY LOCATIONS |
675 |
|
8.4. BATTERY |
676 |
|
8.5. ALTERNATOR |
678 |
|
8.6. STARTER MOTOR |
681 |
|
8.7. LIGHTING SYSTEM |
688 |
|
8.7.1. BULB SPECIFICATIONS |
688 |
|
8.7.2. FASTENERS TORQUE VALUE TABLE |
689 |
|
8.7.3. GENERAL SYMPTOMS AND DIAGNOSTICS |
689 |
|
8.7.4. HEAD LAMP |
693 |
|
8.7.5. SIDE REPEATER LAMP |
700 |
|
8.7.6. ROOF LAMP |
701 |
|
8.7.7. HIGH MOUNTED STOP LAMP |
702 |
|
8.7.8. TAIL LAMP |
703 |
|
8.7.9. FRONT FOG LAMP |
707 |
|
8.7.10. REGISTRATION PLATE LAMP |
708 |
|
8.8. HORN |
709 |
|
8.9. WIPER & WASHER SYSTEM |
711 |
|
8.9.1. FRONT AND REARWIPER ANDWAHSER SYSTEM LAYOUT |
712 |
|
8.9.2. FRONT AND REARWASH/WIPE SWITCH FUNCTIONALITY |
713 |
|
8.9.3. WIPER ANDWIPER CARE |
717 |
|
8.10. POWER SOCKETS |
719 |
|
8.11. GLOWPLUG CONTROL UNIT |
720 |
|
8.12. FUEL GAUGE AND FUEL LEVEL METER |
722 |
|
8.13. COMBI-SWITCH |
724 |
|
8.14. STEERING LOCK CUM IGNITION SWITCH |
730 |
|
8.15. FASCIA SWITCHES |
732 |
|
8.16. HAZARD SWITCH |
736 |
|
8.17. MIRROR SWITCH |
737 |
|
8.18. INFOTAINMENT SYSTEM |
738 |
|
8.18.1. USB/AUX PORT |
739 |
|
8.18.2. USB / AUX PORT |
742 |
|
8.18.3. SPEAKERS |
743 |
|
8.18.4. TWEETER |
744 |
|
8.18.5. ANTENNA |
746 |
|
8.18.6. MICROPHONE |
746 |
|
8.18.7. DTC FOR INFOTAINMENT SYSTEM |
748 |
|
8.19. WINDOW WINDING MODULE |
749 |
|
8.20. POWER WINDOW SWITCHES |
752 |
|
8.21. STEERING WHEEL SWITCHES |
757 |
|
8.22. IGNITION E-KEY |
760 |
|
8.23. INSTRUMENT CLUSTER |
762 |
|
8.23.1. BASIC FUNCTIONALMATRIX |
764 |
|
8.23.2.TELL TALESMATRIX |
765 |
|
8.23.3. DRIVER INFORMATION SYSTEM |
771 |
|
8.23.4. DTC FOR INSTRUMENT CLUSTER |
775 |
|
8.23.5. CONNECTOR DETAILS |
776 |
|
8.23.6. FUEL GAUGE DETAILS |
777 |
|
8.23.7. TEMPERATURE BAR GRAPH DETAILS |
778 |
|
8.23.8. CHIME TABLE |
779 |
|
8.23.9. DISPLAY SCREEN FLOWAND SETTINGS |
779 |
|
8.24 IMMOBILIZER SYSTEM |
785 |
|
8.24.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
790 |
|
8.24.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
791 |
|
8.24.3. DTC FOR IMMOBILIZER |
793 |
|
8.24.4. IGNITION KEYLEARNINGPROCEDURE |
795 |
|
8.25. BODY CONTROLMODULE (BCM) |
798 |
|
8.25.1. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
804 |
|
8.25.2. BCM FUNCTIONS |
816 |
|
8.25.3. DTC FOR BCM |
854 |
|
8.26. CLUTCH PEDAL SENSOR |
861 |
|
8.27. FUSE AND RELAY BOX DETAILS |
864 |
|
8.27.1. BATTERY MOUNTED FUSE BOX (BDU) |
867 |
|
8.27.2. ENGINE FUSE AND RELAY BOX |
868 |
|
8.27.3. CABIN FUSE AND RELAY BOX |
873 |
|
8.27.4. CIRCUIT SCHMATICS |
876 |
|
8.27.5. DTC |
876 |
|
8.28. REVERSE PARK ASSIST SYSTEM |
877 |
|
8.28.1. PARK ASSIST |
877 |
|
8.28.2. PARK ASSIST FUNCTIONALITY OVERVIEW |
877 |
|
8.28.3. PARK ASSIST ACTIVATION PROCEDURE |
877 |
|
8.28.4. PARK ASSIST DEACTIVATION PROCEDURE |
878 |
|
8.28.5. PARK ASSIST AUDIO SETTING |
878 |
|
8.28.6. PARK ASSIST VOLUME |
878 |
|
8.28.7. MIXWITH AUDIO |
878 |
|
8.28.8. PARK ASSIST TONE |
879 |
|
8.28.9. PARK ASSIST DELAY TIMER |
879 |
|
8.28.10. PARK ASSIST HMI INDICATIONS |
879 |
|
8.28.11. PARK ASSIST LIMITATIONS |
880 |
|
8.28.12. PARK ASSIST SYSTEM MAINTENANCE |
880 |
|
8.28.13. PARK ASSIST SYSTEM ARCHITECTURE |
881 |
|
8.28.14. REAR VIEW CAMERA |
882 |
|
8.28.15. ECU TO SENSOR ELECTRICAL INTERFACE |
883 |
|
8.28.16. ECU MOUNTING |
883 |
|
8.28.17. PHYSICAL IMAGE |
885 |
|
8.28.18. SENSOR FITMENT TO THE BUMPER |
885 |
|
9. BODY |
888 |
|
9.1 GENERAL INFORMATION |
892 |
|
9.1.1. LAYOUT |
892 |
|
9.1.2. TIGHTENING TORQUES |
893 |
|
9.1.3. SPECIAL TOOLS |
899 |
|
9.2 ON VEHICLE REPAIRS |
900 |
|
9.2.1. BONNET |
900 |
|
9.2.2. FLOOR CONSOLE |
902 |
|
9.2.3. DASHBOARD SKIN REMOVAL PROCEDURE |
905 |
|
9.2.4. CROSS CAR BEAM WITH COCKPIT ASSEMBLY REMOVAL |
908 |
|
9.2.5. GLOVE BOX |
912 |
|
9.2.6. SIDE AIR VENTS |
913 |
|
9.2.7. FRONT BUMPER |
914 |
|
9.2.8. REAR BUMPER |
915 |
|
9.2.9. FRONT DOOR |
916 |
|
9.2.10. FRONT DOOR TRIMS |
917 |
|
9.2.11. DOOR INNER LOCK HANDLE |
918 |
|
9.2.12. FRONT OUTER DOOR LOCK |
919 |
|
9.2.13. FRONT DOOR LATCH |
920 |
|
9.2.14. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
922 |
|
9.2.15. REAR DOOR |
923 |
|
9.2.16. REAR DOOR TRIM |
924 |
|
9.2.17. REAR OUTER DOOR LOCK |
926 |
|
9.2.18. DOOR LATCH REAR |
927 |
|
9.2.19. TRUNK LID |
928 |
|
9.2.20. TRUNK LID TRIM |
931 |
|
9.2.21. ORVM |
932 |
|
9.2.22. INNER REAR VIEW MIRROR |
933 |
|
9.2.23. FRONT ROW SEAT |
933 |
|
9.2.24. REAR ROW SEAT |
934 |
|
9.2.25. REAR ROW SEAT ARMREST |
935 |
|
9.2.26. FRONT SEAT BELTS |
936 |
|
9.2.27. REAR SEAT BELT |
938 |
|
9.2.28. “A” PILLAR TRIM |
940 |
|
9.2.29. FRONT SCUFF PLATE |
941 |
|
9.2.30. “B" PILLAR TRIMS |
942 |
|
9.2.31. “C” PILLAR TRIM |
943 |
|
9.2.32. GRAB HANDLES |
944 |
|
9.2.33. SUNVISOR |
944 |
|
9.2.34. ROOF LINER |
945 |
|
9.2.35. PLENUM COVER |
946 |
|
9.2.36. GEAR LEVER BOOT |
947 |
|
9.2.37. BONNET INSULATION |
947 |
|
9.2.38. GLASS |
948 |
|
9.2.39. REAR QUARTER GLASS |
949 |
|
9.2.40. FUEL FILLER ASSEMBLY |
950 |
|
9.2.41. FRONT WHEEL ARCH LINER |
952 |
|
9.2.42. REAR WHEEL ARCH LINER |
953 |
|
9.2.43. FRONT FENDER |
954 |
|
9.2.44. FRONT WIPER |
955 |
|
9.2.45. REAR DOOR CHEATER |
956 |
|
10. HVAC |
958 |
|
10.1. GENERAL INFORMATION |
961 |
|
10.1.1. SPECIFICATIONS |
961 |
|
10.1.2. TIGHTENING TORQUES |
963 |
|
10.1.3. PRECAUTIONS |
971 |
|
10.1.4. HVAC SYSTEM LAYOUT & WORKING |
973 |
|
10.1.5. COMPONENTS OF HVAC |
977 |
|
10.1.5.1. CONTROL PANEL |
977 |
|
10.1.5.2. HVAC UNIT |
980 |
|
10.1.5.3. COMPRESSOR |
983 |
|
10.1.5.4. CONDENSOR & RECEIVER DRIER |
984 |
|
10.1.5.5. THERMISTOR / THERMO SENSOR |
985 |
|
10.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR |
988 |
|
10.1.5.7. AIR INLET ACTUATOR |
989 |
|
10.1.6. TROUBLESHOOTING |
990 |
|
10.2. MAINTAINANCE |
1004 |
|
10.2.1. PRELIMINARY INSPECTION |
1004 |
|
10.2.2. REGULAR MAINTENANCE |
1006 |
|
10.3. ON VEHICLE REPAIR |
1011 |
|
10.3.1. CONTROL PANEL ASSEMBLY |
1011 |
|
10.3.2. COMPRESSOR |
1016 |
|
10.3.3. BLOWER |
1016 |
|
10.3.4. BLOWER RESISTER |
1017 |
|
10.3.5. FILTER |
1017 |
|
10.3.6. TXV |
1018 |
|
10.3.7. PRESSURE SENSOR / SWITCH |
1018 |
|
10.3.8. HVAC UNIT |
1019 |
|
10.3.9. CONDENSOR SEALING DUCT |
1020 |
|
10.3.10. CONDENSOR |
1020 |
|
10.3.11. REFRIGERANT HOSES |
1022 |
|
10.3.12. DO's & DON’T's |
1024 |
|
10.4. OVERHAULING HVAC UNIT |
1025 |
|
11.FATC |
1032 |
|
11.1.1. TECHNICAL SPECIFICATIONS |
1035 |
|
11.1.2. TIGHTENING TORQUES |
1037 |
|
A. FOR PETROL VARIENT |
1037 |
|
B. FOR DIESEL VARIENT |
1040 |
|
11.1.3. FATC LAYOUT |
1044 |
|
11.1.4. FATC CONTROL PANEL |
1046 |
|
11.1.5. CONTROL PANEL CONNECTOR DETAILS |
1050 |
|
11.1.6. FATC SENSOR |
1052 |
|
A. SOLAR LOAD SENSOR |
1052 |
|
B. OAT SENSOR |
1053 |
|
C. THERMISTOR OR THERMO SENSOR |
1055 |
|
D. AIR INLET ACTUATOR |
1056 |
|
E. LINEAR POWER MODULE |
1057 |
|
12.SRS |
1059 |
|
12.1. WORKING OF RESTRAINTS |
1062 |
|
A. RESTRAINTSWITHOUT AIRBAGS |
1062 |
|
B. RESTRAINTSWITH AIRBAGS |
1062 |
|
12.2. SYSTEM LAYOUT |
1063 |
|
12.2.1 RESTRAINT WITHOUT AIRBAG |
1063 |
|
12.2.2 RESTRAINT WITH AIRBAG |
1063 |
|
12.3. SAFETY PRECAUTIONS |
1064 |
|
12.4. DISPOSAL OF FAULTY AIR BAG UNIT |
1066 |
|
12.5. SRS POST ACCIDENT PROCEDURE |
1067 |
|
12.6. TIGHTENING TORQUES |
1068 |
|
12.7. COMPONENTS |
1069 |
|
12.7.1 RESTRAINT WITHOUT AIRBAGS |
1069 |
|
A. SEAT BELT |
1069 |
|
B. EMERGENCY LOCKING RETRACTOR (ELR) |
1069 |
|
C. MICROSWITCH / SEAT BELT REMINDERWARNING LAMP |
1069 |
|
12.7.2 RESTRAINT WITH AIRBAGS |
1069 |
|
12.7.2.1.ECU |
1069 |
|
12.7.2.2. SENSORS |
1072 |
|
12.7.2.3. AIR BAGS |
1074 |
|
12.7.2.4. RPLL BELTS |
1076 |
|
12.7.2.5. CLOCK SPRING |
1078 |