TIAGO - 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 |
32 |
|
2.1. GENERAL INFORMATION |
38 |
|
A. ENGINE INTRODUCTION |
38 |
|
B. ELECTRONIC FUEL INJECTION CONTROL |
39 |
|
C. TECHNICAL SPECIFICATION |
40 |
|
D. SPECIAL TOOLS |
41 |
|
E. ASSEMBLY CLEARANCES |
44 |
|
F. SEALANTS |
44 |
|
G. LEAKAGE RATES |
44 |
|
H. RECOMMENDED LUBRICANTS & COOLANTS |
44 |
|
I. SERVICE SCHEDULE |
45 |
|
2.2. TROUBLESHOOTING |
46 |
|
2.3. CONSTRUCTIONAL AND SERVICE DETAILS |
53 |
|
A. ENGINE LIFTING |
53 |
|
B. INTAKE MANIFOLD |
54 |
|
C. CYLINDER HEAD AND COVER |
56 |
|
D. CYLINDER HEAD-A |
58 |
|
E. CYLINDER HEAD-B |
60 |
|
F. CYLINDER BLOCK |
62 |
|
G. OIL SUMP |
64 |
|
H. MOVING PARTS |
66 |
|
I. ENGINE TIMING |
68 |
|
J. EXHAUST MANIFOLD |
70 |
|
K. FUEL INJECTION EQUIPMENT |
72 |
|
L. LUBRICATION PUMP AND COMPONENTS |
74 |
|
M. AIR INTAKE SYSTEM |
76 |
|
N. SPECIAL INSTALLATION |
78 |
|
O. ENGINE SUSPENSION |
81 |
|
2.4. ENGINE TESTS AND MAINTENANCE |
84 |
|
A. PRELIMINARY INSPECTION |
84 |
|
B. ENGINE TESTS |
85 |
|
I. ENGINE COMPRESSION TEST |
85 |
|
II. ENGINE OIL CONSUMPTION TEST |
86 |
|
III. ENGINE OIL PRESSURE TEST |
87 |
|
C. REGULAR MAINTENANCE |
88 |
|
I. ENGINE OIL AND FILTER CHANGE |
88 |
|
II. ENGINE COOLANT REPLACEMENT |
89 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
90 |
|
IV. SPARK PLUG REPLACEMENT |
91 |
|
V. FUEL FILTER REPLACEMENT |
94 |
|
VI. AIR CONDITIONER COMPRESSOR BELT REPLACEMENT |
95 |
|
2.5. REPAIR AND INSPECTION DETAILS |
96 |
|
A. ACCESSORY DRIVING BELT |
96 |
|
B. TIMING CHAIN |
96 |
|
C. CYLINDER HEAD |
96 |
|
D. VALVES |
97 |
|
E. CYLINDER HEAD VALVE SEATS |
99 |
|
F. ROLLER FINGER FOLLOWER |
100 |
|
G. HYDRAULIC LASH ADJUSTER |
100 |
|
H. CAMSHAFT |
100 |
|
I. PISTON AND PISTON RINGS |
102 |
|
J. CONNECTING RODS |
103 |
|
K. CRANKSHAFT |
105 |
|
L. CRANK CASE |
107 |
|
M. FUEL TANK |
108 |
|
N. CANISTER PURGE VALVE |
108 |
|
O. CANISTER |
109 |
|
2.6. ENGINE SYSTEM |
110 |
|
A. AIR INTAKE SYSTEM |
110 |
|
B. BLOW BY SYSTEM |
112 |
|
C. LUBRICATION SYSTEM |
113 |
|
D. EXHAUST SYSTEM |
117 |
|
E. COOLING SYSTEM |
120 |
|
F. FUEL SYSTEM |
123 |
|
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
126 |
|
A. ENGINE REMOVAL AND INSTALLATION |
126 |
|
B. AIR FILTER ASSY |
131 |
|
C. INJECTION SYSTEM |
132 |
|
D. SPARK PLUG |
133 |
|
E. EXHAUST SYSTEM |
133 |
|
F. FUEL SYSTEM |
136 |
|
G. COOLING SYSTEM |
142 |
|
H. REMOVAL OF ACCESSORIES |
145 |
|
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
146 |
|
A. ENGINE DIS-ASSEMBLY |
146 |
|
I. REMOVAL OF INTAKE MANIFOLD |
146 |
|
II. REMOVAL OF EXHAUST MANIFOLD |
147 |
|
III. REMOVAL OF OIL SUMP |
149 |
|
IV. REMOVAL OF SENSORS |
149 |
|
V. REMOVAL OF ACCESSORIES |
150 |
|
VI. REMOVAL OF TIMING CHAIN |
153 |
|
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
154 |
|
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
155 |
|
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
157 |
|
B. ENGINE ASSEMBLY |
160 |
|
I. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
160 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
162 |
|
III. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
164 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
165 |
|
V. ASSEMBLY OF TIMING CHAIN |
167 |
|
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
170 |
|
VII. FITMENT OF ENGINE SENSORS AND PERIPHERALS |
172 |
|
VIII. FITMENT OF OIL SUMP |
173 |
|
IX. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
173 |
|
X. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
175 |
|
2.9. ENGINE MANAGEMENT SYSTEM |
178 |
|
A. ABBREVIATIONS |
178 |
|
B. AN OVERVIEW |
179 |
|
C. ELECTRONIC CONTROL UNIT |
180 |
|
D. SENSORS |
185 |
|
I. T-MAP SENSOR |
186 |
|
II. LAMBDA SENSOR |
187 |
|
III. CAMSHAFT POSITION SENSOR |
189 |
|
IV. KNOCK SENSOR |
190 |
|
V. CRANKSHAFT POSITION SENSOR |
191 |
|
VI. COOLANT TEMPERATURE SENSOR |
192 |
|
E. ACTUATORS |
194 |
|
I. IGNITION COIL |
195 |
|
II. PURGE CONTROL VALVE |
196 |
|
III. SOLENOID VALVE (OCV) |
197 |
|
IV. FUEL INJECTOR |
198 |
|
V. ELECTRONIC THROTTLE BODY |
199 |
|
F. SWITCH |
201 |
|
I. OIL PRESSURE SWITCH |
201 |
|
II. THROTTLE PEDAL SENSOR |
202 |
|
III. CLUTCH SWITCH |
203 |
|
IV. BRAKE SWITCH |
204 |
|
V. VEHICLE SPEED SENSOR |
205 |
|
WHEEL SPEED SENSOR |
206 |
|
3. 1.05L REVOTORQ ENGINE |
207 |
|
3.1. GENERAL INFORMATION |
212 |
|
A. ENGINE INTRODUCTION |
212 |
|
B. TECHNICAL SPECIFICATION |
213 |
|
C. SPECIAL TOOLS |
214 |
|
D. ASSEMBLY CLEARANCES |
218 |
|
E. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
219 |
|
F. SERVICE SCHEDULE |
220 |
|
3.2. TROUBLESHOOTING |
221 |
|
3.3. CONSTRUCTIONAL AND SERVICE DETAILS |
229 |
|
A. ENGINE MOUNTING SYSTEM |
229 |
|
B. CYLINDER HEAD AND COVER |
231 |
|
C. LUBRICATION SYSTEM |
233 |
|
D. ENGINE |
235 |
|
E. OIL SUMP |
237 |
|
F. CYLINDER HEAD |
239 |
|
G. SPECIAL INSTALLATION |
241 |
|
H. EXHAUST SYSTEM |
243 |
|
I. INTAKE SYSTEM |
245 |
|
J. ENGINE SUSPENSION |
247 |
|
K. MOVING PARTS |
249 |
|
L. ENGINE TIMING |
251 |
|
M. FUEL INJECTION EQUIPMENT |
253 |
|
3.4. ENGINE TESTS AND MAINTENANCE |
255 |
|
A. PRELIMINARY INSPECTION |
255 |
|
B. ENGINE TESTS |
255 |
|
C. REGULAR MAINTENANCE |
259 |
|
I. ENGINE OIL AND FILTER CHANGE |
259 |
|
II. ENGINE COOLANT REPLACEMENT |
260 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
261 |
|
IV. FUEL FILTER REPLACEMENT |
262 |
|
V. DRAINING WATER FROM PRE-FILTER |
263 |
|
VI. PRE-FILTER REPLACEMENT |
263 |
|
VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
264 |
|
3.5. REPAIR AND INSPECTION DETAILS |
265 |
|
A. TIMING BELT |
265 |
|
B. FUEL TANK |
265 |
|
C. CYLINDER HEAD |
266 |
|
D. VALVES |
267 |
|
E. VALVE SEATS |
268 |
|
F. CRANKCASE |
269 |
|
G. VALVE SEAT INSERT |
270 |
|
H. HYDRAULIC LASH ADJUSTER |
270 |
|
I. VALVE GUIDES |
271 |
|
J. CAMSHAFT |
272 |
|
K. PISTON AND PISTON RINGS |
273 |
|
L. CONNECTING ROD |
274 |
|
M. CRANKSHAFT |
276 |
|
3.6. ENGINE SYSTEM |
278 |
|
A. AIR INTAKE SYSTEM |
278 |
|
B. EXHAUST SYSTEM |
280 |
|
C. COOLING SYSTEM |
284 |
|
D. LUBRICATION SYSTEM |
287 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM |
290 |
|
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM |
292 |
|
G. VACUUM MANAGEMENT SYSTEM |
293 |
|
H. FUEL SYSTEM |
294 |
|
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
300 |
|
A. ENGINE REMOVAL |
300 |
|
B. ENGINE INSTALLATION |
304 |
|
C. EXHAUST SYSTEM |
305 |
|
D. COOLING SYSTEM |
307 |
|
E. FUEL SYSTEM |
309 |
|
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
316 |
|
A. ENGINE DIS-ASSEMBLY |
316 |
|
I. ON OVERHAUL STAND |
316 |
|
II. REMOVAL OF INTAKE MANIFOLD |
319 |
|
III. REMOVAL OF EXHAUST MANIFOLD |
321 |
|
IV. REMOVAL OF OIL SUMP |
325 |
|
V. REMOVAL OF TIMING BELT |
326 |
|
VI. REMOVAL OF CYLINDER HEAD |
329 |
|
VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
330 |
|
VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
332 |
|
IX. PISTON CONNECTING ROD DIS-ASSEMBLY |
334 |
|
B. ENGINE ASSEMBLY |
340 |
|
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
340 |
|
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
341 |
|
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
342 |
|
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
343 |
|
V. FITMENT OFTIMING BELT |
344 |
|
VI. FITMENT OF OIL SUMP |
347 |
|
VII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
349 |
|
VIII. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
353 |
|
IX. ON ENGINE SUPPORT STAND |
355 |
|
3.9. ENGINE MANAGEMENT SYSTEM |
359 |
|
A. ABBREVIATIONS |
359 |
|
B. AN OVERVIEW |
360 |
|
C. ELECTRONIC CONTROL UNIT (ECU) |
361 |
|
D. EMS SENSORS |
365 |
|
I. CRANK POSITION SENSOR |
365 |
|
II. VEHICLE SPEED SENSOR |
366 |
|
III. WHEEL SPEED SENSOR |
367 |
|
IV. CAMSHAFT POSITION SENSOR |
368 |
|
V. AIR MASS FLOW SENSOR |
369 |
|
VI. INLET METERING VALVE |
370 |
|
VII. VENTURI |
370 |
|
VIII. RAIL PRESSURE SENSOR |
370 |
|
IX. THROTTLE PEDAL SENSOR |
371 |
|
X. WATER IN FUEL SENSOR |
372 |
|
XI. CLUTCH SWITCH |
372 |
|
XII. OIL PRESSURE SWITCH |
373 |
|
XIII. BRAKE SWITCH |
375 |
|
XIV. COOLANT TEMPERATURE SENSOR |
376 |
|
XV. GLOW PLUG |
377 |
|
XVI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
378 |
|
4. DRIVETRAIN-TA65 STAR |
379 |
|
4.1 PRECAUTION |
383 |
|
4.2 SPECIFCICATIONS & TIGHTENING TORQUES |
384 |
|
A. CLUTCH |
384 |
|
B. TRANSAXLE |
389 |
|
C. TIGHTENING TORQUES |
390 |
|
4.3 SPECIAL TOOLS |
391 |
|
A. CLUTCH |
391 |
|
B. TRANSAXLE |
391 |
|
4.4 DIAGNOSIS |
396 |
|
A. CLUTCH |
396 |
|
B. TRANSAXLE |
399 |
|
4.5 MAINTENANCE, ADJUSTMENT & TEST |
400 |
|
A. PRELIMINARY INSPECTION OF CLUTCH |
400 |
|
B. DRIVESHAFT |
401 |
|
4.6 CLUTCH |
403 |
|
A. THEORY OF DIAPHRAGM SPRING CLUTCH |
403 |
|
B. CONSTRUCTIONAL DETAILS |
404 |
|
C. FACTOR AFFECTING CLUTCH WEAR |
406 |
|
D. CLUTCH CABLE - REMOVAL AND INSPECTION |
407 |
|
E. REMOVAL OF CLUTCH FROM THE CAR |
408 |
|
F. INSTALLATION OF CLUTCH ON THE CAR |
408 |
|
H. PROCEDURE FOR CLUTCH ADJUSTMENT |
409 |
|
4.7 TRANSAXLE |
410 |
|
A. GENERAL DISCRIPTION |
410 |
|
B. CUT SECTION OF TRANSAXLE TA 65 STAR |
412 |
|
C. CUT SECTION OF TOP COVER ASSEMBLY |
413 |
|
D. EXPLODED VIEW OF TRANSAXLE |
414 |
|
E. EXPLODED VIEWS OF DIFFERENTIAL |
416 |
|
F. EXPLODED VIEW OF SHIFTER FORK |
418 |
|
G. EXPLODED VIEWS OF GEAR SHIFT LINKAGE ASSSEMBLY |
420 |
|
H. EXPLODED VIEWS OF LAY SHAFT AND INPUT SHAFT |
421 |
|
I. REMOVAL OF CLUTCH FROM THE CAR |
424 |
|
J. TRANSAXLE TA65 STAR (ON BENCH) DISASSSEMBLY |
426 |
|
K. INPUT SHAFT SUB- ASSEMBLY |
432 |
|
L. INPUT SHAFT ASSEMBLY |
432 |
|
M. DISASSEMBLY OF LAY SHAFT |
433 |
|
N. IDENTIFICATION OF COMPONENTS |
435 |
|
O. SUBASSEMBLIE |
438 |
|
P. LAY SHAFT ASSEMBLY |
440 |
|
Q. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL |
443 |
|
R. ASSEMBLY OF TRANSAXLE |
445 |
|
S. ASSEMBLY OF TOP COVER |
448 |
|
T. INSTALLATION OF TRANSAXLE ON CAR |
452 |
|
U. REMOVAL OF GEARSHIFT HOUSING, GEAR SHIFTER AND SELECTOR CABLE |
453 |
|
4.8 DRIVE SHAFT |
455 |
|
A. DRIVE SHAFT PARTS |
455 |
|
B. DISASSEMBLY AND ASSEMBLY PROCEDURE DRIVESHAFT TRIPOT JOINT |
456 |
|
C. DISASSEMBLY AND ASSEMBLY CV JOINT ASSEMBLY (OUTER) |
459 |
|
5. SUSPENSION |
463 |
|
5.1 TECHNICAL SPECIFICATION AND TIGHTENING TORQUE |
467 |
|
5.1.1 SPECIFCICATIONS |
467 |
|
5.1.2 TIGHTENING TORQUES |
468 |
|
5.2 SPECIAL TOOLS |
470 |
|
5.3 DIAGNOSIS |
476 |
|
5.4 PRECAUTION |
477 |
|
5.5 SUSPENSION SYSTEM |
478 |
|
5.6 EXPLODED VIEWS FRONT SUSPENSION SYSTEM |
482 |
|
5.6.1. ASSEMBLY FRONT STRUT EXPLODED VIEW |
482 |
|
5.6.2. LOWER ARM LINK EXPLODED VIEW |
483 |
|
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. REPLACEMENT OF WHEELS |
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. BALANCING WHEELS |
515 |
|
5.10.7. TYRE CARE |
515 |
|
6. BRAKES |
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 ARKING BRAKE LEVER PRIMARY CABLE GREASING |
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 (ELECTRICAL POWER ASSIST SYSTEM-EPAS) (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 |
604 |
|
7.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS |
608 |
|
7.6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
611 |
|
7B. STEERING (ELECTRICAL POWER ASSIST SYSTEM-EPAS) (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 |
|
1.5 SPECIAL TOOLS |
627 |
|
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 |
641 |
|
3.3.5 DO’S & DON’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 FIELD |
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 |
699 |
|
8.7.6 ROOF LAMP |
700 |
|
8.7.7 HIGH MOUNTED STOP LAMP |
701 |
|
8.7.8 TAIL LAMP |
702 |
|
8.7.9 FRONT FOG LAMP |
705 |
|
8.7.10 REGISTRATION PLATE LAMP |
706 |
|
8.8 HORN |
707 |
|
8.9 WIPER & WASHER SYSTEM |
709 |
|
8.9.1 FRONT AND REARWIPER ANDWAHSER SYSTEM LAYOUT |
710 |
|
8.9.2 FRONT AND REARWASH/WIPE SWITCH FUNCTIONALITY |
711 |
|
8.9.3 WIPER ANDWIPER CARE |
715 |
|
8.10 POWER SOCKETS |
717 |
|
8.11 GLOW PLUG CONTROL UNIT |
718 |
|
8.12 FUEL GAUGE AND FUEL LEVEL METER |
720 |
|
8.13 COMBI-SWITCH |
722 |
|
8.14 STEERING LOCK CUM IGNITION SWITCH |
727 |
|
8.15 FASCIA SWITCHES |
730 |
|
8.16 HAZARD SWITCH |
734 |
|
8.17 MIRROR SWITCH |
735 |
|
8.18 INFOTAINMENT SYSTEM |
736 |
|
8.18.1 USB/AUX PORT |
739 |
|
8.18.2 SPEAKERS |
740 |
|
8.18.3 TWEETER |
742 |
|
8.18.4 ANTENNA |
743 |
|
8.18.5 MICROPHONE |
744 |
|
8.18. DTC FOR INFOTAINMENT SYSTEM |
745 |
|
8.19 WINDOW WINDING MODULE |
746 |
|
8.20 POWER WINDOW SWITCHES |
749 |
|
8.21 STEERING WHEEL SWITCHES |
754 |
|
8.22 IGNITION E-KEY |
757 |
|
8.23 INSTRUMENT CLUSTER |
760 |
|
8.23.1 BASIC FUNCTIONALMATRIX |
762 |
|
8.23.2 TELL TALESMATRIX |
763 |
|
8.23.3 DRIVER INFORMATION SYSTEM |
769 |
|
8.23.4 DTC FOR INSTRUMENT CLUSTER |
774 |
|
8.23.5 CONNECTOR DETAILS |
777 |
|
8.23.6 FUEL GAUGE DETAILS |
779 |
|
8.23.7 TEMPERATURE BAR GRAPH DETAILS |
780 |
|
8.23.8 CHIME TABLE |
781 |
|
8.23.9 DISPLAY SCREEN FLOWAND SETTINGS |
781 |
|
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 CONTROL MODULE (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) |
866 |
|
8.27.2 ENGINE FUSE AND RELAY BOX |
867 |
|
8.27.3 CABIN FUSE AND RELAY BOX |
872 |
|
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 ECU TO SENSOR ELECTRICAL INTERFACE |
882 |
|
8.28.15 ECU MOUNTING |
882 |
|
8.28.16 PHYSICAL IMAGES |
884 |
|
8.28.17 SENSOR FITMENT TO THE BUMPER |
885 |
|
9. BODY |
887 |
|
9.1 GENERAL INFORMATION |
891 |
|
9.1.1 LAYOUT |
891 |
|
9.1.2 TIGHTENING TORQUES |
892 |
|
9.1.3 SPECIAL TOOLS |
895 |
|
9.2 ON VEHICLE REPAIRS |
896 |
|
9.2.1 BONNET |
896 |
|
9.2.2 FLOOR CONSOLE |
898 |
|
9.2.3 DASHBOARD |
900 |
|
9.2.4 GLOVE BOX |
909 |
|
9.2.5 SIDE AIR VENTS |
910 |
|
9.2.6 FRONT BUMPER |
910 |
|
9.2.7 REAR BUMPER |
911 |
|
9.2.8 FRONT DOOR |
913 |
|
9.2.9 FRONT DOOR TRIMS |
914 |
|
9.2.10 DOOR INNER LOCK HANDLE |
915 |
|
9.2.11 FRONT OUTER DOOR LOCK |
916 |
|
9.2.12 FRONT DOOR LATCH |
917 |
|
9.2.13 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
919 |
|
9.2.14 REAR DOOR |
920 |
|
9.2.15 REAR DOOR TRIM |
921 |
|
9.2.16 REAR OUTER DOOR LOCK |
923 |
|
9.2.17 DOOR LATCH REAR |
924 |
|
9.2.18 TAIL GATE |
925 |
|
9.2.19 TAIL GATE LATCH CABLE |
928 |
|
9.2.20 TAILGATE TRIM |
929 |
|
9.2.21 ORVM |
930 |
|
9.2.22 INNER REAR VIEW MIRROR |
931 |
|
9.2.23 FRONT ROW SEAT |
931 |
|
9.2.24 REAR ROW SEAT |
932 |
|
9.2.25 FRONT SEAT BELTS |
935 |
|
9.2.26 REAR SEAT BELT |
937 |
|
9.2.27 “A” PILLAR TRIM |
938 |
|
9.2.28 FRONT SCUFF PLATE |
940 |
|
9.2.29 “B" PILLAR TRIMS |
940 |
|
9.2.30 “C” PILLAR TRIM |
941 |
|
9.2.31 GRAB HANDLES |
942 |
|
9.2.32 SUNVISOR |
943 |
|
9.2.33 ROOF LINER |
943 |
|
9.2.34 PLENUM COVER |
944 |
|
9.2.35 GEAR LEVER BOOT |
945 |
|
9.2.36 BONNET INSULATION |
945 |
|
9.2.37 GLASS |
946 |
|
9.2.38 FUEL FILLER ASSEMBLY |
947 |
|
9.2.39 FRONT WHEEL ARCH LINER |
949 |
|
9.2.40 REAR WHEEL ARCH LINER |
950 |
|
9.2.41 FRONT FENDER |
951 |
|
9.2.42 REAR WIPER MOTOR |
953 |
|
9.2.43 FRONT WIPER |
954 |
|
10. HVAC |
955 |
|
10.1 GENERAL INFORMATION |
958 |
|
10.1.1. SPECIFICATIONS |
958 |
|
10.1.2. TIGHTENING TORQUES |
960 |
|
10.1.3. PRECAUTIONS |
968 |
|
10.1.4. HVAC SYSTEM LAYOUT & WORKING |
970 |
|
10.1.5. COMPONENTS OF HVAC |
972 |
|
10.1.5.1. CONTROL PANEL |
972 |
|
10.1.5.2. HVAC UNIT |
975 |
|
10.1.5.3. COMPRESSOR |
978 |
|
10.1.5.4. CONDENSOR & RECEIVER DRIER |
979 |
|
10.1.5.5. THERMISTOR / THERMO SENSOR |
980 |
|
10.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR |
982 |
|
10.1.5.7. AIR INLET ACTUATOR |
983 |
|
10.1.6. TROUBLESHOOTING |
984 |
|
10.2 MAINTAINANCE |
998 |
|
10.2.1. PRELIMINARY INSPECTION |
998 |
|
10.2.2. REGULAR MAINTENANCE |
1000 |
|
10.3 ON VEHICLE REPAIR |
1004 |
|
10.3.1. CONTROL PANEL ASSEMBLY |
1004 |
|
10.3.2. COMPRESSOR |
1009 |
|
10.3.3. BLOWER |
1009 |
|
10.3.4. BLOWER RESISTER |
1010 |
|
10.3.5. FILTER |
1010 |
|
10.3.6. TXV |
1011 |
|
10.3.7. PRESSURE SENSOR / SWITCH |
1011 |
|
10.3.8. HVAC UNIT |
1012 |
|
10.3.9. CONDENSOR SEALING DUCT |
1012 |
|
10.3.10. CONDENSOR |
1013 |
|
10.3.11. REFRIGERANT HOSES |
1014 |
|
10.3.12. DO'S & DON’TS |
1016 |
|
10.4 OVERHAULING HVAC UNIT |
1017 |
|
11. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) |
1024 |
|
11.1.1 TIGHTENING TORQUES |
1027 |
|
11.1.2 WORKING OF RESTRAINTS |
1029 |
|
A. RESTRAINTSWITHOUT AIRBAGS |
1029 |
|
B. RESTRAINTSWITH AIRBAGS |
1029 |
|
11.1.3 SYSTEM LAYOUT |
1030 |
|
11.1.3.1 RESTRAINTWITHOUT AIRBAG |
1030 |
|
11.1.3.2 RESTRAINTWITH AIRBAG |
1030 |
|
11.1.4 SAFETY PRECAUTIONS |
1031 |
|
11.1.5 DISPOSAL OF FAULTY AIR BAG UNIT |
1033 |
|
11.1.6 COMPONENTS |
1034 |
|
11.1.6.1 RESTRAINT WITHOUT AIRBAGS |
1034 |
|
A. SEAT BELT |
1034 |
|
B. EMERGENCY LOCKING RETRACTOR (ELR) |
1034 |
|
C. MICROSWITCH / SEAT BELT REMINDERWARNING LAMP |
1034 |
|
11.1.6.2 RESTRAINT WITH AIRBAGS |
1035 |
|
A. ECU |
1035 |
|
B. SENSORS |
1039 |
|
C. AIR BAGS |
1040 |
|
D. RPLL BELTS |
1043 |
|
E. CLOCK SPRING |
1045 |
|
11.1.7. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT |
1048 |