ALTROZ SERVICE MANUAL - BOOK 1
|
1.2L REVOTRON ENGINE |
6 |
|
1. GENERAL INFORMATION |
12 |
|
A. ENGINE INTRODUCTION |
12 |
|
B. ELECTRONIC FUEL INJECTION CONTROL |
13 |
|
C. TECHNICAL SPECIFICATION |
14 |
|
D. SPECIAL TOOLS |
15 |
|
E. ASSEMBLY CLEARANCES |
18 |
|
F. SEALANTS |
18 |
|
G. LEAKAGE RATES |
18 |
|
2. TROUBLESHOOTING |
19 |
|
3. CONSTRUCTIONAL AND SERVICE DETAILS |
25 |
|
A. ENGINE LIFTING |
25 |
|
B. INTAKE MANIFOLD |
26 |
|
C. CYLINDER HEAD AND COVER |
28 |
|
D. CYLINDER HEAD-A |
30 |
|
E. CYLINDER HEAD-B |
32 |
|
F. CYLINDER BLOCK |
33 |
|
G. OIL SUMP |
35 |
|
H. MOVING PARTS |
36 |
|
I. ENGINE TIMING |
38 |
|
J. EXHAUST MANIFOLD |
40 |
|
K. FUEL INJECTION EQUIPMENT |
41 |
|
L. LUBRICATION PUMP AND COMPONENTS |
42 |
|
M. AIR INTAKE SYSTEM |
44 |
|
N. SPECIAL INSTALLATION |
46 |
|
O. ENGINE SUSPENSION |
49 |
|
4. ENGINE TESTS AND MAINTENANCE |
51 |
|
A. PRELIMINARY INSPECTION |
51 |
|
B. ENGINE TESTS |
52 |
|
I. ENGINE COMPRESSION TEST |
52 |
|
II. ENGINE OIL CONSUMPTION TEST |
53 |
|
III. ENGINE OIL PRESSURE TEST |
54 |
|
C. REGULAR MAINTENANCE |
55 |
|
I. ENGINE OIL AND FILTER CHANGE |
55 |
|
II. ENGINE COOLANT REPLACEMENT |
56 |
|
III. AIR FILTER ELEMENT REPLACEMENT |
60 |
|
IV. SPARK PLUG REPLACEMENT |
61 |
|
V. FUEL FILTER REPLACEMENT |
63 |
|
VI. AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT |
64 |
|
5. REPAIR AND INSPECTION DETAILS |
65 |
|
A. ACCESSORY DRIVING BELT |
65 |
|
B. TIMING CHAIN |
65 |
|
C. CYLINDER HEAD |
65 |
|
D. VALVES |
66 |
|
E. CYLINDER HEAD VALVE SEATS |
67 |
|
F. ROCKER ARM AND SHAFTS |
67 |
|
G. HYDRAULIC LASH ADJUSTER |
68 |
|
H. CAMSHAFT |
68 |
|
I. PISTON AND PISTON RINGS |
69 |
|
J. CONNECTING RODS |
70 |
|
K. CRANKSHAFT |
71 |
|
L. CRANK CASE |
72 |
|
M. FUEL TANK |
73 |
|
N. CANISTER PURGE VALVE |
73 |
|
O. CANISTER |
74 |
|
6. ENGINE SYSTEM |
75 |
|
A. AIR INTAKE SYSTEM |
75 |
|
B. BLOW BY SYSTEM |
77 |
|
C. LUBRICATION SYSTEM |
78 |
|
D. EXHAUST SYSTEM |
82 |
|
E. COOLING SYSTEM |
84 |
|
F. FUEL SYSTEM |
87 |
|
7. ENGINE ON VEHICLE SERVICE PROCEDURE |
90 |
|
A. FUSE BOX SHIFTING PROCEDURE |
90 |
|
B. ENGINE REMOVAL AND INSTALLATION |
91 |
|
C. AIR FILTER ASSY |
97 |
|
D. FUEL RAIL AND INJECTOR |
98 |
|
E. SPARK PLUG |
99 |
|
F. EXHAUST SYSTEM |
100 |
|
G. FUEL SYSTEM |
103 |
|
H. COOLING SYSTEM |
108 |
|
I. COMPRESSOR AND ALTERNATOR BELT REMOVAL |
112 |
|
J. TIMING BELT REMOVAL |
113 |
|
K. WATER PUMP |
117 |
|
L. SOLENOID |
118 |
|
M. ELECTRONIC THROTTLE BODY |
118 |
|
N. STARTER MOTOR |
119 |
|
O. ALTERNATOR |
119 |
|
P. COMPRESSOR |
120 |
|
8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
121 |
|
A. ENGINE DIS-ASSEMBLY |
121 |
|
I. REMOVAL OF INTAKE MANIFOLD |
121 |
|
II. REMOVAL OF EXHAUST MANIFOLD |
122 |
|
III. REMOVAL OF OIL SUMP |
124 |
|
IV. REMOVAL OF SENSORS |
124 |
|
V. REMOVAL OF ACCESSORIES |
125 |
|
VI. REMOVAL OF TIMING CHAIN |
128 |
|
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
130 |
|
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
131 |
|
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
132 |
|
B. ENGINE ASSEMBLY |
136 |
|
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
136 |
|
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
140 |
|
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES |
142 |
|
IV. ASSEMBLY OF CYLINDER HEAD |
143 |
|
V. ASSEMBLY OF ENGINE TIMING CHAIN |
145 |
|
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
148 |
|
VII. ASSEMBLY OF SENSORS AND PERIPHERALS |
150 |
|
VIII. ASSEMBLY OF OIL SUMP |
151 |
|
IX. ASSEMBLY OF EXHAUST MANIFOLD |
151 |
|
X. ASSEMBLY OF INTAKE MANIFOLD S |
153 |
|
9. ENGINE MANAGEMENT SYSTEM |
155 |
|
A. ABBREVIATIONS |
155 |
|
B. AN OVERVIEW |
156 |
|
C. ELECTRONIC CONTROL UNIT |
157 |
|
D. SENSORS |
162 |
|
I. T-MAP SENSOR |
163 |
|
II. LAMBDA SENSOR |
164 |
|
III. CAMSHAFT POSITION SENSOR |
166 |
|
IV. KNOCK SENSOR |
167 |
|
V. CRANKSHAFT POSITION SENSOR |
168 |
|
VI. COOLANT TEMPERATURE SENSOR |
169 |
|
E. ACTUATORS |
171 |
|
I. IGNITION COIL |
172 |
|
II. PURGE CONTROL VALVE |
173 |
|
III. SOLENOID VALVE (OCV) |
174 |
|
IV. FUEL INJECTOR |
175 |
|
V. ELECTRONIC THROTTLE BODY |
176 |
|
F. SWITCH |
178 |
|
I. OIL PRESSURE SWITCH |
178 |
|
II. THROTTLE PEDAL SENSOR |
179 |
|
III. CLUTCH SWITCH |
180 |
|
IV. BRAKE SWITCH |
181 |
|
V. VEHICLE SPEED SENSOR |
182 |
|
VI. WHEEL SPEED SENSOR |
183 |
|
CLUTCH DIESEL |
184 |
|
1.1. GENERAL INFORMATION |
187 |
|
A. CLUCTH MASTER CYLINDER |
188 |
|
B. CONCENTRIC SLAVE CYLINDER (CSC) |
188 |
|
C. PEAK TORQUE LIMITER |
188 |
|
D. HYDRAULIC ADAPTER |
188 |
|
E. SINGLE MASS FLYWHEEL |
189 |
|
F. CONVENTIONAL CLUTCH |
189 |
|
1.2. TECHNICAL SPECIFICATIONS |
190 |
|
A. CLUTCH DISC ASSEMBLY |
190 |
|
B. CONVENTIONAL CLUTCH |
191 |
|
C. SINGLE MASS FLYWHEEL (FOR DIESEL VERSION) |
192 |
|
1.3. TIGHTENING TORQUES |
193 |
|
1.4. SPECIAL TOOLS |
194 |
|
1.5. MAINTENANCE, INSPECTION ANDTESTS |
195 |
|
1.5.1. PRELIMINARY INSPECTION |
195 |
|
1.5.2. REGULAR MAINTENANCE |
196 |
|
A. CLUTCH SWITCH ADJUSTMENT |
196 |
|
B. CLUTCH BLEEDING PROCEDURE |
196 |
|
C. CLUTCH FLUID DRAINING PROCEDURE |
197 |
|
1.6. GENERAL SYMPTOMS DIAGNOSIS |
198 |
|
1.7. EXPLODE VIEWS |
200 |
|
A. CLUTCH PEDAL ASSEMBLY |
200 |
|
B. CONVENTIONAL CLUTCH ASSEMBLY |
201 |
|
C. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
202 |
|
1.8. ON VEHICLE PROCEDURES |
203 |
|
A. FUSE BOX SHIFTING PROCEDURE |
203 |
|
B. CLUTCH PEDAL REMOVAL |
204 |
|
C. CONTROL BRACKET ASSEMBLYREMOVAL |
205 |
|
D. CONVENTIONAL CLUTCH ASSEMBLYREMOVAL |
206 |
|
E. CLUTCH MASTER CYLINDER REMOVAL |
207 |
|
F. FLYWHEEL REMOVAL |
209 |
|
CLUTCH PETROL |
210 |
|
1. GENERAL INFORMATION |
213 |
|
2. TECHNICAL SPECIFICATIONS |
214 |
|
A. CLUTCH DISC |
214 |
|
B. CLUTCH PLATE |
216 |
|
C. FLYWHEEL |
218 |
|
3. TIGHTENING TORQUE |
220 |
|
4. SPECIAL TOOLS |
221 |
|
5 . DIAGNOSIS OF CLUTCH |
222 |
|
6. MAINTENANCE, TESTS AND FACTOR AFFECTING |
225 |
|
A. INSPECTION OF COMPONENTS |
225 |
|
B. TEST |
225 |
|
C. FACTORS AFFECTING CLUTCH |
225 |
|
7. CONSTRUCTIONAL DETAILS |
226 |
|
8. ON VECHILE PROCEDURE |
228 |
|
A. FUSE BOX SHIFTING PROCEDURE |
228 |
|
B. CLUTCH CABLE REMOVAL ANDINSPECTION |
229 |
|
C. REMOVAL OF CLUTCH |
230 |
|
D. FLYWHEEL |
231 |
|
E. CLUTCH ADJUSTMENT PROCEDURE |
232 |
|
TRANSAXLE (TA65 Star) |
259 |
|
1. TECHNICAL SPECIFICATIONS |
263 |
|
2. PRECAUTIONS |
263 |
|
3. GENERAL DESCRIPTION |
264 |
|
4. TIGHTENING TORQUES |
265 |
|
5. SPECIAL TOOLS LIST |
266 |
|
6. DIAGNOSIS |
270 |
|
7. CONSTRUCTIONAL DETAILS |
271 |
|
8. CUT SECTION OF TRANSAXLE TA 65 STAR |
272 |
|
9. CUT SECTION OF TOP COVER ASSEMBLY |
273 |
|
10. EXPLODED VIEWS OF TRANSAXLE |
274 |
|
A. TRANSAXLE HOUSING |
274 |
|
B. TOP COVER ASSEMBLY |
275 |
|
C. DIFFERENTIAL |
276 |
|
D. SHIFTER FORK |
277 |
|
E. GEAR SHIFT LINKAGE ASSEMBLY |
278 |
|
F. LAY SHAFT AND INPUT SHAFT |
279 |
|
11. FUSE BOX SHIFTING PROCEDURE |
281 |
|
12. REMOVAL OF TRANSAXLE FROMVEHICLE |
282 |
|
13. ON VEHICLE ASSEMBLY OFTRANSAXLE |
285 |
|
14. TRANSAXLE TA65 STAR (ON BENCH)DISASSEMBLY |
287 |
|
15. INPUT SHAFT DEEP GROOVEBEARING REMOVAL |
292 |
|
16. INPUT SHAFT DEEP GROOVEBEARING ASSEMBLY |
292 |
|
17. DISASSEMBLY OF LAY SHAFT |
293 |
|
18. IDNETIFICATION OF COMPONENTS |
295 |
|
A. ENGAGING GEARS |
295 |
|
B. SHIFTER SHAFT SUB ASSEMBLY |
296 |
|
C. SHIFTER FORKS |
296 |
|
D. SHIFTER SHAFTS |
297 |
|
F. SYNCHROCONE |
297 |
|
G. SUB ASSEMBLIES |
297 |
|
19. LAY SHAFT ASSEMBLY |
299 |
|
20. DIFFERENTIAL ASSEMBLY: |
302 |
|
1. DISASSEMBLY |
302 |
|
2. ASSEMBLY |
303 |
|
21. TRANSAXLE ASSEMBLY |
304 |
|
22. DISASSEMBLY OF TOP COVER |
309 |
|
23. ASSEMBLY TOP COVER |
310 |
|
24. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX |
312 |
|
25. REMOVAL OF GEAR SHIFTER ANDSELECTOR CABLE |
313 |
|
26. GEAR SHIFTER CABLE ASSEMBLY |
314 |
|
TRANSAXLE (TA5260) |
315 |
|
1. TECHNICAL SPECIFICATIONS |
319 |
|
2. PRECAUTIONS |
319 |
|
3. GENERAL INFORMATION TA5260 |
320 |
|
4. TIGHTENING TORQUES |
321 |
|
5. SPECIAL TOOL LIST |
325 |
|
6. DIAGNOSIS OF TRANSAXLE |
331 |
|
7. CUT SECTION OF TRANSAXLE TA 5260 |
332 |
|
8. CUT SECTION OF TOP COVER ASSEMBLY |
334 |
|
9. EXPLODED VIEWS OF TRANSAXLE |
335 |
|
10. FUSE BOX SHIFTING PROCEDURE |
342 |
|
11. REMOVAL OF TRANSAXLE FROMVEHICLE |
343 |
|
12. DISASSEMBLY OF TRANSAXLE (ONBENCH) |
346 |
|
A. DISASSEMBLY OF INPUT SHAFT |
352 |
|
B. ASSEMBLY OF INPUT SHAFT |
354 |
|
C. REMOVAL OF DEEP GROOVE BALLBEARING FROM LAY SHAFT |
355 |
|
D. ASSEMBLY OF DEEP GROOVE BALLBEARING ON LAY SHAFT |
356 |
|
E. DISASSEMBLY OF LAY SHAFT |
356 |
|
F. ASSEMBLY OF LAY SHAFT |
358 |
|
G. DISASSEMBLY OF DIFFERENTIAL |
359 |
|
H. ASSEMBLY OF DIFFERENTIAL |
361 |
|
I. DISASSEMBLY OF TOP COVER |
362 |
|
J. IDNETIFICATION OF COMPONENTS |
363 |
|
I. SHIFTER SHAFTS |
363 |
|
II. ENGAGING GEARS |
363 |
|
III. SHIFTER SHAFT SUB ASSEMBLY |
364 |
|
13. ASSEMBLIES OF TRANSAXLE ONBENCH |
365 |
|
14. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX |
370 |
|
15. REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE |
371 |
|
16. ASSEMBLY OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE |
372 |
|
17. NEUTRAL SETTING PROCEDURE |
374 |
|
DRIVE SHAFT PETROL |
375 |
|
1. INTRODUCTION |
379 |
|
2. DRIVESHAFT |
380 |
|
3. DRIVE SHAFT PARTS |
381 |
|
4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE |
381 |
|
5. TESTING FOR NOISE |
382 |
|
6. TIGHTENING TORQUES |
383 |
|
7. SPECIAL TOOLS |
383 |
|
8. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE) |
384 |
|
9. ON VEHICLE ASSEMBLY OF DRIVESHAFT (LH & RH SIDE) |
385 |
|
11. ASSEMBLY PROCEDURE FORDRIVESHAFT |
387 |
|
12. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT |
388 |
|
13. DISASSEMBLY PROCEDURE FOR(TRIPOT JOINT) |
389 |
|
14. DISASSEMBLY AND ASSEMBLY OF CVJOINT ASSEMBLY (OUTER) |
392 |
|
15. DO’S AND DON’T’S FOR DRIVE SHAFT |
396 |
|
DRIVE SHAFT DIESEL |
397 |
|
1. INTRODUCTION |
401 |
|
2. DRIVESHAFT |
402 |
|
3. DRIVE SHAFT PARTS |
403 |
|
4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE |
403 |
|
5. TESTING FOR NOISE |
404 |
|
6. TIGHTENING TORQUES |
405 |
|
7. SPECIAL TOOLS |
406 |
|
8. LH SIDE DRIVE SHAFT REMOVAL |
407 |
|
9. LH SIDE DRIVE SHAFT ASSEMBLY |
408 |
|
10. RH SIDE DRIVE SHAFT REMOVAL |
410 |
|
11. RH SIDE DRIVE SHAFT ASSEMBLY |
411 |
|
13. ASSEMBLY PROCEDURE FORDRIVESHAFT |
414 |
|
14. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT |
416 |
|
15. DO’S AND DON’T’S FOR DRIVE SHAFT |
417 |
|
SUSPENSION |
418 |
|
1. GENERAL INFORMATION |
420 |
|
1.1. FRONT SUSPENSION |
420 |
|
1.2. REAR SUSPENSION |
421 |
|
1.3. SHOCK ABSORBER |
423 |
|
2. TECHNICAL SPECIFICATIONS |
424 |
|
3. TIGHTENING TORQUES |
425 |
|
4. SPECIAL TOOLS |
430 |
|
5. DIAGNOSIS |
435 |
|
6. PRECAUTIONS |
436 |
|
7. EXPLODED VIEWS FRONT SUSPENSION |
437 |
|
A) ASSEMBLY FRONT STRUT EXPLODED VIEW |
437 |
|
B) ANTI ROLL BAR MOUNTING EXPLODED VIEW |
438 |
|
C) LOWER LINK EXPLODED VIEW |
439 |
|
8. EXPLODED VIEWS REAR SUSPENSION |
441 |
|
A) REAR SHOCK ABSORBER AND SPRING EXPLODED VIEW |
441 |
|
B) REAR HUB ASSEMBLY EXPLODED VIEW |
442 |
|
C) REAR TWIST BEAM AND PIVOT BUSH EXPLODED VIEW |
443 |
|
9. ON VEHICLE AND ON BENCH REMOVALAND ASSEMBLY PROCEDURE |
444 |
|
9.1 ON VEHICLE FRONT STRUT REMOVALAND ASSEMBLY |
444 |
|
9.2 ON BENCH FRONT STRUT REMOVAL ANDASSEMBLY |
445 |
|
9.3 ON VEHICLE WHEEL HUB REMOVAL ANDASSEMBLY |
446 |
|
9.4 ON BENCH SUB ASSEMBLY OF KNUCKLEAND WHEEL HUB |
449 |
|
9.5 REMOVAL AND ASSEMBLY OFSUBFRAME ASSEMBLY |
450 |
|
9.6 ON VEHICLE REMOVAL AND ASSEMBLYOF ANTI ROLL BAR |
451 |
|
9.7 REMOVAL AND ASSEMBLY OF LOWERARM BALL JOINT |
451 |
|
9.8 ON BENCH LOWER ARM PIVOT BUSHREMOVAL AND ASSEMBLY |
453 |
|
9.9 ON VEHICLE SUBFRAME ASSEMBLY |
454 |
|
9.10 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING REMOVAL ANDASSEMBLY |
455 |
|
9.11 ON BENCH DISASSEMBLY ANDASSEMBLY OF REAR SHOCK ABSORBER |
456 |
|
9.12 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING ASSEMBLY |
457 |
|
9.13 ON VEHICLE TORSION BEAM REMOVALAND ASSEMBLY |
458 |
|
10 SUSPENSION PRE-LOADING CONDITION |
461 |
|
STEERING (EPAS) |
463 |
|
1. GENERAL INFORMATION |
467 |
|
2. SYSTEM LAYOUT |
467 |
|
3. BLOCK DIAGRAM OF EPAS SYSTEM |
468 |
|
4. TIGHTENING TORQUES |
469 |
|
5. SPECIAL TOOLS |
471 |
|
6. MAINTENANCE, INSPECTION AND TEST |
473 |
|
6.1 PRELIMINARY INSPECTION |
473 |
|
6.2. REGULAR MAINTENANCE |
474 |
|
7. ON VEHICLE REPAIRS |
476 |
|
7.1. STEERING WHEEL REMOVAL |
476 |
|
7.2 STEERING COLUMN REMOVAL |
477 |
|
7.3 INTERMEDIATE SHAFT REMOVAL |
478 |
|
7.4. RACK & PINION ASSEMBLY REMOVAL |
479 |
|
8. OVERHAULING |
481 |
|
8.1. DISASSEMBLY OF RACK & PINON |
482 |
|
8.2. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE |
484 |
|
8.3. OBJ ON-VEHICLE REMOVAL |
485 |
|
8.4. WHEEL ALIGNMENT |
486 |
|
8.5. CAMBER ADJUSTMENT |
487 |
|
9. TROUBLESHOOTING AND DIAGNOSIS |
488 |
|
10. STEERING ANGLE CALIBRATION |
492 |
|
11. TUNING DATA SELECTION |
495 |
|
BRAKES |
499 |
|
1. TECHNICAL SPECIFICATIONS |
503 |
|
2. TIGHTENING TORQUES |
504 |
|
3. SPECIAL TOOL |
505 |
|
4. PRECAUTIONS |
505 |
|
5. DIAGNOSIS |
506 |
|
6. NESSECITY OF ABS WITH EBD |
509 |
|
7. BRAKE HYDRAULIC LINES |
510 |
|
10. ABS COMPONENTS |
516 |
|
10.1. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU) |
517 |
|
10.2. HYDRAULIC CONTROL UNIT |
518 |
|
10.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED) |
518 |
|
10.4. ABS SYSTEM FAILURE WARNING LIGHT |
519 |
|
11. MAINTENANCE, ADJUSTMENTS & TEST |
520 |
|
11.1. FRONT BRAKE MAINTENANCE |
520 |
|
11.2. REAR BRAKE MAINTENANCE |
522 |
|
11.3 BRAKE TROUBLE SHOOTING |
528 |
|
11.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
529 |
|
12. BRAKE PEDAL ASSEMBLY |
531 |
|
13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE |
532 |
|
14. REPAIRS |
533 |
|
14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT |
534 |
|
14 .2. REMOVAL OF FRONT BRAKE DISC |
541 |
|
14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY |
542 |
|
14.4. REAR BRAKE ASSEMBLY |
544 |
|
14.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY |
545 |
|
14.6. REMOVAL AND INSTALLATION OF PARKING BRAKE LEVER (LOW VERSION) |
551 |
|
14.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE (LOW VERSION) |
552 |
|
14.8 PARKING BRAKE CABLE ADJUSTMENTPROCEDURE (FOR HIGH & LOW END |
553 |
|
14.9 REMOVAL OF PARKING BRAKE LEVER (HIGH VERSION) |
554 |
|
14.10 REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE (HIGH VERSION) |
555 |
|
14.11. REMOVAL AND REFITMENT OF ABSECU / HCU |
556 |
|
14.12. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR |
557 |
|
14.13. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR |
558 |
|
15. TROUBLE SHOOTING & DIAGNOSIS |
560 |
|
16. ABS ECU CONNECTOR (K2) |
562 |
|
BODY |
564 |
|
1 TECHNICAL SPECIFICATION |
569 |
|
1.1 LAYOUT |
569 |
|
1.2 TIGHTENING TORQUES |
570 |
|
1.3 SPECIAL TOOL |
572 |
|
2 ON VEHICLE REPAIRS |
573 |
|
2.1 BONNET |
573 |
|
2.5 COCKPIT REMOVAL ( COMPLETE ASSY) |
582 |
|
2.6 GLOVE BOX |
586 |
|
2.7 SIDE AIR VENTS |
587 |
|
2.8 FRONT BUMPER |
588 |
|
2.9 REAR BUMPER |
589 |
|
2.10 FRONT DOOR |
590 |
|
2.11 FRONT DOOR TRIMS |
591 |
|
2.12 DOOR INNER LOCK HANDLE |
592 |
|
2.13 FRONT OUTER DOOR HANDLE |
593 |
|
2.14 FRONT DOOR LATCH |
593 |
|
2.15 FRONT DOOR GLASS AND WINDOWWINDING MECHANISM |
594 |
|
2.16 REAR DOOR |
595 |
|
2.17 REAR DOOR TRIM |
596 |
|
2.18 REAR OUTER DOOR HANDLE |
598 |
|
2.19 DOOR LATCH REAR |
599 |
|
2.20 TAIL GATE |
600 |
|
2.21 INNER REAR VIEW MIRROR |
602 |
|
2.22 ORVM |
602 |
|
2.23 FRONT ROW SEAT |
603 |
|
2.24 REAR ROW SEAT |
604 |
|
2.25. FRONT SEAT BELT |
605 |
|
2.26 REAR SEAT BELT |
607 |
|
2.27 “A” PILLAR TRIM |
607 |
|
2.28 FRONT SCUFF PLATE |
608 |
|
2.29 “B” PILLAR TRIMS |
608 |
|
2.30 “C” PILLAR TRIMS |
609 |
|
2.31. GRAB HANDLE |
609 |
|
2.32 SUNVISOR |
610 |
|
2.33 ROOF LINEAR |
610 |
|
2.34 PLENUM COVER |
611 |
|
2.35 GEAR LEVER BOOT |
611 |
|
2.36 BONNET INSULATION |
611 |
|
2.37 GLASS |
612 |
|
2.38 FUEL FILLER ASSEMBLY |
613 |
|
2.39 FRONT WHEEL ARCH LINER |
614 |
|
2.40 REAR WHEEL ARCH LINER |
615 |
|
2.41 FRONT FENDER |
616 |
|
2.42 REAR WIPER MOTOR |
617 |
|
2.43 FRONT WIPER |
617 |
|
ELECTRICAL |
619 |
|
1. TECHNICAL SPECIFICATION |
619 |
|
2. GENERAL PRECAUTIONS |
621 |
|
3. FUSE BOX / RELAY LOCATIONS (Applicable for RHD variants) |
625 |
|
4. BATTERY |
626 |
|
5. ALTERNATOR |
628 |
|
5.1. CHECKS ON ENGINE |
628 |
|
5.2. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALTERNATOR & BATTERY |
629 |
|
6. STARTER MOTOR |
632 |
|
7. LIGHTING SYSTEM |
640 |
|
7.1. BULB SPECIFICATIONS |
640 |
|
7.2. FASTENERS TORQUE VALUE TABLE |
641 |
|
7.3. GENERAL SYMPTOMS AND DIAGNOSTICS |
641 |
|
7.4. HEADLAMP |
644 |
|
7.5. SIDE REPEATER LAMP (LH/RH) |
649 |
|
7.6. ROOF LAMP |
649 |
|
7.7. HIGH MOUNTED STOP LAMP |
650 |
|
7.8. TAIL LAMP |
651 |
|
7.9. FRONT FOG LAMP |
654 |
|
7.10. REGISTRATION PLATE LAMP |
655 |
|
8. HORN |
656 |
|
9. WIPER & WASHER SYSTEM |
657 |
|
9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT |
657 |
|
9.3. WIPER AND WIPER CARE |
661 |
|
10. POWER SOCKETS |
663 |
|
11. GLOWPLUG CONTROL UNIT |
663 |
|
12. FUEL GAUGE AND FUEL LEVEL METER |
665 |
|
13. INSPECTION OF FUEL GAUGE |
665 |
|
14 COMBI-SWITCH |
666 |
|
14.1 COMBI SWITCH CONNECTION DETAILS |
667 |
|
14.2 REMOVAL & REFITMENT OF COMBISWITCH |
669 |
|
14.3 COMBI STALK REPLACEMENTPROCEDURE |
670 |
|
15. FASCIA SWITCHES (IF APPLICABLE |
672 |
|
16. STEERING CUM IGNITION SWITCH (IF APPLICABLE) |
674 |
|
17. HAZARD SWITCH |
675 |
|
19. MIRROR SWITCH (IF APPLICABLE) |
677 |
|
20. SILVER BOX |
679 |
|
20.1 SILVER BOX (XZ-HIGH VERSION) |
679 |
|
20.2. SILVER BOX (XM-MID VERSION) |
681 |
|
21. INFOTAINMENT SYSTEM |
683 |
|
21.1 INFOTAINMENT SYSTEM (XZ – HIGH) |
683 |
|
21.2. INFOTAINMENT SYSTEM (XM – MID) |
685 |
|
21.3 USB PORT |
687 |
|
21.4 SPEAKERS |
688 |
|
21.5 ANTENNA (IF APPLICABLE) |
689 |
|
21.6. MICROPHONE (XZ-HIGH) |
690 |
|
21.7. MICROPHONE (XM - MID |
691 |
|
21.8. TWEETERS |
691 |
|
21.9. DTC FOR INFOTAINMENT SYSTEM |
693 |
|
22. WINDOW WINDING MODULE |
694 |
|
23. POWER WINDOW SWITCHES & INHIBITSWITCH |
697 |
|
24. STEERING WHEEL SWITCHES |
702 |
|
25. IGNITION E-KEY (IF APPLICABLE) |
704 |
|
26. INSTRUMENT CLUSTER |
707 |
|
26.1. BASIC FUNCTIONAL MATRIX |
712 |
|
26.2. MAIN CONNECTOR PIN-OUTS |
713 |
|
26.3. FUEL GAUGE DETAILS |
714 |
|
26.4. TEMPERATURE BAR GRAPH DETAILS |
715 |
|
26.5. CHIME TABLE |
716 |
|
27. IMMOBILIZER SYSTEM (IF APPLICABLE) |
717 |
|
27.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
721 |
|
27.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
722 |
|
27.3. IGNITION KEY LEARNINGPROCEDURE |
724 |
|
28. BODY CONTROL MODULE (BCM |
726 |
|
28.1 CONNECTION DETAILS (PINOUT DEATAILS) |
727 |
|
28.2 BCM SPECIFICATION |
731 |
|
28.3 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
732 |
|
28.4 BCM FEATURES (IF APPLICABLE) |
737 |
|
28.5 BCM FUNCTIONS |
739 |
|
28.6 BCM REPLACEMENT STRATEGY |
740 |
|
29. FUSE AND RELAY BOX DETAILS |
742 |
|
30. REVERSE PARK ASSIST SYSTEM |
750 |
|
31. PASSIVE ENTRY PASSIVE START(PEPS) |
764 |
|
HVAC |
775 |
|
1. HVAC SYSTEM LAYOUT |
779 |
|
2. TECHNICAL SPECIFICATIONS |
780 |
|
3. TIGHTENING TORQUES |
783 |
|
4. PRECAUTIONS |
786 |
|
5. HVAC SYSTEM LAYOUT AND WORKING |
787 |
|
6. CONTROL PANEL |
789 |
|
7. HVAC UNIT COMPONENTS |
791 |
|
8. COMPRESSOR |
792 |
|
9. CONDENSER |
794 |
|
10. RECEIVER DRIER (R.D) |
794 |
|
11. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT) |
794 |
|
12. TRINARY PRESSURE SENSOR |
795 |
|
13. MODE & TEMPRATURE CONTROL ACTUATOR |
796 |
|
14. INSPECTION OF MODE AND TEMPERATURE ACTUATOR |
797 |
|
15. TROUBLESHOOTING |
799 |
|
16. MAINTENANCE |
809 |
|
A. PRELIMINARY INSPECTION |
809 |
|
B. REGULAR MAINTENANCE |
811 |
|
17. ON VEHICLE REPAIRS |
815 |
|
A. AC FILTER REMOVAL AND ASSEMBLY |
815 |
|
B. COMPRESSOR REMOVAL AND ASSEMBLY |
815 |
|
C. CONTROL PANEL REMOVAL AND ASSEMBLY |
816 |
|
D. BLOWER MOTOR REMOVAL AND ASSEMBLY |
817 |
|
E. FRONT HVAC UNIT REMOVAL AND ASSEMBLY |
818 |
|
F. CONDENSER REMOVAL AND ASSEMBLY |
819 |
|
18. DO’S AND DONT’S FOR A/C SYSTEM |
821 |
|
FATC |
825 |
|
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM |
829 |
|
2. FATC SYSTEM LAYOUT |
829 |
|
3. TECHNICAL SPECIFICATIONS |
830 |
|
4. TIGHTENING TORQUES |
834 |
|
5. PRECAUTIONS |
837 |
|
6. HMI CLIMATE CONTRL DISPLAY |
838 |
|
7. CONTROL PANEL |
840 |
|
8. CONTROL PANEL MODULE CONNECTOR DETAILS |
845 |
|
9. FATC UNIT |
847 |
|
A. BLOWER |
847 |
|
B. EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE) |
847 |
|
C. HEATER COIL |
847 |
|
10. FATC SENSOR & ACTUATOR |
848 |
|
A. EVAPORATER SENSOR |
848 |
|
B. TRINARY PRESSURE SENSOR |
849 |
|
C. INCAR SENSOR |
849 |
|
D. MODE ACTUATOR |
850 |
|
E. TEMPERATURE ACTUATOR |
850 |
|
F. FRESH AIR / RECIRCULATION ACTUATOR |
850 |
|
G. BLOWER CONTROL MODULE |
851 |
|
11. COMPRESSOR |
851 |
|
12. CONDENSER AND RECEIVER DRIER CONDENSER |
852 |
|
13. TROUBLESHOOTING |
853 |
|
14. MAINTENANCE |
864 |
|
A PRELIMINARY INSPECTION |
864 |
|
B. REGULAR MAINTENANCE |
866 |
|
15. ON VEHICLE REPAIR |
870 |
|
A. AC FILTER REMOVAL AND ASSEMBLY |
870 |
|
B. CONTROL PANEL REMOVAL AND ASSEMBLY |
870 |
|
C. BLOWER MOTOR REMOVAL AND ASSEMBLY |
871 |
|
D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY |
872 |
|
E. REAR VENT REMOVAL AND ASSEMBLY |
874 |
|
F. COMPRESSOR REMOVAL ANDASEMBLY |
875 |
|
G. CONDENSER REMOVAL AND ASSEMBLY |
875 |
|
16. DO’S AND DONT’S FOR A/C SYSTEM |
877 |
|
SUPPLEMENTARY RESTRAINT SYSTEM (SRS) |
878 |
|
1.1. WORKING OF RESTRAINTS |
880 |
|
1.2. SYSTEM LAYOUT |
882 |
|
1.3. SAFETY PRECAUTIONS |
883 |
|
1.4. DISPOSAL OF FAULTY AIR BAG UNIT |
885 |
|
1.5. SRS POST ACCIDENT PROCEDURE |
886 |
|
1.6. TIGHTENING TORQUES |
887 |
|
1.7. COMPONENTS |
891 |
|
1.7.1. RESTRAINT WITHOUT AIRBAGS |
891 |
|
1.7.2. RESTRAINT WITH AIRBAGS |
891 |
|
1.7.2.1. ECU |
891 |
|
1.7.2.2. FRONT IMPACT SENSOR (FIS) |
895 |
|
1.7.2.3. AIR BAGS |
897 |
|
1.7.2.4. RPLL BELTS |
899 |
|
1.7.2.5. CLOCK SPRING |
902 |
|
WHEELS AND TYRES |
907 |
|
1.1 GENERAL INFORMATION |
909 |
|
A. SPECIFICATIONS |
909 |
|
B. CONSTRUCTION |
910 |
|
C. TIGHTENING TORQUES |
912 |
|
1.2 GENERAL SYMPTOMS DIAGNOSIS |
913 |
|
A. DIAGNOSIS CHART |
913 |
|
B. TYRE WEAR PATTERN |
915 |
|
C. WEAR CAUSES |
916 |
|
D. TYRE VIBRATION DIAGNOSIS |
917 |
|
1.3 MAINTENANCE, INSPECTION AND TESTS |
918 |
|
A. PRELIMINARY INSPECTION |
918 |
|
B. REGULAR MAINTENANCE |
919 |
|
I. INFLATION |
919 |
|
II. WHEEL BALANCING |
919 |
|
III. TYRE ROTATION |
920 |
|
IV. WHEEL RUN OUT |
921 |
|
V. DO'S AND DON’TS |
921 |
|
1.4 WHEEL AND TYRE REPLACEMENT |
922 |
|
A. PRECAUTIONS DURING TYREREPLACEMENT |
922 |
|
B. TYRE REPLACEMENT |
923 |
|
C. WHEEL ASSEMBLY REPLACEMENT |
923 |
|
D. WHEEL REMOVAL |
923 |