ALTROZ SERVICE MANUAL
|
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 |
|
1.5L REVOTORQ ENGINE |
184 |
|
CONTENTS |
185 |
|
1. GENERAL INFORMATION |
189 |
|
A. ENGINE INTRODUCTION |
189 |
|
B. TECHNICAL SPECIFICATION |
190 |
|
C. SPECIAL TOOLS |
191 |
|
D. ASSEMBLY CLEARANCES |
195 |
|
2. TROUBLESHOOTING |
196 |
|
3. CONSTRUCTIONAL AND SERVICE DETAILS |
200 |
|
A. Engine Lifting Hook |
200 |
|
B. Intake Manifold and Fuel Injection System |
201 |
|
C. Lubrication system |
203 |
|
D. Air Filter, Snorkel, Blow By Pipe |
206 |
|
E. Starter Motor, Compressor and Alternator |
208 |
|
F. Timing Belt, Auto Tensioner, Water pump |
210 |
|
G. Exhaust manifold, CATCON, Turbocharger |
212 |
|
H. Cylinder head and Components |
215 |
|
I. Piston, Crankshaft and Components |
218 |
|
J. Engine Suspension |
220 |
|
K. EGR Valve, Thermostat and Components |
222 |
|
L. Crankcase and Components |
225 |
|
4. ENGINE TESTS AND MAINTENANCE |
227 |
|
A. PRELIMINARY INSPECTION |
227 |
|
B. ENGINE TESTS |
227 |
|
C. REGULAR MAINTENANCE |
232 |
|
5. REPAIR AND INSPECTION DETAILS |
241 |
|
A. TIMING BELT |
241 |
|
B. FUEL TANK |
241 |
|
C. CYLINDER HEAD |
242 |
|
D. VALVES |
242 |
|
E. VALVE SEATS |
244 |
|
F. CRANKCASE |
245 |
|
G. VALVE SEAT INSERT |
246 |
|
H. HYDRAULIC LASH ADJUSTER |
246 |
|
I. VALVE GUIDES |
247 |
|
J. CAMSHAFT |
248 |
|
K. PISTON AND PISTON RINGS |
249 |
|
L. CONNECTING ROD |
250 |
|
M. CRANK SHAFT |
252 |
|
6. ENGINE SYSTEMS |
254 |
|
A. AIR INTAKE SYSTEM |
254 |
|
B. EXHAUST SYSTEM |
257 |
|
C. COOLING SYSTEM |
261 |
|
D. LUBRICATION SYSTEM |
264 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM (EGR) |
268 |
|
F. BLOW-BY VENTILATION SYSTEM |
270 |
|
G. VACUUM MANAGEMENT SYSTEM |
271 |
|
H. FUEL SYSTEM |
272 |
|
7. ENGINE ON VEHICLE SERVICEPROCEDUR |
278 |
|
A. FUSE BOX SHIFTING PROCEDURE: |
278 |
|
B. ENGINE REMOVAL |
279 |
|
C. ENGINE INSTALLATION |
285 |
|
D. EXHAUST SYSTEM |
286 |
|
E. COOLING SYSTEM |
289 |
|
F. FUEL SYSTEM |
294 |
|
G. TURBOCHARGER REMOVAL ANDREFITMENT |
301 |
|
H. TIMING BELT REMOVAL AND REFITMENT |
303 |
|
I. STARTER MOTOR REMOVAL ANDREFITMENT |
304 |
|
J. ALTERNATOR MOTOR REMOVAL ANDREFITMENT |
305 |
|
K. COMPRESSOR MOTOR REMOVAL ANDREFITMENT |
306 |
|
L. HIGH PRESSURE PUMP REMOVAL ANDREFITMENT |
307 |
|
8. ENGINE OVERHAULING |
310 |
|
A. ENGINE DIS-ASSEMBLY |
310 |
|
i. ON OVERHAUL STAND |
310 |
|
ii. REMOVAL OF EGR VALVE & OIL FILTER |
314 |
|
iii. REMOVAL OF INTAKE MANIFOLD |
315 |
|
iv. REMOVAL OF EXHAUST MANIFOLD |
317 |
|
v. REMOVAL OF EVRV AND THERMOSTAT |
318 |
|
vi. REMOVAL OF OIL SUMP |
319 |
|
vii. REMOVAL OF TIMING BELT |
320 |
|
viii. REMOVAL OF CYLINDER HEAD |
325 |
|
ix. REMOVAL OF CYLINDER HEAD SUBASSEMBLIES |
326 |
|
x. REMOVAL OF CYLINDER BLOCK SUBASSEMBLI |
329 |
|
xi. PISTON CONNECTING RODDISASSEMBLY |
331 |
|
B. ENGINE ASSEMBLY |
337 |
|
i. FITMENT OF CYLINDER HEAD SUBASSEMBLIES |
337 |
|
ii. FITMENT OF PISTON AND CONNECTINGROD SUB-ASSEMBLIES |
338 |
|
iii. FITMENT OF CYLINDER BLOCK SUBASSEMBLIE |
339 |
|
iv. FITMENT OF CYLINDER HEAD ONCYLINDER BLOCK |
341 |
|
v. FITMENT OF TIMING BELT |
343 |
|
vi. FITMENT OF ENGINE SUPPORT |
347 |
|
vii. FITMENT OF OIL SUMP |
348 |
|
viii. FITMENT OF EXHAUST MANIFOLD ANDOTHER COMPONENTS |
349 |
|
ix. FITMENT OF INTAKE MANIFOLD |
353 |
|
x. FITMENT OF PERIPHERALS |
355 |
|
9. ENGINE MANAGEMENT SYSTEM |
358 |
|
A. ABBREVIATIONS |
358 |
|
B. AN OVERVIEW |
358 |
|
C. ELECTRONIC CONTROL UNIT (ECU) |
359 |
|
D. EMS SENSORS |
364 |
|
CLUTCH DIESEL |
379 |
|
1.1. GENERAL INFORMATION |
382 |
|
A. CLUCTH MASTER CYLINDER |
383 |
|
B. CONCENTRIC SLAVE CYLINDER (CSC) |
383 |
|
C. PEAK TORQUE LIMITER |
383 |
|
D. HYDRAULIC ADAPTER |
383 |
|
E. SINGLE MASS FLYWHEEL |
384 |
|
F. CONVENTIONAL CLUTCH |
384 |
|
1.2. TECHNICAL SPECIFICATIONS |
385 |
|
A. CLUTCH DISC ASSEMBLY |
385 |
|
B. CONVENTIONAL CLUTCH |
386 |
|
C. SINGLE MASS FLYWHEEL (FOR DIESEL VERSION) |
387 |
|
1.3. TIGHTENING TORQUES |
388 |
|
1.4. SPECIAL TOOLS |
389 |
|
1.5. MAINTENANCE, INSPECTION ANDTESTS |
390 |
|
1.5.1. PRELIMINARY INSPECTION |
390 |
|
1.5.2. REGULAR MAINTENANCE |
391 |
|
A. CLUTCH SWITCH ADJUSTMENT |
391 |
|
B. CLUTCH BLEEDING PROCEDURE |
391 |
|
C. CLUTCH FLUID DRAINING PROCEDURE |
392 |
|
1.6. GENERAL SYMPTOMS DIAGNOSIS |
393 |
|
1.7. EXPLODE VIEWS |
395 |
|
A. CLUTCH PEDAL ASSEMBLY |
395 |
|
B. CONVENTIONAL CLUTCH ASSEMBLY |
396 |
|
C. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
397 |
|
1.8. ON VEHICLE PROCEDURES |
398 |
|
A. FUSE BOX SHIFTING PROCEDURE |
398 |
|
B. CLUTCH PEDAL REMOVAL |
399 |
|
C. CONTROL BRACKET ASSEMBLYREMOVAL |
400 |
|
D. CONVENTIONAL CLUTCH ASSEMBLYREMOVAL |
401 |
|
E. CLUTCH MASTER CYLINDER REMOVAL |
402 |
|
F. FLYWHEEL REMOVAL |
404 |
|
CLUTCH PETROL |
405 |
|
1. GENERAL INFORMATION |
408 |
|
2. TECHNICAL SPECIFICATIONS |
409 |
|
A. CLUTCH DISC |
409 |
|
B. CLUTCH PLATE |
411 |
|
C. FLYWHEEL |
413 |
|
3. TIGHTENING TORQUE |
415 |
|
4. SPECIAL TOOLS |
416 |
|
5 . DIAGNOSIS OF CLUTCH |
417 |
|
6. MAINTENANCE, TESTS AND FACTOR AFFECTING |
420 |
|
A. INSPECTION OF COMPONENTS |
420 |
|
B. TEST |
420 |
|
C. FACTORS AFFECTING CLUTCH |
420 |
|
7. CONSTRUCTIONAL DETAILS |
421 |
|
8. ON VECHILE PROCEDURE |
423 |
|
A. FUSE BOX SHIFTING PROCEDURE |
423 |
|
B. CLUTCH CABLE REMOVAL ANDINSPECTION |
424 |
|
C. REMOVAL OF CLUTCH |
425 |
|
D. FLYWHEEL |
426 |
|
E. CLUTCH ADJUSTMENT PROCEDURE |
427 |
|
TRANSAXLE (TA65 Star) |
454 |
|
1. TECHNICAL SPECIFICATIONS |
458 |
|
2. PRECAUTIONS |
458 |
|
3. GENERAL DESCRIPTION |
459 |
|
4. TIGHTENING TORQUES |
460 |
|
5. SPECIAL TOOLS LIST |
461 |
|
6. DIAGNOSIS |
465 |
|
7. CONSTRUCTIONAL DETAILS |
466 |
|
8. CUT SECTION OF TRANSAXLE TA 65 STAR |
467 |
|
9. CUT SECTION OF TOP COVER ASSEMBLY |
468 |
|
10. EXPLODED VIEWS OF TRANSAXLE |
469 |
|
A. TRANSAXLE HOUSING |
469 |
|
B. TOP COVER ASSEMBLY |
470 |
|
C. DIFFERENTIAL |
471 |
|
D. SHIFTER FORK |
472 |
|
E. GEAR SHIFT LINKAGE ASSEMBLY |
473 |
|
F. LAY SHAFT AND INPUT SHAFT |
474 |
|
11. FUSE BOX SHIFTING PROCEDURE |
476 |
|
12. REMOVAL OF TRANSAXLE FROMVEHICLE |
477 |
|
13. ON VEHICLE ASSEMBLY OFTRANSAXLE |
480 |
|
14. TRANSAXLE TA65 STAR (ON BENCH)DISASSEMBLY |
482 |
|
15. INPUT SHAFT DEEP GROOVEBEARING REMOVAL |
487 |
|
16. INPUT SHAFT DEEP GROOVEBEARING ASSEMBLY |
487 |
|
17. DISASSEMBLY OF LAY SHAFT |
488 |
|
18. IDNETIFICATION OF COMPONENTS |
490 |
|
A. ENGAGING GEARS |
490 |
|
B. SHIFTER SHAFT SUB ASSEMBLY |
491 |
|
C. SHIFTER FORKS |
491 |
|
D. SHIFTER SHAFTS |
492 |
|
F. SYNCHROCONE |
492 |
|
G. SUB ASSEMBLIES |
492 |
|
19. LAY SHAFT ASSEMBLY |
494 |
|
20. DIFFERENTIAL ASSEMBLY: |
497 |
|
1. DISASSEMBLY |
497 |
|
2. ASSEMBLY |
498 |
|
21. TRANSAXLE ASSEMBLY |
499 |
|
22. DISASSEMBLY OF TOP COVER |
504 |
|
23. ASSEMBLY TOP COVER |
505 |
|
24. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX |
507 |
|
25. REMOVAL OF GEAR SHIFTER ANDSELECTOR CABLE |
508 |
|
26. GEAR SHIFTER CABLE ASSEMBLY |
509 |
|
TRANSAXLE (TA5260) |
510 |
|
1. TECHNICAL SPECIFICATIONS |
514 |
|
2. PRECAUTIONS |
514 |
|
3. GENERAL INFORMATION TA5260 |
515 |
|
4. TIGHTENING TORQUES |
516 |
|
5. SPECIAL TOOL LIST |
520 |
|
6. DIAGNOSIS OF TRANSAXLE |
526 |
|
7. CUT SECTION OF TRANSAXLE TA 5260 |
527 |
|
8. CUT SECTION OF TOP COVER ASSEMBLY |
529 |
|
9. EXPLODED VIEWS OF TRANSAXLE |
530 |
|
10. FUSE BOX SHIFTING PROCEDURE |
537 |
|
11. REMOVAL OF TRANSAXLE FROMVEHICLE |
538 |
|
12. DISASSEMBLY OF TRANSAXLE (ONBENCH) |
541 |
|
A. DISASSEMBLY OF INPUT SHAFT |
547 |
|
B. ASSEMBLY OF INPUT SHAFT |
549 |
|
C. REMOVAL OF DEEP GROOVE BALLBEARING FROM LAY SHAFT |
550 |
|
D. ASSEMBLY OF DEEP GROOVE BALLBEARING ON LAY SHAFT |
551 |
|
E. DISASSEMBLY OF LAY SHAFT |
551 |
|
F. ASSEMBLY OF LAY SHAFT |
553 |
|
G. DISASSEMBLY OF DIFFERENTIAL |
554 |
|
H. ASSEMBLY OF DIFFERENTIAL |
556 |
|
I. DISASSEMBLY OF TOP COVER |
557 |
|
J. IDNETIFICATION OF COMPONENTS |
558 |
|
I. SHIFTER SHAFTS |
558 |
|
II. ENGAGING GEARS |
558 |
|
III. SHIFTER SHAFT SUB ASSEMBLY |
559 |
|
13. ASSEMBLIES OF TRANSAXLE ONBENCH |
560 |
|
14. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX |
565 |
|
15. REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE |
566 |
|
16. ASSEMBLY OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE |
567 |
|
17. NEUTRAL SETTING PROCEDURE |
569 |
|
DRIVE SHAFT PETROL |
570 |
|
1. INTRODUCTION |
574 |
|
2. DRIVESHAFT |
575 |
|
3. DRIVE SHAFT PARTS |
576 |
|
4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE |
576 |
|
5. TESTING FOR NOISE |
577 |
|
6. TIGHTENING TORQUES |
578 |
|
7. SPECIAL TOOLS |
578 |
|
8. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE) |
579 |
|
9. ON VEHICLE ASSEMBLY OF DRIVESHAFT (LH & RH SIDE) |
580 |
|
10. DISASSEMBLY PROCEDURE FOR DRIVESHAFT |
581 |
|
11. ASSEMBLY PROCEDURE FORDRIVESHAFT |
582 |
|
12. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT |
583 |
|
13. DISASSEMBLY PROCEDURE FOR(TRIPOT JOINT) |
584 |
|
14. DISASSEMBLY AND ASSEMBLY OF CVJOINT ASSEMBLY (OUTER) |
587 |
|
15. DO’S AND DON’T’S FOR DRIVE SHAFT |
591 |
|
DRIVE SHAFT DIESEL |
592 |
|
1. INTRODUCTION |
596 |
|
2. DRIVESHAFT |
597 |
|
3. DRIVE SHAFT PARTS |
598 |
|
4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE |
598 |
|
5. TESTING FOR NOISE |
599 |
|
6. TIGHTENING TORQUES |
600 |
|
7. SPECIAL TOOLS |
601 |
|
8. LH SIDE DRIVE SHAFT REMOVAL |
602 |
|
9. LH SIDE DRIVE SHAFT ASSEMBLY |
603 |
|
10. RH SIDE DRIVE SHAFT REMOVAL |
605 |
|
11. RH SIDE DRIVE SHAFT ASSEMBLY |
606 |
|
12. DISASSEMBLY PROCEDURE FOR DRIVESHAFT |
608 |
|
13. ASSEMBLY PROCEDURE FORDRIVESHAFT |
609 |
|
14. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT |
611 |
|
15. DO’S AND DON’T’S FOR DRIVE SHAFT |
612 |
|
SUSPENSION |
613 |
|
1. GENERAL INFORMATION |
615 |
|
1.1. FRONT SUSPENSION |
615 |
|
1.2. REAR SUSPENSION |
616 |
|
1.3. SHOCK ABSORBER |
618 |
|
2. TECHNICAL SPECIFICATIONS |
619 |
|
3. TIGHTENING TORQUES |
620 |
|
4. SPECIAL TOOLS |
625 |
|
5. DIAGNOSIS |
630 |
|
6. PRECAUTIONS |
631 |
|
7. EXPLODED VIEWS FRONT SUSPENSION |
632 |
|
A) ASSEMBLY FRONT STRUT EXPLODED VIEW |
632 |
|
B) ANTI ROLL BAR MOUNTING EXPLODED VIEW |
633 |
|
C) LOWER LINK EXPLODED VIEW |
634 |
|
8. EXPLODED VIEWS REAR SUSPENSION |
636 |
|
A) REAR SHOCK ABSORBER AND SPRING EXPLODED VIEW |
636 |
|
B) REAR HUB ASSEMBLY EXPLODED VIEW |
637 |
|
C) REAR TWIST BEAM AND PIVOT BUSH EXPLODED VIEW |
638 |
|
9. ON VEHICLE AND ON BENCH REMOVALAND ASSEMBLY PROCEDURE |
639 |
|
9.1 ON VEHICLE FRONT STRUT REMOVALAND ASSEMBLY |
639 |
|
9.2 ON BENCH FRONT STRUT REMOVAL ANDASSEMBLY |
640 |
|
9.3 ON VEHICLE WHEEL HUB REMOVAL ANDASSEMBLY |
641 |
|
9.4 ON BENCH SUB ASSEMBLY OF KNUCKLEAND WHEEL HUB |
644 |
|
9.5 REMOVAL AND ASSEMBLY OFSUBFRAME ASSEMBLY |
645 |
|
9.6 ON VEHICLE REMOVAL AND ASSEMBLYOF ANTI ROLL BAR |
646 |
|
9.7 REMOVAL AND ASSEMBLY OF LOWERARM BALL JOINT |
646 |
|
9.8 ON BENCH LOWER ARM PIVOT BUSHREMOVAL AND ASSEMBLY |
648 |
|
9.9 ON VEHICLE SUBFRAME ASSEMBLY |
649 |
|
9.10 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING REMOVAL ANDASSEMBLY |
650 |
|
9.11 ON BENCH DISASSEMBLY ANDASSEMBLY OF REAR SHOCK ABSORBER |
651 |
|
9.12 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING ASSEMBLY |
652 |
|
9.13 ON VEHICLE TORSION BEAM REMOVALAND ASSEMBLY |
653 |
|
10 SUSPENSION PRE-LOADING CONDITION |
656 |
|
STEERING (EPAS) |
658 |
|
1. GENERAL INFORMATION |
662 |
|
2. SYSTEM LAYOUT |
662 |
|
3. BLOCK DIAGRAM OF EPAS SYSTEM |
663 |
|
4. TIGHTENING TORQUES |
664 |
|
5. SPECIAL TOOLS |
666 |
|
6. MAINTENANCE, INSPECTION AND TEST |
668 |
|
6.1 PRELIMINARY INSPECTION |
668 |
|
6.2. REGULAR MAINTENANCE |
669 |
|
7. ON VEHICLE REPAIRS |
671 |
|
7.1. STEERING WHEEL REMOVAL |
671 |
|
7.2 STEERING COLUMN REMOVAL |
672 |
|
7.3 INTERMEDIATE SHAFT REMOVAL |
673 |
|
7.4. RACK & PINION ASSEMBLY REMOVAL |
674 |
|
8. OVERHAULING |
676 |
|
8.1. DISASSEMBLY OF RACK & PINON |
677 |
|
8.2. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE |
679 |
|
8.3. OBJ ON-VEHICLE REMOVAL |
680 |
|
8.4. WHEEL ALIGNMENT |
681 |
|
8.5. CAMBER ADJUSTMENT |
682 |
|
9. TROUBLESHOOTING AND DIAGNOSIS |
683 |
|
10. STEERING ANGLE CALIBRATION |
687 |
|
11. TUNING DATA SELECTION |
690 |
|
BRAKES |
694 |
|
1. TECHNICAL SPECIFICATIONS |
698 |
|
2. TIGHTENING TORQUES |
699 |
|
3. SPECIAL TOOL |
700 |
|
4. PRECAUTIONS |
700 |
|
5. DIAGNOSIS |
701 |
|
6. NESSECITY OF ABS WITH EBD |
704 |
|
7. BRAKE HYDRAULIC LINES |
705 |
|
8. VACUUM BRAKE BOOSTER |
706 |
|
9. WORKING OF ANTI-LOCK BRAKING (ABS) SYSTEM |
707 |
|
10. ABS COMPONENTS |
711 |
|
10.1. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU) |
712 |
|
10.2. HYDRAULIC CONTROL UNIT |
713 |
|
10.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED) |
713 |
|
10.4. ABS SYSTEM FAILURE WARNING LIGHT |
714 |
|
11. MAINTENANCE, ADJUSTMENTS & TEST |
715 |
|
11.1. FRONT BRAKE MAINTENANCE |
715 |
|
11.2. REAR BRAKE MAINTENANCE |
717 |
|
11.3 BRAKE TROUBLE SHOOTING |
723 |
|
11.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
724 |
|
12. BRAKE PEDAL ASSEMBLY |
726 |
|
13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE |
727 |
|
14. REPAIRS |
728 |
|
14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT |
729 |
|
14 .2. REMOVAL OF FRONT BRAKE DISC |
736 |
|
14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY |
737 |
|
14.4. REAR BRAKE ASSEMBLY |
739 |
|
14.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY |
740 |
|
14.6. REMOVAL AND INSTALLATION OF PARKING BRAKE LEVER (LOW VERSION) |
746 |
|
14.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE (LOW VERSION) |
747 |
|
14.8 PARKING BRAKE CABLE ADJUSTMENTPROCEDURE (FOR HIGH & LOW END |
748 |
|
14.9 REMOVAL OF PARKING BRAKE LEVER (HIGH VERSION) |
749 |
|
14.10 REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE (HIGH VERSION) |
750 |
|
14.11. REMOVAL AND REFITMENT OF ABSECU / HCU |
751 |
|
14.12. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR |
752 |
|
14.13. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR |
753 |
|
15. TROUBLE SHOOTING & DIAGNOSIS |
755 |
|
16. ABS ECU CONNECTOR (K2) |
757 |
|
BODY |
759 |
|
1 TECHNICAL SPECIFICATION |
764 |
|
1.1 LAYOUT |
764 |
|
1.2 TIGHTENING TORQUES |
765 |
|
1.3 SPECIAL TOOL |
767 |
|
2 ON VEHICLE REPAIRS |
768 |
|
2.1 BONNET |
768 |
|
2.2 ARM REST |
770 |
|
2.3 FLOOR CONSOLE |
771 |
|
2.4 DASHBOARD SKIN |
773 |
|
2.5 COCKPIT REMOVAL ( COMPLETE ASSY) |
777 |
|
2.6 GLOVE BOX |
781 |
|
2.7 SIDE AIR VENTS |
782 |
|
2.8 FRONT BUMPER |
783 |
|
2.9 REAR BUMPER |
784 |
|
2.10 FRONT DOOR |
785 |
|
2.11 FRONT DOOR TRIMS |
786 |
|
2.12 DOOR INNER LOCK HANDLE |
787 |
|
2.13 FRONT OUTER DOOR HANDLE |
788 |
|
2.14 FRONT DOOR LATCH |
788 |
|
2.15 FRONT DOOR GLASS AND WINDOWWINDING MECHANISM |
789 |
|
2.16 REAR DOOR |
790 |
|
2.17 REAR DOOR TRIM |
791 |
|
2.18 REAR OUTER DOOR HANDLE |
793 |
|
2.19 DOOR LATCH REAR |
794 |
|
2.20 TAIL GATE |
795 |
|
2.21 INNER REAR VIEW MIRROR |
797 |
|
2.22 ORVM |
797 |
|
2.23 FRONT ROW SEAT |
798 |
|
2.24 REAR ROW SEAT |
799 |
|
2.25. FRONT SEAT BELT |
800 |
|
2.26 REAR SEAT BELT |
802 |
|
2.27 “A” PILLAR TRIM |
802 |
|
2.28 FRONT SCUFF PLATE |
803 |
|
2.29 “B” PILLAR TRIMS |
803 |
|
2.30 “C” PILLAR TRIMS |
804 |
|
2.31. GRAB HANDLE |
804 |
|
2.32 SUNVISOR |
805 |
|
2.33 ROOF LINEAR |
805 |
|
2.34 PLENUM COVER |
806 |
|
2.35 GEAR LEVER BOOT |
806 |
|
2.36 BONNET INSULATION |
806 |
|
2.37 GLASS |
807 |
|
2.38 FUEL FILLER ASSEMBLY |
808 |
|
2.39 FRONT WHEEL ARCH LINER |
809 |
|
2.40 REAR WHEEL ARCH LINER |
810 |
|
2.41 FRONT FENDER |
811 |
|
2.42 REAR WIPER MOTOR |
812 |
|
2.43 FRONT WIPER |
812 |
|
ELECTRICAL |
814 |
|
1. TECHNICAL SPECIFICATION |
814 |
|
2. GENERAL PRECAUTIONS |
816 |
|
3. FUSE BOX / RELAY LOCATIONS (Applicable for RHD variants) |
820 |
|
4. BATTERY |
821 |
|
5. ALTERNATOR |
823 |
|
5.1. CHECKS ON ENGINE |
823 |
|
5.2. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALTERNATOR & BATTERY |
824 |
|
6. STARTER MOTOR |
827 |
|
7. LIGHTING SYSTEM |
835 |
|
7.1. BULB SPECIFICATIONS |
835 |
|
7.2. FASTENERS TORQUE VALUE TABLE |
836 |
|
7.3. GENERAL SYMPTOMS AND DIAGNOSTICS |
836 |
|
7.4. HEADLAMP |
839 |
|
7.5. SIDE REPEATER LAMP (LH/RH) |
844 |
|
7.6. ROOF LAMP |
844 |
|
7.7. HIGH MOUNTED STOP LAMP |
845 |
|
7.8. TAIL LAMP |
846 |
|
7.9. FRONT FOG LAMP |
849 |
|
7.10. REGISTRATION PLATE LAMP |
850 |
|
8. HORN |
851 |
|
9. WIPER & WASHER SYSTEM |
852 |
|
9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT |
852 |
|
9.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
853 |
|
9.3. WIPER AND WIPER CARE |
856 |
|
10. POWER SOCKETS |
858 |
|
11. GLOWPLUG CONTROL UNIT |
858 |
|
12. FUEL GAUGE AND FUEL LEVEL METER |
860 |
|
13. INSPECTION OF FUEL GAUGE |
860 |
|
14 COMBI-SWITCH |
861 |
|
14.1 COMBI SWITCH CONNECTION DETAILS |
862 |
|
14.2 REMOVAL & REFITMENT OF COMBISWITCH |
864 |
|
14.3 COMBI STALK REPLACEMENTPROCEDURE |
865 |
|
15. FASCIA SWITCHES (IF APPLICABLE |
867 |
|
16. STEERING CUM IGNITION SWITCH (IF APPLICABLE) |
869 |
|
17. HAZARD SWITCH |
870 |
|
19. MIRROR SWITCH (IF APPLICABLE) |
872 |
|
20. SILVER BOX |
874 |
|
20.1 SILVER BOX (XZ-HIGH VERSION) |
874 |
|
20.2. SILVER BOX (XM-MID VERSION) |
876 |
|
21. INFOTAINMENT SYSTEM |
878 |
|
21.1 INFOTAINMENT SYSTEM (XZ – HIGH) |
878 |
|
21.2. INFOTAINMENT SYSTEM (XM – MID) |
880 |
|
21.3 USB PORT |
882 |
|
21.4 SPEAKERS |
883 |
|
21.5 ANTENNA (IF APPLICABLE) |
884 |
|
21.6. MICROPHONE (XZ-HIGH) |
885 |
|
21.7. MICROPHONE (XM - MID |
886 |
|
21.8. TWEETERS |
886 |
|
21.9. DTC FOR INFOTAINMENT SYSTEM |
888 |
|
22. WINDOW WINDING MODULE |
889 |
|
23. POWER WINDOW SWITCHES & INHIBITSWITCH |
892 |
|
24. STEERING WHEEL SWITCHES |
897 |
|
25. IGNITION E-KEY (IF APPLICABLE) |
899 |
|
26. INSTRUMENT CLUSTER |
902 |
|
26.1. BASIC FUNCTIONAL MATRIX |
907 |
|
26.2. MAIN CONNECTOR PIN-OUTS |
908 |
|
26.3. FUEL GAUGE DETAILS |
909 |
|
26.4. TEMPERATURE BAR GRAPH DETAILS |
910 |
|
26.5. CHIME TABLE |
911 |
|
27. IMMOBILIZER SYSTEM (IF APPLICABLE) |
912 |
|
27.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
916 |
|
27.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
917 |
|
27.3. IGNITION KEY LEARNINGPROCEDURE |
919 |
|
28. BODY CONTROL MODULE (BCM |
921 |
|
28.1 CONNECTION DETAILS (PINOUT DEATAILS) |
922 |
|
28.2 BCM SPECIFICATION |
926 |
|
28.3 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
927 |
|
28.4 BCM FEATURES (IF APPLICABLE) |
932 |
|
28.5 BCM FUNCTIONS |
934 |
|
28.6 BCM REPLACEMENT STRATEGY |
935 |
|
29. FUSE AND RELAY BOX DETAILS |
937 |
|
30. REVERSE PARK ASSIST SYSTEM |
945 |
|
31. PASSIVE ENTRY PASSIVE START(PEPS) |
959 |
|
HVAC |
970 |
|
1. HVAC SYSTEM LAYOUT |
974 |
|
2. TECHNICAL SPECIFICATIONS |
975 |
|
3. TIGHTENING TORQUES |
978 |
|
4. PRECAUTIONS |
981 |
|
5. HVAC SYSTEM LAYOUT AND WORKING |
982 |
|
6. CONTROL PANEL |
984 |
|
7. HVAC UNIT COMPONENTS |
986 |
|
8. COMPRESSOR |
987 |
|
9. CONDENSER |
989 |
|
10. RECEIVER DRIER (R.D) |
989 |
|
11. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT) |
989 |
|
12. TRINARY PRESSURE SENSOR |
990 |
|
13. MODE & TEMPRATURE CONTROL ACTUATOR |
991 |
|
14. INSPECTION OF MODE AND TEMPERATURE ACTUATOR |
992 |
|
15. TROUBLESHOOTING |
994 |
|
16. MAINTENANCE |
1004 |
|
A. PRELIMINARY INSPECTION |
1004 |
|
B. REGULAR MAINTENANCE |
1006 |
|
17. ON VEHICLE REPAIRS |
1010 |
|
A. AC FILTER REMOVAL AND ASSEMBLY |
1010 |
|
B. COMPRESSOR REMOVAL AND ASSEMBLY |
1010 |
|
C. CONTROL PANEL REMOVAL AND ASSEMBLY |
1011 |
|
D. BLOWER MOTOR REMOVAL AND ASSEMBLY |
1012 |
|
E. FRONT HVAC UNIT REMOVAL AND ASSEMBLY |
1013 |
|
F. CONDENSER REMOVAL AND ASSEMBLY |
1014 |
|
18. DO’S AND DONT’S FOR A/C SYSTEM |
1016 |
|
FATC |
1020 |
|
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM |
1024 |
|
2. FATC SYSTEM LAYOUT |
1024 |
|
3. TECHNICAL SPECIFICATIONS |
1025 |
|
4. TIGHTENING TORQUES |
1029 |
|
5. PRECAUTIONS |
1032 |
|
6. HMI CLIMATE CONTRL DISPLAY |
1033 |
|
7. CONTROL PANEL |
1035 |
|
8. CONTROL PANEL MODULE CONNECTOR DETAILS |
1040 |
|
9. FATC UNIT |
1042 |
|
A. BLOWER |
1042 |
|
B. EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE) |
1042 |
|
C. HEATER COIL |
1042 |
|
10. FATC SENSOR & ACTUATOR |
1043 |
|
A. EVAPORATER SENSOR |
1043 |
|
B. TRINARY PRESSURE SENSOR |
1044 |
|
C. INCAR SENSOR |
1044 |
|
D. MODE ACTUATOR |
1045 |
|
E. TEMPERATURE ACTUATOR |
1045 |
|
F. FRESH AIR / RECIRCULATION ACTUATOR |
1045 |
|
G. BLOWER CONTROL MODULE |
1046 |
|
11. COMPRESSOR |
1046 |
|
12. CONDENSER AND RECEIVER DRIER CONDENSER |
1047 |
|
13. TROUBLESHOOTING |
1048 |
|
14. MAINTENANCE |
1059 |
|
A PRELIMINARY INSPECTION |
1059 |
|
B. REGULAR MAINTENANCE |
1061 |
|
15. ON VEHICLE REPAIR |
1065 |
|
A. AC FILTER REMOVAL AND ASSEMBLY |
1065 |
|
B. CONTROL PANEL REMOVAL AND ASSEMBLY |
1065 |
|
C. BLOWER MOTOR REMOVAL AND ASSEMBLY |
1066 |
|
D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY |
1067 |
|
E. REAR VENT REMOVAL AND ASSEMBLY |
1069 |
|
F. COMPRESSOR REMOVAL ANDASEMBLY |
1070 |
|
G. CONDENSER REMOVAL AND ASSEMBLY |
1070 |
|
16. DO’S AND DONT’S FOR A/C SYSTEM |
1072 |
|
SUPPLEMENTARY RESTRAINT SYSTEM (SRS) |
1073 |
|
1.1. WORKING OF RESTRAINTS |
1075 |
|
1.2. SYSTEM LAYOUT |
1077 |
|
1.3. SAFETY PRECAUTIONS |
1078 |
|
1.4. DISPOSAL OF FAULTY AIR BAG UNIT |
1080 |
|
1.5. SRS POST ACCIDENT PROCEDURE |
1081 |
|
1.6. TIGHTENING TORQUES |
1082 |
|
1.7. COMPONENTS |
1086 |
|
1.7.1. RESTRAINT WITHOUT AIRBAGS |
1086 |
|
1.7.2. RESTRAINT WITH AIRBAGS |
1086 |
|
1.7.2.1. ECU |
1086 |
|
1.7.2.2. FRONT IMPACT SENSOR (FIS) |
1090 |
|
1.7.2.3. AIR BAGS |
1092 |
|
1.7.2.4. RPLL BELTS |
1094 |
|
1.7.2.5. CLOCK SPRING |
1097 |
|
WHEELS AND TYRES |
1102 |
|
1.1 GENERAL INFORMATION |
1104 |
|
A. SPECIFICATIONS |
1104 |
|
B. CONSTRUCTION |
1105 |
|
C. TIGHTENING TORQUES |
1107 |
|
1.2 GENERAL SYMPTOMS DIAGNOSIS |
1108 |
|
A. DIAGNOSIS CHART |
1108 |
|
B. TYRE WEAR PATTERN |
1110 |
|
C. WEAR CAUSES |
1111 |
|
D. TYRE VIBRATION DIAGNOSIS |
1112 |
|
1.3 MAINTENANCE, INSPECTION AND TESTS |
1113 |
|
A. PRELIMINARY INSPECTION |
1113 |
|
B. REGULAR MAINTENANCE |
1114 |
|
I. INFLATION |
1114 |
|
II. WHEEL BALANCING |
1114 |
|
III. TYRE ROTATION |
1115 |
|
IV. WHEEL RUN OUT |
1116 |
|
V. DO'S AND DON’TS |
1116 |
|
1.4 WHEEL AND TYRE REPLACEMENT |
1117 |
|
A. PRECAUTIONS DURING TYREREPLACEMENT |
1117 |
|
B. TYRE REPLACEMENT |
1118 |
|
C. WHEEL ASSEMBLY REPLACEMENT |
1118 |
|
D. WHEEL REMOVAL |
1118 |