HARRIER BS VI - SERVICE MANUAL
|
HARRIER BS VI - Service Manual |
1 |
|
KRYOTEC ENGINE |
6 |
|
TABLE OF CONTENTS |
7 |
|
1. GENERAL INFORMATION |
9 |
|
A. ENGINE INTRODUCTION |
9 |
|
B. TECHNICAL SPECIFICATION |
10 |
|
C. ASSEMBLY CLEARANCES |
11 |
|
D. LEAKAGE RATES |
14 |
|
2. TROUBLESHOOTING |
18 |
|
3. CONSTRUCTIONAL AND SERVICE DETAILS |
26 |
|
4. EXPLODED VIEW |
31 |
|
5. ENGINE TESTS AND DIAGNOSIS |
71 |
|
A. ENGINE TESTS |
71 |
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B. REGULAR MAINTENANCE |
75 |
|
i. ENGINE OIL AND FILTER CHANGE |
75 |
|
ii. ENGINE COOLANT REPLACEMENT |
76 |
|
iii. AIR FILTER ELEMENT REPLACEMENT |
77 |
|
iv. FUEL FILTER REPLACEMENT |
78 |
|
v. DRAINING WATER FROM FUEL FILTER |
79 |
|
vi. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
80 |
|
vii. DIESEL PARTICULATE FILTER (DPF) REGENERATION / CLEANING |
81 |
|
viii. HYDROSTATIC LOCKED ENGINE |
81 |
|
ix. CHECKING ENGINE OIL PRESSURE |
82 |
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6. REPAIR AND INSPECTION DETAILS |
83 |
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A. TIMING BELT |
83 |
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B. FUEL TANK |
84 |
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C. CYLINDER HEAD |
85 |
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D. CYLINDER HEAD GASKET |
86 |
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E. VALVE SPRING |
87 |
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F. CYLINDER BORE DEGLAZING |
88 |
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G. MEASURING BEARING CLEARANCE USING PLASTIGAGE |
89 |
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82H. EXHAUST PIPE |
90 |
|
7. ENGINE ON VEHICLE SERVICE |
91 |
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A. ENGINE REMOVAL |
91 |
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B. ENGINE FITMENT |
96 |
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C. CYLINDER HEAD |
98 |
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E. BALANCE SHAFT |
106 |
|
F. VIBRATION DAMPER |
108 |
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G. OIL COOLER |
109 |
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H. ENGINE OIL FILTER |
111 |
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I. OIL PAN |
112 |
|
J. DIESEL WARNING LIGHT |
114 |
|
K. DIESEL HIGH PRESSURE |
116 |
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L. ENGINE OIL PUMP |
117 |
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M. OIL PRESSURE REGULATOR |
118 |
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N. EXHAUST MANIFOLD |
119 |
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O. INTAKE MANIFOLD |
120 |
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P. EXHAUST SYSTEM |
125 |
|
Q. FUEL SYSTEM |
137 |
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8. ENGINE ON STAND |
146 |
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A. CLUTCH |
146 |
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B. ENGINE - POSITION ON STAND AND REMOVE |
148 |
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C. ENGINE (MANUAL TRANSMISSION) SEPARATION AND REASSEMBLY |
149 |
|
D. DISASSEMBLY AND REASSEMBLY FOLLOWING INSPECTION |
154 |
|
E. CYLINDER HEAD AND OIL PAN FOR INSPECTION |
169 |
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F. CYLINDER HEAD |
177 |
|
G. CAMSHAFT |
181 |
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H. PISTON |
184 |
|
C635 TRANSAXLE |
186 |
|
1. TECHNICAL SPECIFICATION |
188 |
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2. PRECAUTIONS |
188 |
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3. COMMON PROBLEM CAUSES OR PRE-DIAGNOSTIC INSPECTION |
189 |
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4. TIGHTENING TORQUES |
195 |
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5. SPECIAL TOOLS |
201 |
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6. DISASSEMBLY OF TRANSAXLE FROM VEHICLE |
204 |
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7. ASSEMLY OF TRANSAXLE ON VEHICLE |
207 |
|
8. FLUID |
211 |
|
9. TRANSAXLE DISASSEMBLY ON BENCH |
212 |
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10. TRANSAXLE ASSEMBLY ON BENCH |
217 |
|
11. DIFFERENTIAL BEARING REMOVAL |
223 |
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12. DIFFERENTIAL BEARING ASSEMBLY |
223 |
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13. DISASSEMBLY GEARSHIFT CONTROL CABLE |
224 |
|
14. ASSEMBLY GEARSHIFT CONTROL CABLE |
226 |
|
15. REMOVAL GEARSHIFT MECHANISM |
230 |
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16. ASSEMBLY GEARSHIFT MECHANISM |
232 |
|
17. ASSEMBLY DIFFERENTIAL OIL SEAL |
232 |
|
18. INPUT SHAFT DISASSEMBLY |
233 |
|
19. INPUT SHAFT ASSEMBLY |
234 |
|
20. DISASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th) |
236 |
|
21. ASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th) |
238 |
|
22. DISASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.) |
242 |
|
23. ASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.) |
244 |
|
24. REMOVAL BACKUP (REVERSE) LAMP SWITCH |
247 |
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25. ASSEMBLY BACKUP (REVERSE) LAMP SWITCH |
248 |
|
DRIVESHAFT |
249 |
|
1.1. GENERAL INFORMATION |
251 |
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1.2. GENERAL GUIDELINES FOR TESTING |
252 |
|
1.3. DRIVE SHAFT PARTS |
253 |
|
1.4. TIGHTENING TORQUES |
254 |
|
1.5. SPECIAL TOOL |
256 |
|
1.6 ON BENCH PROCEDURE |
257 |
|
1.7 ON VEHICLE PROCEDURE |
259 |
|
A. DRIVE SHAFT LH REMOVAL |
259 |
|
B. RH DRIVE SHAFT REMOVAL |
263 |
|
6F33 TRANSAXLE |
267 |
|
1. TECHNICAL SPECIFICATIONS |
269 |
|
2. TIGHTENING TORQUE |
273 |
|
73. SPECIAL TOOLS |
275 |
|
4. GENERAL INFORMATION |
276 |
|
5. COMPONENTS (FOR INFORMATION) |
277 |
|
6. DETAIL OF A/T COMPONENTS (FOR INFORMATION) |
279 |
|
7. EXPLODED VIEWS |
284 |
|
8. REMOVAL AND RE-FITMENT |
286 |
|
9. TOWING SERVICE |
293 |
|
10. AUTO TRANSAXLE FLUID CHECK AND CHANGE INTERVAL |
294 |
|
11. REMOVAL OF TRANSAXLE FROM VEHICLE |
296 |
|
12. ASSEMBLY OF TRANSAXLE ON VEHICLE |
299 |
|
13. REMOVAL OF GEAR SHIFTING CABLE ONVEHICLE |
302 |
|
14. ASSEMBLY GEARSHIFT CONTROL CABLE |
305 |
|
15. REMOVAL GEARSHIFT MECHANISM |
308 |
|
16. ASSEMBLY GEARSHIFT MECHANISM |
310 |
|
17. OIL COOLER HOSES REMOVAL |
311 |
|
18. OIL COOLER HOSES REFITMENT |
312 |
|
19. TCU (TRANSMISSION CONTROL UNIT) |
313 |
|
DRIVESHAFT (AT) |
314 |
|
1. GENERAL INFORMATION |
316 |
|
2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
317 |
|
3. DRIVE SHAFT PARTS |
318 |
|
4. TIGHTENING TORQUES |
319 |
|
5. SPECIAL TOOL |
322 |
|
6. ON BENCH PROCEDURE |
323 |
|
7. ON VEHICLE PROCEDURE |
328 |
|
CLUTCH |
337 |
|
1. GENERAL INFORMATION |
339 |
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2. TECHNICAL SPECIFICATION |
339 |
|
3. LUBRICANT SPECIFICATION |
339 |
|
4. CLUTCH PRESSURE PLATE |
340 |
|
5. CLUTCH DISC ASSEMBLY |
340 |
|
6. EXPLODED VIEW |
341 |
|
7. TIGHTENING TORQUE |
342 |
|
8. SPECIAL TOOLS |
342 |
|
9. GENERAL SYMPTOMS DIAGNOSIS |
343 |
|
A. CLUTCH GRAB / CHATTER |
343 |
|
B. CLUTCH SLIPS |
343 |
|
C. CLUTCH PEDAL NOISE |
344 |
|
10. ON VEHICLE PROCEDURES |
345 |
|
A. SPECIAL TOOL ASSEMBLY |
345 |
|
B. DISASSEMBLY PROCEDURE |
345 |
|
C. ASSEMBLY PROCEDURE |
347 |
|
CLUTCH RELEASE SYSTEM |
348 |
|
1. CLUTCH SYSTEM LAYOUT |
350 |
|
2. CLUTCH SYSTEM COMPONENTS |
351 |
|
3. REGULAR MAINTENANCE |
352 |
|
4. CLUTCH PEDAL ASSEMBLY |
353 |
|
5. BRAKE PEDAL ASSEMBLY |
354 |
|
6. REMOVAL OF ACCELERATOR PEDAL |
355 |
|
7. REMOVAL OF CLUTCH CONTROL BRACKET |
356 |
|
8. ASSEMBLY OF CLUTCH CONTROL BRACKET |
358 |
|
9. BRAKE SWITCH INSTALLTION PROCEDURE |
360 |
|
SUSPENSION |
361 |
|
1. GENERAL INFORMATION |
363 |
|
2. TECHNICAL SPECIFICATIONS |
366 |
|
3. TIGHTENING TORQUES |
367 |
|
4. SPECIAL TOOLS |
372 |
|
5. DIAGNOSIS |
375 |
|
6. PRECAUTIONS |
376 |
|
7. EXPLODED VIEWS OF FRONT SUSPENSION |
377 |
|
8. EXPLODED VIEWS REAR SUSPENSION |
380 |
|
9. ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY |
381 |
|
10. ON BENCH FRONT STRUT DISASSEMBLY |
384 |
|
11. ON BENCH FRONT STRUT ASSEMBLY |
385 |
|
12. REMOVAL AND ASSEMBLY OF WHEEL DISC |
388 |
|
13. ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB |
389 |
|
14. REMOVAL OF SUBFRAME ASSEMBLY |
390 |
|
15. INSTALLATION OF SUBFRAME ASSEMBLY |
392 |
|
16. LCA REAR HYDRA-BUSH INSTALLATION |
392 |
|
17. REMOVAL OF ANTI ROLL BAR |
393 |
|
18. REMOVAL AND ASSEMBLY OF REAR DAMPER ASSEMBLY AND COIL SPRINGS |
394 |
|
19. ECIE CONDITION |
394 |
|
20. INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS |
395 |
|
21. REAR SUSPENSION DISMANTLING OR INSTALLATION |
396 |
|
22. RTB BUSH INSTALLATION |
399 |
|
23. PAN HARD ROD BUSH INSTALLATION AND REMOVAL |
400 |
|
24. INSTALLATION AND REMOVAL OF DAMPER BOTTOM BUSH |
401 |
|
BRAKES |
402 |
|
1. SPECIFICATION |
404 |
|
2. SYSTEM DETAILS |
405 |
|
3. TIGHTENING TORQUES |
407 |
|
4. GENERAL SYMPTOMS DIAGNOSIS |
411 |
|
5. NECESSITY OF ABS with EBD |
413 |
|
6. VACUUM BRAKE BOOSTER |
413 |
|
7. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
415 |
|
8. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
418 |
|
9. WHEEL SPEED SENSOR |
420 |
|
10. ABS SYSTEM FAILURE WARNING LIGHT |
421 |
|
11. MAINTENANCE, INSPECTION AND TEST |
422 |
|
12. REAR DRUM BRAKES |
423 |
|
13. REMOVAL OF SHOES |
426 |
|
14. REGULAR MAINTENANCE |
430 |
|
15. ON VEHICLE REPAIRS |
436 |
|
16. DISMANTLING, INSPECTION AND ASSEMBLY |
446 |
|
HVAC |
451 |
|
1. HVAC SYSTEM LAYOUT |
453 |
|
2. SPECIFICATIONS: HVAC UNIT |
454 |
|
3. TIGHTENING TORQUES |
460 |
|
4. PRECAUTIONS |
464 |
|
5. HVAC SYSTEM LAYOUT AND WORKING |
465 |
|
6. CONTROL PANEL |
468 |
|
7. FRONT HVAC UNIT |
470 |
|
8. TRINARY PRESSURE SWITCH |
472 |
|
9. MODE & TEMPRATURE CONTROL AC-TUATOR |
473 |
|
10. COMPRESSOR |
474 |
|
11. CONDENSER |
476 |
|
12. RECEIVER DRIER (R.D) |
476 |
|
13. INSPECTION OF MODE AND TEMPERATURE ACTUATOR |
477 |
|
14. TROUBLESHOOTING |
479 |
|
15. MAINTENANCE |
490 |
|
16. ON VEHICLE REPAIRS |
498 |
|
17. DO’S AND DONT’S FOR A/C SYSTEM |
507 |
|
FATC |
508 |
|
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM |
510 |
|
2. TECHNICAL SPECIFICATIONS |
512 |
|
3. TIGHTENING TORQUES |
518 |
|
4. PRECAUTIONS |
522 |
|
5. HMI CLIMATE CONTRL DISPLAY |
523 |
|
6. CONTROL PANEL |
524 |
|
7. CONTROL PANEL MODULE CONNECTOR DETAILS |
529 |
|
8. FATC UNIT |
531 |
|
9. FATC SENSOR & ACTUATOR |
533 |
|
10. COMPRESSOR |
539 |
|
11. CONDENSER |
540 |
|
12. RECEIVER DRIER (R.D) |
540 |
|
13. REMOVAL OF INFOTAINMENT SYSTEM |
541 |
|
14. TROUBLESHOOTING |
542 |
|
15. MAINTENANCE |
553 |
|
16. ON VEHICLE REPAIR |
561 |
|
17. DO’S AND DONT’S FOR A/C SYSTEM |
570 |
|
BODY |
571 |
|
1.1 GENERAL INFORMATION |
574 |
|
1.2 TIGHTENING TORQUES |
575 |
|
1.3 SPECIAL TOOL |
578 |
|
1.4 ON VEHICLE REPAIRS |
579 |
|
1.4.1 BONNET |
579 |
|
1.4.2 ARM REST |
581 |
|
1.4.3 FLOOR CONSOLE |
582 |
|
1.4.4 DASHBOARD SKIN |
583 |
|
1.4.5 GLOVE BOX |
591 |
|
1.4.6 SIDE AIR VENTS |
591 |
|
1.4.7 FRONT BUMPER |
593 |
|
1.4.8 REAR BUMPER |
595 |
|
1.4.9 FRONT DOOR |
597 |
|
1.4.10 FRONT DOOR TRIMS |
598 |
|
1.4.11 DOOR INNER LOCK HANDLE |
599 |
|
1.4.12 FRONT OUTER DOOR LOCK |
600 |
|
1.4.13 FRONT DOOR LATCH |
601 |
|
1.4.14 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
602 |
|
1.4.15 REAR DOOR |
603 |
|
1.4.16 REAR DOOR TRIM |
604 |
|
1.4.17 REAR OUTER DOOR LOCK |
605 |
|
1.4.18 DOOR LATCH REAR |
606 |
|
1.4.19 TAIL GATE |
607 |
|
1.4.20 TAIL GATE TRIM |
609 |
|
1.4.21 ORVM |
610 |
|
1.4.23 FRONT ROW SEAT |
611 |
|
1.4.24 REAR ROW SEAT |
612 |
|
1.4.25 FRONT SEAT BELT |
613 |
|
1.4.26 REAR SEAT BELT |
615 |
|
1.4.27 “A” PILLAR TRIM |
616 |
|
1.2.28. FRONT SCUFF PLATE |
616 |
|
1.4.29 “B” PILLAR TRIMS: |
617 |
|
1.2.30.REAR SCUFF PLATE |
617 |
|
1.4.31 REAR QUARTER TRIM |
618 |
|
1.4.32 “C” PILLAR TRIMS |
619 |
|
1.4.33 GRAB HANDLE: |
619 |
|
1.4.34 SUNVISOR |
620 |
|
1.4.35 ROOF LINEAR |
620 |
|
1.4.36 PLENUM COVER: |
621 |
|
1.4.37 GEAR LEVER BOOT |
621 |
|
1.4.38 BONNET INSULATION |
621 |
|
1.4.39 GLASS |
621 |
|
1.4.40 FUEL FILLER ASSEMBLY. |
623 |
|
1.4.41 FRONT WHEEL ARCH LINER |
624 |
|
1.4.42 REAR WHEEL ARCH LINER |
625 |
|
1.4.43 FRONT FENDER |
626 |
|
1.4.44 REAR WIPER MOTOR |
627 |
|
1.4.45 FRONT WIPER |
628 |
|
1.4.46 SUNROOF |
629 |
|
1.4.47 WIND DEFLECTOR |
630 |
|
1.4.48 FRONT GLASS PANEL |
631 |
|
1.4.50 SUNSHADE ROLLO ASSEMBLY |
633 |
|
1.4.51 MECHANISM ELECTRIC DRIVE ASSEMBLY |
634 |
|
1.4.52 ROLLO ELECTRIC DRIVE ASSEMBLYREMOVAL |
634 |
|
1.4.53 MECHANISM MAINTENANCE |
635 |
|
1.4.54 WATER CHANNEL MAINTENANCE |
638 |
|
1.4.55 SUNROOF RESET PROCEDURE - INITIALIZING THE POWER SUNROOF |
638 |
|
1.4.56 SUNROOF RESET PROCEDURE - SELF LEARNING THE POWER SUNROOF |
639 |
|
ELECTRICAL |
640 |
|
1. INSTRUMENT CLUSTER |
643 |
|
1.1. BASIC FUNCTIONAL MATRIX |
645 |
|
1.2. TELL TALES INFORMATION |
646 |
|
1.3 GAUGES |
651 |
|
1.4 Driver Information System (For Q5 7" Instrument Cluster) |
657 |
|
1.5 Display Messages for TFT Screen |
666 |
|
1.6 DRIVER INFORMATION SYSTEM (For Q5 4" Instrument Cluster) |
671 |
|
1.7 DISPLAY MESSAGE ON LCD SCREEN |
675 |
|
1.8 REMINDER FEATURES |
676 |
|
2. MAIN CONNECTOR PIN-OUTS |
677 |
|
3. FUEL GAUGE DETAILS |
679 |
|
4. TEMPERATURE BAR GRAPH DETAILS |
680 |
|
5. Reminder Features (Audible) |
681 |
|
6. INSTRUMENT CLUSTER REMOVAL |
682 |
|
7. IMMOBILIZER SYSTEM (IF APPLICABLE) |
683 |
|
8 FUEL GAUGE DETAILS |
691 |
|
9. TEMPERATURE BAR GRAPH DETAILS |
692 |
|
10. CHIME TABLE |
693 |
|
11. DISPLAY SCREEN FLOW AND SETTINGS |
693 |
|
12. IGNITION KEY LEARNING PROCEDURE |
696 |
|
13. BODY CONTROL MODULE (BCM) |
699 |
|
13.1 REMOVAL OF BCM |
699 |
|
13.2 CONNECTION DETAILS |
700 |
|
13.3 BCM SPECIFICATION |
705 |
|
13.4 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
706 |
|
14. FUSE AND RELAY BOX DETAILS |
712 |
|
14.1 CHECKING FUSES |
712 |
|
14.2 CHECKING RELAYS |
712 |
|
14.3 FUSE AND RELAY BOX LAYOUT |
714 |
|
14.4 BATTERY MOUNTED FUSE BOX |
715 |
|
14.5 ENGINE FUSE AND RELAY BOX |
715 |
|
14.6 CABIN FUSE AND RELAY BOX |
718 |
|
15. REVERSE PARK ASSIST SYSTEM |
720 |
|
15.1 REAR VIEW CAMERA (If Applicable) |
724 |
|
15.2 BCM TO SENSOR ELECTRICAL INTERFACE |
727 |
|
15.3 REVERSE PARK ASSIST SYSTEM |
732 |
|
15.4 REAR VIEW CAMERA REMOVAL |
734 |
|
15.5 TROUBLESHOOTING |
735 |
|
16. PASSIVE ENTRY PASSIVE START (PEPS) |
736 |
|
16.1 PEPS ECU |
737 |
|
16.2 START STOP SWITCH |
739 |
|
16.3 ELECTRONIC STEERING COLUMN LOCK (ESCL) |
740 |
|
16.4 DOOR AND TAILGATE HANDLE SWITCHES WITH HARNESS |
742 |
|
16.5 LF ANTENNAS |
743 |