Table of Contents 1 1236

SAFARI STORME MY14

1. GENERAL 4
1.1 TECHNICAL SPECIFICATIONS 6
1.2 CHASSIS TYPE AND SALES DESIGNATION 12
1.3 LUBRICANTS AND COOLANT RECOMMENDATIONS 13
1.4 SERVICE AND MAINTENANCE SCHEDULE 15
1.5 ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS 20
2. PRECAUTIONS 21
2.1 GENERAL PRECAUTIONS 23
2.2 SAFETY AGAINST PERSONAL INJURY 24
A. WORKING WITH VEHICLES FITTED WITH AIRBAG 24
B. WORKING WITH ENGINE 'ON' 25
2.3 AVOIDING DAMAGE 26
2.4 USED OIL HANDLING AND DISPOSAL 26
2.5 FUEL HANDLING PRECAUTIONS 27
2.6 HAZARDOUS MATERIAL 28
3. ENGINE 29
3.1 GENERAL INFORMATION 33
3.1.1 SPECIFICATION 33
3.1.2 TIGHTENING TORQUES 34
3.1.3 SPECIAL TOOLS 52
3.1.4 GENERAL SYMPTOMS DIAGNOSIS 53
3.2 MAINTENANCE, INSPECTION AND TESTS 56
3.2.1 PRELIMINARY INSPECTION 56
3.2.2 REGULAR MAINTENANCE 58
A. ENGINE OIL REPLACEMENT 58
B. OIL FILTER REPLACEMENT 59
C. AIR FILTER CLEANING 59
D. FUEL FILTER REPLACEMENT 60
E. DRAINING WATER FROM PREFILTER CUM SEDIMENTOR 61
F. PREFILTER CUM SEDIMENTOR REPLACEMENT 61
G. PREFILTER CARTIRDGE REPLACEMENT 62
H. COOLANT REPLACEMENT 66
3.2.3 ON VEHICLE PROCEDURES 67
A. ENGINE REMOVAL 67
B. AIR FILTER ASSEMBLY REMOVAL 69
C. POWER STEERING PUMP BELT (STRETCH BELT) 69
D. ALTERNATOR AND AC BELT 70
E. INJECTOR REMOVAL 71
F. TIMING BELT REMOVAL 72
G. TIMING BELT FITMENT 74
3.3 OVERHAULING 77
3.3.1 ENGINE DISMANTLING (ON STAND) 77
3.3.2 CYLINDER HEAD 84
3.3.3 TIMING SYSTEM 96
3.3.4 ENGINE BLOCK 99
3.3.5 ENGINE ASSEMBLY 124
3.4 AIR INTAKE SYSTEM 133
3.5 COOLING SYSTEM 142
3.6 LUBRICATION SYSTEM 149
3.7 FUEL SYSTEM 155
3.8 EXHAUST SYSTEM 171
3.9 ENGINE MANAGEMENT SYSTEM (EMS) 189
3.10 DIAGNOSTIC USER MANUAL 222
4. CLUTCH 232
4.1 GENERAL INFORMATION 235
4.1.1 SPECIFICATIONS 235
A. CLUTCH DISC ASSEMBLY 235
B. SELF ADJUSTING CLUTCH COVER ASSEMBLY 236
C. SINGLE MASS FLYWHEEL 237
4.1.2 CLUTCH SYSTEM LAYOUT 238
A. CLUTCH MASTER CYLINDER 239
B. CONCENTRIC SLAVE CYLINDER 239
C. PEAK TORQUE LIMITER 239
D. HYDRAULIC ADAPTER 240
E. SINGLE MASS FLYWHEEL 240
F. SELF ADJUSTING CLUTCH 240
4.1.3 TIGHTENING TORQUES 241
4.1.4 SPECIAL TOOLS 244
4.1.5 GENERAL SYMPTOMS DIAGNOSIS 245
4.2 MAINTENANCE, INSPECTION AND TESTS 247
4.2.1 PRELIMINARY INSPECTION 247
4.2.2 REGULAR MAINTENANCE 248
A. CLUTCH SWITCH ADJUSTMENT 248
B. CLUTCH BLEEDING PROCEDURE 248
C. CLUTCH FLUID DRAINING PROCEDURE 249
4.2.3 REPAIRS 250
A. CLUTCH PEDAL ASSEMBLY 250
B. SELF ADJUSTING CLUTCH ASSEMBLY 255
C. CLUTCH HYDRAULIC SYSTEM COMPONENTS 260
D. SINGLE MASS FLYWHEEL (ON VEHICLE) 265
5A. 5 SPEED GEARBOX- G 76 MK II 266
5A.1 GENERAL INFORMATION 270
5A.1.1 SPECIFICATIONS 270
5A.1.2 TIGHTENING TORQUES 271
5A.1.3 SPECIAL TOOLS 275
5A.1.4 GENERAL SYMPTOMS DIAGNOSIS 279
5A.2 MAINTENANCE, INSPECTION AND TEST 280
5A.2.1 PRELIMINARY INSPECTION 280
5A.2.2 REGULAR MAINTENANCE 280
5A.2.3 ON VEHICLE PROCEDURES 281
A. GEARBOX REMOVAL 281
5A.3 OVERHAULING 283
5A.3.1 INFORMATION FOR OVERHAULING 283
A. COMPONENT INDENTIFICATION 283
B. PRECAUTIONS 286
C. CONSTRUCTIONAL DETAILS 287
5A.3.2 GEARBOX DISMANTLING (ON BENCH) 290
5A.3.3 DISMANTLING OF SUB-ASSEMBLIES 297
A. MAIN SHAFT 297
B. DRIVE SHAFT 308
C. REVERSE IDLER SHAFT 309
D. COUNTER SHAFT 311
E. FRONT COVER 314
F. TOP COVER 315
G. REAR COVER (4X2) 317
H. ADAPTOR (4X4) 318
I. SHIFTER SHAFTS & FORKS 319
J. NON-ADJUSTABLE SHIFTER LINKAGE 321
5A.3.4 GEAR BOX ASSEMBLY 325
5B. 6 SPEED GEARBOX - G 6450 334
5B.1 GENERAL INFORMATION 338
5B.1.1 SPECIFICATIONS 338
5B.1.2 TIGHTENING TORQUE 339
5B.1.3 SPECIAL TOOLS 344
5B.1.4 GENERAL SYMPTOMS DIAGNOSIS 348
5B.2 MAINTENANCE, INSPECTION AND TEST 349
5B.2.1 PRELIMINARY INSPECTION 349
5B.2.2 REGULAR MAINTENANCE 349
5B.2.3 ON VEHICLE PROCEDURE 350
A. GEARBOX REMOVAL 350
5B.2.4A CONSTRUCTION OF GEAR BOX (4X2) 352
5B.2.4B CONSTRUCTION OF GEAR BOX (4X4) 353
5B.3 OVERHAULING 354
5B.3.1 INFORMATION FOR OVERHAULING 354
A. COMPONENT INDENTIFICATION 354
B. PRECAUTIONS 356
5B.3.2 GEAR BOX DISMANTLING ON BENCH PROCEDURE 357
5B.3.3 INSPECTION 367
5B.3.4 GEAR BOX ASSEMBLY ON BENCH PROCEDURE 369
6. TRANSFER CASE 385
6.1 GENERAL INFORMATION 389
6.1.1 SPECIFICATIONS 389
6.1.2 CONSTRUCTION 390
6.1.3 COMPONENTS OF TRANSFER CASE 392
A. ECU 392
B. TRANSFER CASE SWITCH 394
C. WARNING LAMP 394
D. GEROTOR PUMP 394
6.1.4 WORKING OF TRANSFER CASE 395
6.1.5 TIGHTENING TORQUES 399
6.1.6 SPECIAL TOOLS 402
6.1.7 GENERAL SYMPTOMS & DIAGNOSIS 405
6.2 MAINTENANCE 406
6.2.1 PRELIMINARY INSPECTION 406
6.2.2 REGULAR MAINTENANCE 406
A. CHANGING TRANSFER CASE OIL 406
B. TRANSFER CASE OIL CHECK 406
6.2.3 ON VEHICLE REPAIRS 407
A. TRANSFER CASE 407
B. TRANSFER CASE ELECTRONIC CONTROL UNIT (ECU) 408
C TRANSFER CASE SWITCH 409
6.3 OVERHAULING 409
6.3.1 PRECAUTIONS 409
6.3.2 DISMANTLING 409
A. REAR YOKE 409
B. REAR COVER ASSEMBLY 410
C. LOCKUP SHIFT PART 412
D. CHAIN DRIVE 413
E. GEROTOR PUMP 413
F. REDUCTION SHIFT PART 414
G. FRONT OUTPUT SHAFT AND YOKE 415
H. ADAPTER, INPUT SHAFT & CARRIER ASSEMBLY 416
6.3.3 INSPECTION & CLEANING 419
6.3.4 ASSEMBLY 419
A. ADAPTER & INPUT SHAFT 419
B. FRONT OUTPUT SHAFT & YOKE 421
C. ASSEMBLY OF REDUCTION SHIFT PART 422
D. ASSEMBLY OF OUTPUT SHAFT & GEROTOR PUMP 423
E. CHAIN DRIVE 425
F. ASSEMBLY OF LOCK UP SHIFT PART 426
G. REAR COVER ASSEMBLY 426
H. REAR OUTPUT YOKE 429
6.4 DIAGNOSTIC OF ECU 430
7. SUSPENSION 433
7.1 FRONT SUSPENSION 435
7.1.1 GENERAL INFORMATION 438
7.1.1.1 SPECIFICATIONS 438
7.1.1.2 CONSTRUCTION 439
7.1.1.3 TIGHTENING TORQUES 440
7.1.1.4 SPECIAL TOOLS 445
7.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 448
7.1.2 MAINTENANCE 449
7.1.2.1 PRELIMINARY INSPECTION 449
7.1.2.2 REGULAR MAINTENANCE 449
A. WHEEL ALIGNMENT 449
B. ANTI ROLL BAR MOUNTING GREASING 450
7.1.2.3 ON VEHICLE REPAIRS 451
A. ANTI ROLL BAR (ARB) 451
B. FRONT STRUT ASSEMBLY 452
C. LOWER WISHBONE 453
D. UPPER WISHBONE 454
E. BUMP STOPPER 456
7.1.3 OVERHAULING 456
7.1.3.1 PRECAUTIONS 456
7.1.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 457
A. FRONT STRUT 457
B. UPPER WISHBONE BUSH 458
C. UPPER WISHBONE BALL JOINT 460
D. LOWER WISHBONE BALL JOINT REMOVAL 460
7.2 REAR SUSPENSION 436
7.2.1 GENERAL INFORMATION 461
7.2.1.1 SPECIFICATIONS 461
7.2.1.2 CONSTRUCTION 462
7.2.1.3 TIGHTENING TORQUES 463
7.2.1.4 SPECIAL TOOLS 466
7.2.2 MAINTENANCE 469
7.2.2.1 ON VEHICLE REPAIRS 469
A. ANTIROLL BAR 469
B. UPPER LINK 471
C. LOWER LINK 472
D. PAN HARD ROD 472
E. REAR SHOCK ABSORBER 473
F. REAR COIL SPRING 474
7.2.3 OVERHAULING 475
7.2.3.1 PRECAUTIONS 475
7.2.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 475
A. UPPER LINK BUSH 475
B. LOWER LINK BUSH 476
C. PAN HARD ROD BUSH 477
7.3 WHEELS AND TYRES 437
7.3.1 GENERAL INFORMATION 479
7.3.1.1 SPECIFICATIONS 479
7.3.1.2 CONSTRUCTION 480
7.3.1.3 TIGHTENING TORQUES 481
7.3.1.4 GENERAL SYMPTOMS DIAGNOSIS 482
A. DIAGNOSIS CHART 482
B. TYRE WEAR PATTERN 485
C. WEAR CAUSES 487
D. TYRE VIBRATION DIAGNOSIS 489
7.3.2 MAINTENANCE, INSPECTION AND TESTS 490
7.3.2.1 PRELIMINARY INSPECTION 490
7.3.2.2 REGULAR MAINTENANCE 491
A. INFLATION 491
B. WHEEL BALANCING 491
C. TYRE ROTATION 492
D WHEEL RUN OUT 493
E. DO'S AND DON’TS 494
7.3.2.3 WHEEL AND TYRE REPLACEMENT 495
A. PRECAUTIONS DURING TYRE REPLACEMENT 495
B. TYRE REPLACEMENT 496
C. WHEEL ASSEMBLY REPLACEMENT 496
8. FRONT AXLE 497
8.1 FRONT AXLE (4X4) 497
8.1.1 GENERAL INFORMATION 500
8.1.1.1 SPECIFICATION 500
8.1.1.2 SYSTEM LAYOUT 4X4 501
8.1.1.3 TIGHTENING TORQUES 502
8.1.1.4 SPECIAL TOOLS 506
8.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 511
8.1.2 MAINTENANCE 512
8.1.2.1 PRELIMINARY INSPECTION 512
8.1.2.2 REGULAR MAINTENANCE 512
8.1.2.3 ON VEHICLE REPAIRS 513
A. FRONT AXLE ASSEMBLY 513
B. ELECTRICAL DISCONNECT ASSEMBLY 517
C. TONER RING 518
8.1.3 OVERHAULING 519
8.1.3.1 PRECAUTIONS 519
8.1.3.2 CONSTRUCTIONAL DETAILS 519
8.1.3.3 DISMANTLING INSPECTION AND ASSEMBLY 523
8.2 FRONT AXLE (4X2) 553
8.2.1 GENERAL INFORMATION 556
8.2.1.1 TECHNICAL SPECIFICATIONS 556
8.2.1.2 CONSTRUCTION AND LAYOUT 556
8.2.1.3 TIGHTENING TORQUE 557
8.2.1.4 SPECIAL TOOLS 558
8.2.2 MAINTENANCE 560
8.2.2.1 ON VEHICLE REPAIRS 560
8.2.3 OVERHAULING 564
8.2.3.1 FRONT AXLE EXPLODED VIEW 564
8.2.3.2 HUB REPLACEMENT 565
8.2.3.3 TONER RING REPLACEMENT 567
8.2.3.4 HUB BEARING REPLACEMENT 568
9. REAR AXLE 15” 569
9.1 SECTION - 1 572
9.1.1 AXLE SPECIFICATION AND SERVICE DATA 573
9.1.2 AXLE LUBRICATION 574
9.1.3 AXLE IDENTIFICATION 574
9.1.4 EXPLODED VIEW 575
9.1.5 PARTS DESCRIPTIONS 576
9.2 DISASSEMBLY OF AXLE 577
9.2.1 AXLE SHAFT DISASSEMBLY / OIL SEAL REMOVAL 577
9.2.2 REMOVAL OF CARRIER SECTION FROM BANJO 578
9.3 CARRIER SECTION DISASSEMBLY 578
9.3.1 DISASSEMBLY OF CARRIER SECTION & DIFFERENTIAL 578
9.3.2 RING GEAR REMOVAL 579
9.3.3 CASE DISASSEMBLY STD 580
9.3.4 DRIVE PINION REMOVAL 581
9.3.5 RING GEAR PINION ASSEMBLY THEORY 582
9.3.6 ESTABLISHING PINION & GEAR DEPTH USING SERVICE TOOLS 584
9.3.7 CASE REASSEMBLY (STANDARD DIFFCASE ASSEMBLY) 586
9.3.8 ASSEMBLY OF DIFFERENTIAL IN CARRIER 587
9.3.9 INTERPRETATION OF CONTACT PATTERN 590
9.4 DIS-ASSEMBLY & REASSEMBLY OF LIMITED SLIP DIFFERENTIAL 591
9.4.1 DIS-ASSEMBLY OF TRAC-LOK DIFFERENTIAL 591
9.4.2 INSPECTION OF ALL THE PARTS FOR WEAR, SCORE, ETC 593
9.4.3 RE ASSEMBLY 593
9.5 AXLE SHAFT DIS-ASSEMBLY & RE-ASSEMBLY 595
9.5.1 DIS-ASSEMBLY OF AXLE SHAFT ASSEMBLY 595
9.5.2 ASSEMBLY OF AXLE SHAFT ASSEMBLY 596
9.6 RE-ASSEMBLY OF AXLE 597
9.6.1 INSTALL CARRIER SECTION ON BANJO BEAM 597
9.6.2 INSTALL AXLE SHAFT ASSEMBLY ON BANJO BEAM 597
9.7 TROUBLE SHOOTING 599
10. PROPELLER SHAFT 601
10.1 GENERAL INFORMATION 604
10.1.1 ADJUSTMENT / REPAIR DATA 604
10.1.2 SYSTEM LAYOUT 605
A. FOR 4X2 DRIVE 605
B. FOR 4X4 DRIVE 606
10.1.3 TIGHTENING TORQUE 607
10.1.4 SPECIAL TOOL 608
10.1.5 GENERAL SYMPTOMS DIAGNOSIS 609
10.2 MAINTENANCE, INSPECTION AND TESTS 610
10.2.1 PRELIMINARY INSPECTION 610
10.2.2 REGULAR MAINTENANCE 610
10.2.3 ON VEHICLE REPAIRS 611
A. PROPELLER SHAFT (4X2) 612
B. PROPELLER SHAFT (4X4) 613
C. TVD (TORSIONAL VIBRATION DAMPERS) 614
10.3 OVERHAULING 615
10.3.1 CONSTRUCTIONAL DETAILS 615
A. PROPELLER SHAFT 4X2 DRIVE 615
B. PROPELLER SHAFT 4X4 DRIVE 616
10.3.2 UNIVERSAL JOINT 617
10.3.3 CENTRE BEARING 620
11. BRAKES 623
11.1 GENERAL INFORMATION 627
11.1.1 SPECIFICATION 627
11.1.2 SYSTEM DETAILS 628
11.1.3 TIGHTENING TORQUES 632
11.1.4 GENERAL SYMPTOMS DIAGNOSIS 636
11.2 MAINTENANCE, INSPECTION AND TEST 638
11.2.1 PRELIMINARY INSPECTION 638
A. FRONT BRAKE AND REAR BRAKE 638
B. PARKING BRAKE 638
C. BRAKE HOSES AND LINES 638
D. ROAD TEST 638
E. REAR DRUM BRAKES 639
F. WHEEL CYLINDER SERVICING 645
11.2.2 REGULAR MAINTENANCE 647
A. BRAKE BLEEDING PROCEDURE 647
B. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) 648
C. CALIPER PAD REPLACEMENT 653
D. PARKING BRAKE ADJUSTMENT 654
E. BRAKE FLUID DRAINING PROCEDURE 655
F. BRAKE LIGHT SWITCH ADJUSTMENT 656
G. BOOSTER FILTER REPLACEMENT 657
H. GREASING 658
I. DISC RUN-OUT MEASUREMENT PROCEDURE 659
11.2.3 ON VEHICLE REPAIRS 659
A. CALIPER ASSEMBLY WITH CARRIER 659
B. BRAKE DISC REMOVAL 660
C. PARKING BRAKE 663
D. BRAKE PEDAL 667
E. VACUUM LINES 670
F. BOOSTER ASSEMBLY 671
G. PARKING BRAKE (DRUM IN HAT) 676
11.3 OVERHAULING 678
11.3.1 PRECAUTIONS 678
11.3.2 DISMANTLING, INSPECTION AND ASSEMBLY 679
A. FRONT CALIPER ASSEMBLY 679
B. REAR CALIPER ASSEMBLY 684
11.4 LOAD SENSING PRESSURE VALVE (LSPV) (FOR NON ABS VEHICLE ONLY) 688
12. ANTI-LOCK BRAKING SYSTEM (ABS) 690
12.1 GENERAL INFORMATION 693
12.1.1 NECESSITY OF ABS WITH EBD 693
12.1.2 TECHNICAL SPECIFICATIONS 694
12.1.3 TIGHTENING TORQUES 695
12.1.4 SCHEMATIC OF HYDRAULIC CIRCUIT 697
12.1.5 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 698
12.1.6 COMPONENTS 702
A. ABS ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 703
B. WHEEL SPEED SENSOR (WSS) 706
C. ABS SYSTEM FAILURE WARNING LIGHT 707
12.2 REPAIRS 708
A. ABS ECU / HCU 708
B. FRONT WHEEL SPEED SENSOR 711
C. FRONT TONER RING 712
D. REAR WHEEL SPEED SENSOR 712
E. REAR TONER RING 713
12.3 TROUBLE SHOOTING AND DIAGNOSIS 714
A. ROAD TEST 714
B. TABLE OF ABS 8.1 - FALL-BACK LEVEL 714
12.4 ABS DIAGNOSTIC USER MANUAL 715
12.4.1 GENERAL 715
12.4.2 OPERATING PROCEDURE 716
13. STEERING 726
13.1 GENERAL INFORMATION 730
13.1.1 SPECIFICATIONS 730
13.1.2 SYSTEM LAYOUT 731
13.1.3 TIGHTENING TORQUES 732
13.1.4 SPECIAL TOOLS 738
13.1.5 GENERAL SYMPTOMS DIAGNOSIS 739
13.2 MAINTENANCE, INSPECTION AND TEST 746
13.2.1 PRELIMINARY INSPECTION 746
13.2.2 REGULAR MAINTENANCE 747
A. POWER STEERING OIL REPLACEMENT 747
B. POWER STEERING RESERVOIR ASSY 748
C. HYDRAULIC SYSTEM AIR BLEEDING 749
D. TOE IN ADJSUTMENT 750
E. STEERING WHEEL ALIGNMENT/ CENTRALISING 750
F. STEERING WHEEL PLAY 751
G. POWER STEERING OIL FLUSHING PROCEDURE 751
13.2.3 REPAIRS 752
13.2.3.1 STEERING WHEEL 752
13.2.3.2 SYSTEM LAYOUT 757
13.2.3.3 STEERING RESERVOIR & POWER STEERING PUMP 762
A. STEERING RESERVOIR 763
B. POWER STEERING PUMP 763
13.2.3.4 RACK AND PINION ASSEMBLY 764
13.3 RACK & PINION UNIT OVERHAULING 765
13.3.1 GENERAL INSTRUCTIONS 765
13.3.2 RACK AND PINION ASSEMBLY 766
13.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 767
13.3.3.1 OUTER BALL JOINT (OBJ) 767
13.3.3.2 BELLOW KIT 768
13.3.3.3 INNER BALL JOINT (IBJ) 769
13.3.3.4 FEED PIPE 770
13.3.3.5 DO’S & DON’TS 771
14. ELECTRICAL 774
14.1 TECHNICAL SPECIFICATIONS 779
14.2 GENERAL ELECTRCIAL PRECAUTIONS 782
14.3 STARTING AND CHARGING SYSTEM 785
14.3.1 BATTERY 785
14.3.2 ALTERNATOR 791
14.3.3 STARTER MOTOR 804
14.4 LIGHTING SYSTEM 818
14.4.1 BULB SPECIFICATIONS 818
14.4.2 TORQUE VALUE TABLE 818
14.4.3 DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS 819
14.4.4 HEAD LAMP 822
14.4.5 FRONT FOG LAMP 828
14.4.6 FRONT ROOF LAMP 829
14.4.7 SECOND AND THIRD ROW ROOF LAMP 830
14.4.8 REGISTRATION PLATE LAMP 831
14.4.9 CENTER HIGH MOUNTED STOP LAMP 831
14.4.10 PUDDLE LAMP 833
14.4.11 GLOVE BOX LAMP 834
14.4.12 TAIL LAMP 834
14.4.13 REAR FOG LAMP (IF FITTED) 835
14.5 HORN 837
14.6 POWER SOCKET 839
14.7 CIGAR LIGHTER 841
14.8 BUZZER 842
14.9 WIPER & WASHER SYSTEM 843
14.9.1 FRONT AND REAR WIPER AND WAHSER SYSTEM COMPONENT LOCATIONS 843
14.9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 844
14.9.3 FRONT AND REAR WIPER SYSTEM COMPONENTS 845
14.9.3.1 FRONT WIPER MOTOR 845
14.9.3.2 FRONT WIPER ARM & BLADE 848
14.9.3.3 REAR WIPER ARM & BLADE 849
14.9.3.4 REAR WIPER MOTOR 850
14.9.3.5 WIPER CARE 852
14.9.4 WAHSER SYSTEM COMPONENT 853
14.9.4.1 WAHSER BOTTLE 853
14.9.4.2 WASHER PUMP 853
14.9.4.3 FRONT WAHSER NOZZLE 854
14.9.4.4 REAR WASHER NOZZLE 855
14.9.5 DIAGNOSTIC INFORMATION AND PROCEDURES 856
14.10 ELECTRICAL SWITCHES 857
14.10.1 COMBINATION – SWITCH 857
14.10.2 IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION 864
14.10.3 MASTER LIGHT SWITCH 867
14.10.4 ORVM SWITCH 870
14.10.5 WINDOW WINDING SWITCHES 873
14.10.6 BONNET SWITCH 879
14.10.7 HAZARD WARNING SWITCH 880
14.10.8 TRANSFER CASE SWITCH 881
14.10.9 GLOVE BOX SWITCH 882
14.10.10 REVERSE LIGHT SWITCH 883
14.10.11 HAND BRAKE SWITCH 885
14.10.12 INERTIA SWITCH 886
14.11 WINDOW WINDING CONTROLLER 888
14.12 BODY CONTROL MODULE (BCM) 905
14.13 IMMOBILIZER SYSTEM 948
14.14 INSTRUMENT CLUSTER 970
14.15 REVERSE PARKING SYSTEM WITH ULTRASONIC SENSOR (IF EQUIPPED) 983
14.16 ENTERTAINMENT SYSTEM 999
14.17 GENERAL ELECTRICAL INFORMATION 1013
15. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) 1021
15.1 TIGHTENING TORQUES 1026
15.2 WORKING OF RESTRAINTS 1026
A. RESTRAINTS WITHOUT AIRBAGS 1026
B. RESTRAINTS WITH AIRBAGS 1026
15.3 SYSTEM LAYOUT 1027
A. RESTRAINTS WITHOUT AIRBAGS 1027
B. RESTRAINTS WITH AIRBAGS 1027
15.4 SAFETY PRECAUTIONS 1028
15.5 DISPOSAL OF FAULTY AIR BAG UNIT 1030
15.6 COMPONENTS 1031
15.6.1 RESTRAINT WITHOUT AIRBAGS 1031
A. SEAT BELT 1031
B. EMERGENCY LOCKING RETRACTOR (ELR) 1031
C. MICROSWITCH AND SEAT BELT REMINDER (SBR) WARNING LAMP 1031
15.6.2 RESTRAINT WITH AIRBAGS 1032
A. ECU 1032
B. SENSORS 1037
C. AIR BAGS 1039
D. CLOCK SPRING 1041
E. RPLL BELTS 1044
F. SRS WARNING LAMP 1046
15.7 DIAGNOSTIC USER MANUAL 1047
15.8. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 1055
16. BODY 1056
16.1 GENERAL INFORMATION 1061
16.1.1 SPECIFICATIONS 1061
16.1.2 LAYOUT 1065
16.1.3 TIGHTENING TORQUES 1066
16.1.4 SPECIAL TOOL 1069
16.2 ON VEHICLE REPAIRS 1070
16.2.1 BONNET 1070
16.2.2 FLOOR CONSOLE 1074
16.2.3 DASHBOARD 1076
16.2.4 TOP UTILITY BIN 1080
16.2.5 GLOVE BOX 1080
16.2.6 SIDE AIR VENTS 1081
16.2.7 CENTRAL FINISHER 1083
16.2.8 FRONT BUMPER 1084
16.2.9 REAR BUMPER 1087
16.2.10 DOOR TRIMS 1090
16.2.11 FRONT DOOR 1093
16.2.12 DOOR LOCK HANDLE AND DOOR LATCH 1096
16.2.13 FRONT OUTER DOOR LOCK BARREL AND HANDLE 1097
16.2.14 FRONT DOOR LATCH 1098
16.2.15 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 1100
16.2.16 REAR DOOR 1102
16.2.17 REAR OUTER DOOR LOCK 1104
16.2.18 DOOR LATCH REAR 1106
16.2.19 TAILGATE TRIM 1107
16.2.20 TAIL GATE 1110
16.2.21 ORVM 1115
16.2.22 INNER REAR VIEW MIRROR 1116
16.2.23 FRONT ROW SEAT 1116
16.2.24 SECOND ROW SEAT 1117
16.2.25 THIRD ROW SEAT 1118
16.2.26 SEAT BELTS 1119
16.2.27 SECOND ROW SEAT BELT 1121
16.2.28 “A” PILLAR TRIM 1122
16.2.29 “B” PILLAR TRIMS 1123
16.2.30 “C” PILLAR TRIM 1124
16.2.31 “D” PILLAR TRIM 1125
16.2.32 REAR QUARTER TRIM 1126
16.2.33 GRAB HANDLES 1126
16.2.34 SUNVISOR 1127
16.2.35 PLENUM COVER ASSEMBLY 1128
16.2.36 STONE GUARD 1128
16.2.37 FRONT WHEEL ARCH LINER 1128
16.2.38 GEAR LEVER BOOT 1129
16.2.39 BONNET INSULATION 1129
16.2.40 FUEL FILLER ASSEMBLY 1130
16.2.41 GLASS 1132
16.2.42 ROOF LINER ASSEMBLY 1137
16.2.43 FRONT FENDER 1138
16.2.44 FRONT WHEEL ARCH COVER 1139
16.2.45 SILL FINISHER 1139
16.2.46 REAR WHEEL ARCH LINER 1140
16.2.47 SIDE FOOT STEP 1141
16.2.48 SPOILER 1142
16.3 BODY REPAIR 1143
17. HVAC 1155
17.1 GENERAL INFORMATION 1159
17.1.1 SPECIFICATIONS 1159
17.1.2 TIGHTENING TORQUES 1161
17.1.3 PRECAUTIONS 1166
17.1.4 HVAC SYSTEM LAYOUT AND WORKING 1168
17.1.5 COMPONENTS OF HVAC 1172
17.1.5.1 CONTROL PANEL 1173
17.1.5.2 FRONT HVAC UNIT 1176
17.1.5.3 ROOF AC UNIT (IF FITTED) 1178
17.1.5.4 COMPRESSOR 1180
17.1.5.5 CONDENSER 1181
17.1.5.6 THERMISTER OR THERMO SENSOR 1182
17.1.5.7 TRINARY PRESSURE SWITCH 1184
17.1.5.8 ACTUATOR 1185
17.1.5.9 AIR INLET ACTUATOR 1189
17.1.5.10 REAR BLOWER SWITCH 1189
17.1.6 TROUBLESHOOTING 1191
17.2 MAINTENANCE 1204
17.2.1 PRELIMINARY INSPECTION 1204
A. AC SYSTEM PERFORMANCE TEST 1204
B. LEAK DETECTION 1206
17.2.2 REGULAR MAINTENANCE 1206
A. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 1206
B. FLUSHING OF AC SYSTEM 1208
C. REPLENISHING COMPRESSOR OIL 1209
D. PRESSURE TEST USING MANIFOLD GAUGES 1210
17.3 ON VEHICLE REPAIRS 1212
17.3.1 CONTROL PANEL ASSEMBLY 1212
17.3.2 COMPRESSOR 1212
17.3.3 FRONT HVAC UNIT 1213
17.3.4 ROOF AC UNIT 1214
17.3.5 HEATER HOSE 1215
17.3.6 BLOWER (FRONT HVAC UNIT) 1216
17.3.7 BLOWER CONTROL MODULE 1216
17.3.8 PRESSURE SWITCH 1217
17.3.9 CONDENSER 1217
17.3.10 REFRIGERANT HOSES/PIPES 1218
17.3.11 FRONT AC DUCTING 1219
17.3.12 CONDENSER SEALING DUCT 1220
17.3.13 RECEIVER DRIER BOTTLE 1220
17.4 OVERHAULING 1221
17.4.1 BLOWER 1221
17.4.2 FRONT HVAC UNIT 1223
17.4.3 ROOF AC 1230
17.4.4 COMPRESSOR 1232
17.4.5 DO’S AND DONT’S FOR A/C SYSTEM 1235

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