Table of Contents 1 1906

HEXA

1. GENERAL 3
1.1. VEHICLE SPECIFICATION 8
1.2. VEHICLE DIMENSIONS 11
1.3. RECOMMENDATIONS 12
1.3.1. REPAIRS AND REPLACEMENT 12
1.4. GENERAL INFORMATION 14
1.4.1. ABBREVIATIONS USED IN THIS MANUAL 14
1.4.2. VEHICLE IDENTIFICATION NUMBER (VIN) 14
1.5. VEHICLE JACKING AND LIFTING POINTS 15
1.6. SPARE WHEEL REPLACEMENT 16
1.7. EMERGENCY TOWING INFORMATION 16
1.8. JUMP STARTING 17
1.9. SERVICE AND MAINTENANCE SCHEDULE 18
1.10. LUBRICANTS, FLUIDS AND CAPACITIES 25
1.10.1. LUBRICANTS 25
1.10.2. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 25
1.10.3. RECOMMENDED FUEL 27
1.11. GENERAL FITTING REMINDERS 27
1.11.1. WORKSHOP SAFETY 27
1.11.2. PREPARATION 27
1.11.3. DISMANTLING 27
1.11.4. GENERAL INSPECTION 28
1.11.5. JOINTS AND JOINT FACES 28
1.11.6. FLEXIBLE HYDRAULIC PIPES, HOSES 28
2. ENGINE 320Nm 29
2.1. GENERAL INFORMATION 37
2.1.1. ENGINE INTRODUCTION 37
2.1.2. TECHNICAL SPECIFICATION 38
2.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 39
2.1.4. SERVICE SCHEDULE 40
2.1.5. ASSEMBLY CLEARANCES 42
2.1.6. SPECIAL TOOLS 43
2.2. GENERAL SYMPTOMS DIAGNOSIS 44
2.3. CONSTRUCTIONAL AND SERVICE DETAILS 47
2.3.1. ENGINE MOUNTING COMPONENTS 47
2.3.2. CYLINDER HEAD AND COVER 49
2.3.3. LUBRICATION SYSTEM COMPONENTS 51
2.3.4. ENGINE 53
2.3.5. OIL SUMP 55
2.3.6. CYLINDER HEAD 57
2.3.7. SPECIAL INSTALLATION 59
2.3.8. EXHAUST SYSTEM COMPONENTS 61
2.3.9. INTAKE SYSTEM COMPONENTS 63
2.3.10. ENGINE SUSPENSION 65
2.3.11. MOVING PARTS 67
2.3.12. ENGINE TIMING 69
2.3.13. FUEL INJECTION EQUIPMENT 71
2.4. ENGINE TESTS AND MAINTENANCE 73
2.4.1. PRELIMINARY INSPECTION 73
2.4.2. ENGINE TESTS 73
2.4.3. REGULAR MAINTENANCE 76
2.4.3.1. ENGINE OIL REPLACEMENT 76
2.4.3.2. OIL FILTER REPLACEMENT 76
2.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT 77
2.4.3.4. MAIN FUEL FILTER REPLACEMENT 77
2.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR 78
2.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT 79
2.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT 80
2.4.3.8. COOLANT REPLACEMENT 84
2.5. REPAIR AND INSPECTION DETAILS 85
2.5.1. TIMING BELT 85
2.5.2. FUEL TANK 85
2.5.3. CYLINDER HEAD 86
2.5.4. VALVES 87
2.5.5. VALVE SEATS 88
2.5.6. CRANKCASE 89
2.5.7. VALVE SEAT INSERT 90
2.5.8. HYDRAULIC LASH ADJUSTER 90
2.5.9. CYLINDER HEAD COVER 90
2.5.10. VALVE GUIDES 91
2.5.11. CAMSHAFT 92
2.5.12. PISTON AND PISTON RINGS 93
2.5.13. CONNECTING ROD 94
2.5.14. CRANKSHAFT 96
2.6. ENGINE SYSTEM 98
2.6.1. AIR INTAKE SYSTEM 98
2.6.2. BLOW BY SYSTEM 100
2.6.3. VACUUM MANAGEMENT SYSTEM 101
2.6.4. COOLING SYSTEM 103
2.6.5. LUBRICATION SYSTEM 106
2.6.6. FUEL SYSTEM 110
2.6.7. EXHAUST SYSTEM 119
2.6.8. EXHAUST GAS RECIRCULATION SYSTEM 122
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE 124
2.7.1. ENGINE REMOVAL 124
2.7.2. AIR FILTER ASSEMBLY REMOVAL 126
2.7.3. POWER STEERING PUMP BELT (STRETCH BELT) 126
2.7.4. ALTERNATOR AND AC BELT 127
2.7.5. INJECTOR REMOVAL 128
2.7.6. TIMING BELT REMOVAL 129
2.7.7. FITMENT OF TIMING BELT 131
2.7.8. INTERCOOLER REMOVAL 134
2.7.9. RADIATOR REMOVAL 135
2.7.10. COOLANT TANK REMOVAL 137
2.7.11. RADIATOR FAN SHROUD REMOVAL 138
2.7.12. THERMOSTAT REMOVAL 138
2.7.13. FUEL RAIL REMOVAL 139
2.7.14. FUEL FILLER ASSEMBLY REMOVAL 140
2.7.15. FUEL TANK 141
2.7.16. TANK UNIT REMOVAL 142
2.7.17. FUEL LEVEL SENSOR REMOVAL 144
2.7.18. TANK PRESSURE VALVE REMOVAL 145
2.7.19. FUEL TANK PURGING PROCEDURE 146
2.7.20. POST SILENCER AND INTERMEDIATE PIPE 147
2.7.21. PRE-SILENCER AND MAIN SILENCER 147
2.7.22. FRONT EXHAUST PIPE 148
2.7.23. CLOSE COUPLED CATALYTIC CONVERTER 148
2.7.24. EGR COOLER MODULE 149
2.7.25. TURBOCHARGER 151
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 154
2.8.1. ENGINE DIS-ASSEMBLY 155
2.8.1.1. REMOVAL OF INTAKE MANIFOLD 155
2.8.1.2. REMOVAL OF EXHAUST MANIFOLD 160
2.8.1.3. REMOVAL OF OIL SUMP 163
2.8.1.4. REMOVAL OF TIMING BELT 164
2.8.1.5. REMOVAL OF CYLINDER HEAD 166
2.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 168
2.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 171
2.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY 172
2.8.2. ENGINE ASSEMBLY 179
2.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 179
2.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 180
2.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 181
2.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 182
2.8.2.5. FITMENT OFTIMING BELT 183
2.8.2.6. FITMENT OF OIL SUMP 185
2.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 186
2.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 189
2.8.2.9. ON ENGINE SUPPORT STAND 194
2.9. ENGINE MANAGEMENT SYSTEM (EMS) 196
2.9.1. SYSTEM OVERVIEW 197
2.9.2. BLOCK DIAGRAM 198
2.9.3. CONNECTOR PIN ASSIGNMENT 199
2.9.4. ANTI-CRANKING FUNCTION 204
2.9.5. SENSORS AND ACTUATORS DETAILS 205
2.9.5.1. CRANK ANGLE SENSOR 205
2.9.5.2. CAM SENSOR 206
2.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 208
2.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 209
2.9.5.5. COOLANT TEMPERATURE SENSOR 211
2.9.5.6. FUEL TEMPERATURE SENSOR (FTS) 212
2.9.5.7. INLET METERING VALVE (IMV) 213
2.9.5.8. VENTURI 213
2.9.5.9. RAIL PRESSURE SENSOR 213
2.9.5.10. WATER IN FUEL SENSOR 214
2.9.5.11. ACCELERATOR PEDAL SENSOR 215
2.9.5.12. BRAKE SWITCH 216
2.9.5.13. CLUTCH SWITCH 218
2.9.5.14. GLOW PLUGS 219
2.9.5.15. VTT ACTUATOR 220
2.9.5.16. EGR VALVE ACTUATOR 222
2.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 224
2.9.5.18. INTAKE THROTTLE VALVE 225
2.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 226
3. ENGINE - 400Nm AUTOMATIC TRANSMISSION 227
3.1. GENERAL INFORMATION 235
3.1.1. ENGINE INTRODUCTION 235
3.1.2. TECHNICAL SPECIFICATION 236
3.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 237
3.1.4. SERVICE SCHEDULE 238
3.1.5. ASSEMBLY CLEARANCES 240
3.1.6. SPECIAL TOOLS 241
3.2. GENERAL SYMPTOMS DIAGNOSIS 242
3.3. CONSTRUCTIONAL AND SERVICE DETAILS 245
3.3.1. ENGINE MOUNTING COMPONENTS 245
3.3.2. CYLINDER HEAD AND COVER 247
3.3.3. LUBRICATION SYSTEM COMPONENTS 249
3.3.4. ENGINE 251
3.3.5. OIL SUMP 253
3.3.6. CYLINDER HEAD 255
3.3.7. SPECIAL INSTALLATION 257
3.3.8. EXHAUST SYSTEM COMPONENTS 259
3.3.9. INTAKE SYSTEM COMPONENTS 261
3.3.10. ENGINE SUSPENSION 263
3.3.11. MOVING PARTS 265
3.3.12. ENGINE TIMING 267
3.3.13. FUEL INJECTION EQUIPMENT 269
3.4. ENGINE TESTS AND MAINTENANCE 271
3.4.1. PRELIMINARY INSPECTION 271
3.4.2. ENGINE TESTS 271
3.4.3. REGULAR MAINTENANCE 274
3.4.3.1. ENGINE OIL REPLACEMENT 274
3.4.3.2. OIL FILTER REPLACEMENT 274
3.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT 275
3.4.3.4. MAIN FUEL FILTER REPLACEMENT 275
3.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR 276
3.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT 277
3.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT 278
3.4.3.8. COOLANT REPLACEMENT 282
3.5. REPAIR AND INSPECTION DETAILS 283
3.5.1. TIMING BELT 283
3.5.2. FUEL TANK 283
3.5.3. CYLINDER HEAD 284
3.5.4. VALVES 285
3.5.5. VALVE SEATS 286
3.5.6. CRANKCASE 287
3.5.7. VALVE SEAT INSERT 288
3.5.8. HYDRAULIC LASH ADJUSTER 288
3.5.9. CYLINDER HEAD COVER 288
3.5.10. VALVE GUIDES 289
3.5.11. CAMSHAFT 290
3.5.12. PISTON AND PISTON RINGS 291
3.5.13. CONNECTING ROD 292
3.5.14. CRANKSHAFT 294
3.6. ENGINE SYSTEM 296
3.6.1. AIR INTAKE SYSTEM 296
3.6.2. BLOW BY SYSTEM 298
3.6.3. VACUUM MANAGEMENT SYSTEM 299
3.6.4. COOLING SYSTEM 301
3.6.5. LUBRICATION SYSTEM 304
3.6.6. FUEL SYSTEM 308
3.6.7. EXHAUST SYSTEM 317
3.6.8. EXHAUST GAS RECIRCULATION SYSTEM 320
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE 322
3.7.1. ENGINE REMOVAL 322
3.7.2. AIR FILTER ASSEMBLY REMOVAL 324
3.7.3. POWER STEERING PUMP BELT (STRETCH BELT) 324
3.7.4. ALTERNATOR AND AC BELT 325
3.7.5. INJECTOR REMOVAL 326
3.7.6. TIMING BELT REMOVAL 327
3.7.7. FITMENT OF TIMING BELT 329
3.7.8. INTERCOOLER REMOVAL 332
3.7.9. RADIATOR REMOVAL 333
3.7.10. COOLANT TANK REMOVAL 335
3.7.11. RADIATOR FAN SHROUD REMOVAL 336
3.7.12. THERMOSTAT REMOVAL 336
3.7.13. FUEL RAIL REMOVAL 337
3.7.14. FUEL FILLER ASSEMBLY REMOVAL 338
3.7.15. FUEL TANK 339
3.7.16. TANK UNIT REMOVAL 340
3.7.17. FUEL LEVEL SENSOR REMOVAL 342
3.7.18. TANK PRESSURE VALVE REMOVAL 343
3.7.19. FUEL TANK PURGING PROCEDURE 344
3.7.20. POST SILENCER AND INTERMEDIATE PIPE 345
3.7.21. PRE-SILENCER AND MAIN SILENCER 345
3.7.22. FRONT EXHAUST PIPE 346
3.7.23. CLOSE COUPLED CATALYTIC CONVERTER 346
3.7.24. EGR COOLER MODULE 347
3.7.25. TURBOCHARGER 349
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 352
3.8.1. ENGINE DIS-ASSEMBLY 353
3.8.1.1. REMOVAL OF INTAKE MANIFOLD 353
3.8.1.2. REMOVAL OF EXHAUST MANIFOLD 358
3.8.1.3. REMOVAL OF OIL SUMP 361
3.8.1.4. REMOVAL OF TIMING BELT 362
3.8.1.5. REMOVAL OF CYLINDER HEAD 364
3.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 366
3.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 369
3.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY 370
3.8.2. ENGINE ASSEMBLY 377
3.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 377
3.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 378
3.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 379
3.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 380
3.8.2.5. FITMENT OF TIMING BELT 381
3.8.2.6. FITMENT OF OIL SUMP 383
3.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 384
3.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 387
3.8.2.9. ON ENGINE SUPPORT STAND 392
3.9. ENGINE MANAGEMENT SYSTEM (EMS) 394
3.9.1. SYSTEM OVERVIEW 395
3.9.2. BLOCK DIAGRAM 396
3.9.3. CONNECTOR PIN ASSIGNMENT 397
3.9.4. ANTI-CRANKING FUNCTION 402
3.9.5. SENSORS AND ACTUATORS DETAILS 403
3.9.5.1. CRANK ANGLE SENSOR 403
3.9.5.2. CAM SENSOR 404
3.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 406
3.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 407
3.9.5.5. COOLANT TEMPERATURE SENSOR 409
3.9.5.6. FUEL TEMPERATURE SENSOR (FTS) 410
3.9.5.7. INLET METERING VALVE (IMV) 411
3.9.5.8. VENTURI 411
3.9.5.9. RAIL PRESSURE SENSOR 411
3.9.5.10. WATER IN FUEL SENSOR 412
3.9.5.11. ACCELERATOR PEDAL SENSOR 413
3.9.5.12. BRAKE SWITCH 414
3.9.5.13. CLUTCH SWITCH 416
3.9.5.14. GLOW PLUGS 417
3.9.5.15. VTT ACTUATOR 418
3.9.5.16. EGR VALVE ACTUATOR 420
3.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 422
3.9.5.18. INTAKE THROTTLE VALVE 423
3.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 424
4. ENGINE - 400Nm MANUAL TRANSMISSION 425
4.1. GENERAL INFORMATION 433
4.1.1. ENGINE INTRODUCTION 433
4.1.2. TECHNICAL SPECIFICATION 434
4.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 435
4.1.4. SERVICE SCHEDULE 436
4.1.5. ASSEMBLY CLEARANCES 438
4.1.6. SPECIAL TOOLS 439
4.2. GENERAL SYMPTOMS DIAGNOSIS 440
4.3. CONSTRUCTIONAL AND SERVICE DETAILS 443
4.3.1. ENGINE MOUNTING COMPONENTS 443
4.3.2. CYLINDER HEAD AND COVER 445
4.3.3. LUBRICATION SYSTEM COMPONENTS 447
4.3.4. ENGINE 449
4.3.5. OIL SUMP 451
4.3.6. CYLINDER HEAD 453
4.3.7. SPECIAL INSTALLATION 455
4.3.8. EXHAUST SYSTEM COMPONENTS 457
4.3.9. INTAKE SYSTEM COMPONENTS 459
4.3.10. ENGINE SUSPENSION 461
4.3.11. MOVING PARTS 463
4.3.12. ENGINE TIMING 465
4.3.13. FUEL INJECTION EQUIPMENT 467
4.4. ENGINE TESTS AND MAINTENANCE 469
4.4.1. PRELIMINARY INSPECTION 469
4.4.2. ENGINE TESTS 469
4.4.3. REGULAR MAINTENANCE 472
4.4.3.1. ENGINE OIL REPLACEMENT 472
4.4.3.2. OIL FILTER REPLACEMENT 472
4.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT 473
4.4.3.4. MAIN FUEL FILTER REPLACEMENT 473
4.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR 474
4.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT 475
4.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT 476
4.4.3.8. COOLANT REPLACEMENT 480
4.5. REPAIR AND INSPECTION DETAILS 481
4.5.1. TIMING BELT 481
4.5.2. FUEL TANK 481
4.5.3. CYLINDER HEAD 482
4.5.4. VALVES 483
4.5.5. VALVE SEATS 484
4.5.6. CRANKCASE 485
4.5.7. VALVE SEAT INSERT 486
4.5.8. HYDRAULIC LASH ADJUSTER 486
4.5.9. CYLINDER HEAD COVER 486
4.5.10. VALVE GUIDES 487
4.5.11. CAMSHAFT 488
4.5.12. PISTON AND PISTON RINGS 489
4.5.13. CONNECTING ROD 490
4.5.14. CRANKSHAFT 492
4.6. ENGINE SYSTEM 494
4.6.1. AIR INTAKE SYSTEM 494
4.6.2. BLOW BY SYSTEM 496
4.6.3. VACUUM MANAGEMENT SYSTEM 497
4.6.4. COOLING SYSTEM 499
4.6.5. LUBRICATION SYSTEM 502
4.6.6. FUEL SYSTEM 506
4.6.7. EXHAUST SYSTEM 515
4.6.8. EXHAUST GAS RECIRCULATION SYSTEM 518
4.7. ENGINE ON VEHICLE SERVICE PROCEDURE 520
4.7.1. ENGINE REMOVAL 520
4.7.2. AIR FILTER ASSEMBLY REMOVAL 522
4.7.3. POWER STEERING PUMP BELT (STRETCH BELT) 522
4.7.4. ALTERNATOR AND AC BELT 523
4.7.5. INJECTOR REMOVAL 524
4.7.6. TIMING BELT REMOVAL 525
4.7.7. FITMENT OF TIMING BELT 527
4.7.8. INTERCOOLER REMOVAL 530
4.7.9. RADIATOR REMOVAL 531
4.7.10. COOLANT TANK REMOVAL 533
4.7.11. RADIATOR FAN SHROUD REMOVAL 534
4.7.12. THERMOSTAT REMOVAL 534
4.7.13. FUEL RAIL REMOVAL 535
4.7.14. FUEL FILLER ASSEMBLY REMOVAL 536
4.7.15. FUEL TANK 537
4.7.16. TANK UNIT REMOVAL 538
4.7.17. FUEL LEVEL SENSOR REMOVAL 540
4.7.18. TANK PRESSURE VALVE REMOVAL 541
4.7.19. FUEL TANK PURGING PROCEDURE 542
4.7.20. POST SILENCER AND INTERMEDIATE PIPE 543
4.7.21. PRE-SILENCER AND MAIN SILENCER 543
4.7.22. FRONT EXHAUST PIPE 544
4.7.23. CLOSE COUPLED CATALYTIC CONVERTER 544
4.7.24. EGR COOLER MODULE 545
4.7.25. TURBOCHARGER 547
4.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 550
4.8.1. ENGINE DIS-ASSEMBLY 551
4.8.1.1. REMOVAL OF INTAKE MANIFOLD 551
4.8.1.2. REMOVAL OF EXHAUST MANIFOLD 556
4.8.1.3. REMOVAL OF OIL SUMP 559
4.8.1.4. REMOVAL OF TIMING BELT 560
4.8.1.5. REMOVAL OF CYLINDER HEAD 562
4.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 564
4.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 567
4.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY 568
4.8.2. ENGINE ASSEMBLY 575
4.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 575
4.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 576
4.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 577
4.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 578
4.8.2.5. FITMENT OFTIMING BELT 579
4.8.2.6. FITMENT OF OIL SUMP 581
4.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 582
4.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 585
4.8.2.9. ON ENGINE SUPPORT STAND 590
4.9. ENGINE MANAGEMENT SYSTEM (EMS) 592
4.9.1. SYSTEM OVERVIEW 593
4.9.2. BLOCK DIAGRAM 594
4.9.3. CONNECTOR PIN ASSIGNMENT 595
4.9.4. ANTI-CRANKING FUNCTION 600
4.9.5. SENSORS AND ACTUATORS DETAILS 601
4.9.5.1. CRANK ANGLE SENSOR 601
4.9.5.2. CAM SENSOR 602
4.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 604
4.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 605
4.9.5.5. COOLANT TEMPERATURE SENSOR 607
4.9.5.6. FUEL TEMPERATURE SENSOR (FTS) 608
4.9.5.7. INLET METERING VALVE (IMV) 609
4.9.5.8. VENTURI 609
4.9.5.9. RAIL PRESSURE SENSOR 609
4.9.5.10. WATER IN FUEL SENSOR 610
4.9.5.11. ACCELERATOR PEDAL SENSOR 611
4.9.5.12. BRAKE SWITCH 612
4.9.5.13. CLUTCH SWITCH 614
4.9.5.14. GLOW PLUGS 615
4.9.5.15. VTT ACTUATOR 616
4.9.5.16. EGR VALVE ACTUATOR 618
4.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 620
4.9.5.18. INTAKE THROTTLE VALVE 621
4.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 622
5. CLUTCH - 320Nm 623
5.1. GENERAL INFORMATION 629
5.1.1. SPECIFICATIONS 629
5.1.1.1. CLUTCH DISC ASSEMBLY 629
5.1.1.2. SELF ADJUSTING CLUTCH COVER ASSEMBLY 630
5.1.1.3. SINGLE MASS FLYWHEEL 631
5.1.2. CLUTCH SYSTEM LAYOUT 632
5.1.2.1. CLUTCH MASTER CYLINDER 633
5.1.2.2. CONCENTRIC SLAVE CYLINDER 633
5.1.2.3. PEAK TORQUE LIMITER 633
5.1.2.4. HYDRAULIC ADAPTER 634
5.1.2.5. SINGLE MASS FLYWHEEL 634
5.1.2.6. SELF ADJUSTING CLUTCH 634
5.1.3. TIGHTENING TORQUES 635
5.1.4. SPECIAL TOOLS 639
5.1.5. GENERAL SYMPTOMS DIAGNOSIS 640
5.2. MAINTENANCE, INSPECTION AND TESTS 642
5.2.1. PRELIMINARY INSPECTION 642
5.2.2. REGULAR MAINTENANCE 643
5.2.2.1. CLUTCH SWITCH ADJUSTMENT 643
5.2.2.2. CLUTCH BLEEDING PROCEDURE 643
5.2.2.3. CLUTCH FLUID DRAINING PROCEDURE 644
5.2.3. REPAIRS 645
5.2.3.1. CLUTCH PEDAL ASSEMBLY 645
5.2.3.2. SELF ADJUSTING CLUTCH ASSEMBLY 650
5.2.3.3. CLUTCH HYDRAULIC SYSTEM COMPONENTS 655
5.2.3.4. SINGLE MASS FLYWHEEL (ON VEHICLE) 660
6. CLUTCH - 400Nm 661
6.1. GENERAL INFORMATION 667
6.1.1. SPECIFICATIONS 667
6.1.1.1. CLUTCH DISC ASSEMBLY 667
6.1.1.2. SELF ADJUSTING CLUTCH COVER ASSEMBLY 668
6.1.1.3. SINGLE MASS FLYWHEEL 669
6.1.2. CLUTCH SYSTEM LAYOUT 670
6.1.2.1. CLUTCH MASTER CYLINDER 671
6.1.2.2. CONCENTRIC SLAVE CYLINDER 671
6.1.2.3. PEAK TORQUE LIMITER 671
6.1.2.4. HYDRAULIC ADAPTER 672
6.1.2.5. SINGLE MASS FLYWHEEL 672
6.1.2.6. SELF ADJUSTING CLUTCH 672
6.1.3. TIGHTENING TORQUES 673
6.1.4. SPECIAL TOOLS 677
6.1.5. GENERAL SYMPTOMS DIAGNOSIS 678
6.2. MAINTENANCE, INSPECTION AND TESTS 680
6.2.1. PRELIMINARY INSPECTION 680
6.2.2. REGULAR MAINTENANCE 681
6.2.2.1. CLUTCH SWITCH ADJUSTMENT 681
6.2.2.2. CLUTCH BLEEDING PROCEDURE 681
6.2.2.3. CLUTCH FLUID DRAINING PROCEDURE 682
6.2.3. REPAIRS 683
6.2.3.1. CLUTCH PEDAL ASSEMBLY 683
6.2.3.2. SELF ADJUSTING CLUTCH ASSEMBLY 688
6.2.3.3. CLUTCH HYDRAULIC SYSTEM COMPONENTS 693
6.2.3.4. SINGLE MASS FLYWHEEL (ON VEHICLE) 698
7. GEAR BOX GBS-76 699
7.1. GENERAL INFORMATION 706
7.1.1. SPECIFICATIONS 706
7.1.2. TIGHTENING TORQUES 707
7.1.3. SPECIAL TOOLS 711
7.1.4. GENERAL SYMPTOMS DIAGNOSIS 715
7.2. MAINTENANCE, INSPECTION AND TEST 716
7.2.1. PRELIMINARY INSPECTION 716
7.2.2. REGULAR MAINTENANCE 716
7.2.3. ON VEHICLE PROCEDURES 717
7.2.3.1. GEARBOX REMOVAL 717
7.3. OVERHAULING 719
7.3.1. INFORMATION FOR OVERHAULING 719
7.3.1.1. COMPONENT INDENTIFICATION 719
7.3.1.2. PRECAUTIONS 722
7.3.1.3. CONSTRUCTIONAL DETAILS 723
7.3.2. GEARBOX DISMANTLING (ON BENCH) 726
7.3.3. DISMANTLING OF SUB-ASSEMBLIES 733
7.3.3.1. MAIN SHAFT 733
7.3.3.2. DRIVE SHAFT 744
7.3.3.3. REVERSE IDLER SHAFT 745
7.3.3.4. COUNTER SHAFT 747
7.3.3.5. FRONT COVER 750
7.3.3.6. TOP COVER 751
7.3.3.7. REAR COVER (4X2) 752
7.3.3.8. ADAPTOR (4X4) 753
7.3.3.9. SHIFTER SHAFTS & FORKS 754
7.3.3.10. NON-ADJUSTABLE SHIFTER LINKAGE 756
7.3.4. GEAR BOX ASSEMBLY 759
8. GEAR BOX G-6450 768
8.1. GENERAL INFORMATION 769
8.1.1. SPECIFICATIONS 769
8.1.2. TIGHTENING TORQUE 770
8.1.3. SPECIAL TOOLS 775
8.1.4. GENERAL SYMPTOMS DIAGNOSIS 779
8.2. MAINTENANCE, INSPECTION, AND TEST 780
8.2.1. PRELIMINARY INSPECTION 780
8.2.2. REGULAR MAINTENANCE 780
8.2.3. ON VEHICLE PROCEDURE 781
8.2.3.1. GEARBOX REMOVAL 781
8.2.4. CONSTRUCTION OF GEAR BOX 783
8.3. OVERHAULING 785
8.3.1. INFORMATION FOR OVERHAULING 785
8.3.1.1. COMPONENT INDENTIFICATION 785
8.3.2. GEAR BOX DISMANTLING ON BENCH PROCEDURE 788
8.3.3. INSPECTION 798
8.3.4. GEAR BOX ASSEMBLY ON BENCH PROCEDURE 800
9. AUTOMATIC TRANSMISSION 816
9.1. TRANSMISSION BASE SPECIFICATION 820
9.2. TRANSMISSION SYSTEM OVERVIEW 821
9.3. EXPLANATION OF THE SELECTOR LEVER POSITIONS 822
9.4. PRINCIPLE OF OPERATIONS 824
9.5. EXPLODED VIEW OF TRANSMISSION 831
9.6. MAINTENANCE AND SERVICE / FREQUENCY 833
9.7. FLUID DRAIN AND OIL PAN REMOVING PROCEDURE 834
9.8. OIL PAN INSTALLATION PROCEDURE 835
9.9. TRANSMISSION FLUID FILL TUBE REMOVING AND INSTALLATION PROCEDURE 835
9.10. TRANSMISSION FLUID LEVEL AFTER REPAIRS PROCEDURE 836
9.11. TRANSMISSION FLUID LEVEL CHECKING PROCEDURE 837
9.12. ESD (ELECTROSTATIC DISCHARGE) NOTICE 838
9.13. REAR WHEEL DRIVE TRANSMISSION REMOVING PROCEDURE 839
9.14. REAR WHEEL DRIVE TRANSMISSION INSTALLING PROCEDURE 844
9.15. ALL-WHEEL DRIVE TRANSMISSION REMOVING PROCEDURE 850
9.16. ALL-WHEEL DRIVE TRANSMISSION INSTALLING PROCEDURE 857
9.17. TORQUE CONVERTER REMOVING PROCEDURE 863
9.18. TORQUE CONVERTER INSTALLING PROCEDURE 864
9.19. OIL FILTER-LIP SEAL REMOVING & INSTALLING PROCEDURE 865
9.20. MECHATRONIC REMOVING PROCEDURE 866
9.21. MECHATRONIC INSTALLING PROCEDURE 868
9.22. SELECTOR SHAFT & LIP SEAL REMOVING PROCEDURE 870
9.23. SELECTOR SHAFT & LIP SEAL INSTALLING PROCEDURE 871
9.24. SHIFT LINKAGE ADJUSTMENT PROCEDURE 872
9.25. TRANSMISSION AIR OIL COOLER REMOVAL WITHOUT HOSES AND TUBES 874
9.26. TRANSMISSION WATER OIL COOLER REMOVAL PROCEDURE 877
10. TORQUE ON DEMAND (TOD) 879
10.1. GENERAL INFORMATION 881
10.1.1. SPECIFICATIONS 881
10.1.2. LAYOUT 882
10.2. COMPONENTS OF TOD 883
10.2.1. ECU 883
10.2.1.1. GENERAL 883
10.2.1.2. LOCATION 883
10.2.1.3. ECU INPUT/ OUTPUT BLOCK DIAGRAM 884
10.2.1.4. PINOUT 885
10.2.2. MOMENTARY SWITCH 886
10.2.3. WARNING LAMP 886
10.2.4. CLUTCH COIL 887
10.3. WORKING OF TOD 887
10.4. TIGHTENING TORQUES 892
10.5. SPECIAL TOOLS 894
10.6. GENERAL SYMPTOMS AND DIAGNOSIS 897
10.7. MAINTENANCE 898
10.8. ON VEHICLE REPAIRS 899
10.8.1. TRANSFER CASE 899
10.8.2. TOD ELECTRONIC CONTROL UNIT (ECU) 900
10.9. OVERHAULING 901
10.9.1. DISMANTLING 901
10.9.1.1. REAR YOKE 901
10.9.1.2. REAR COVER ASSEMBLY 901
10.9.1.3. CLUTCH PACK ASSEMBLY 903
10.9.1.4. CHAIN DRIVE 905
10.9.1.5. GEROTOR PUMP 906
10.9.1.6. FRONT OUTPUT SHAFT AND YOKE 908
10.9.1.7. ADAPTER, INPUT SHAFT AND CARRIER ASSEMBLY 909
10.10. INSPECTION AND CLEANING 910
10.10.1. ASSEMBLY 910
10.10.1.1. ADAPTER AND INPUT SHAFT 910
10.10.1.2. FRONT OUTPUT SHAggFT AND YOKE 911
10.10.1.3. ASSEMBLY OF OUTPUT SHAFT AND GEROTOR PUMP 912
10.10.1.4. CHAIN DRIVE 914
10.10.1.5. CLUTCH PACK 915
10.10.1.6. COVER ASSEMBLY 919
10.10.1.7. REAR OUTPUT YOKE 921
11. FRONT SUSPENSION 922
11.1. GENERAL INFORMATION 928
11.1.1. SPECIFICATIONS 928
11.1.2. CONSTRUCTION 929
11.1.3. TIGHTENING TORQUES 930
11.1.4. SPECIAL TOOLS 935
11.2. GENERAL SYMPTOMS AND DIAGNOSIS 939
11.3. MAINTENANCE 940
11.3.1. PRELIMINARY INSPECTION 940
11.3.2. REGULAR MAINTENANCE 940
11.4. ON VEHICLE REPAIRS 942
11.4.1. ANTI ROLL BAR (ARB) REMOVAL 942
11.4.2. FRONT STRUT ASSEMBLY REMOVAL 943
11.4.3. LOWER WISHBONE REMOVAL 944
11.4.4. UPPER WISHBONE REMOVAL 945
11.4.5. BUMP STOPPER 946
11.5. OVERHAULING 947
11.5.1. PRECAUTIONS 947
11.5.2. DISMANTLING, INSPECTION AND ASSEMBLY 947
11.5.2.1. FRONT STRUT DISMANTLING./ DAMPER REPLACEMENT 947
11.5.2.2. FRONT DAMPER BOTTOM BUSH 950
11.5.2.3. UPPER WISHBONE BUSH 950
11.5.2.4. UPPER WISHBONE BALL JOINT 952
11.5.2.5. LOWER WISHBONE BALL JOINT REMOVAL 952
12. REAR SUSPENSION 953
12.1. GENERAL INFORMATION 957
12.1.1. SPECIFICATIONS 957
12.1.2. CONSTRUCTION 958
12.1.3. TIGHTENING TORQUES 959
12.1.4. SPECIAL TOOLS 962
12.2. MAINTENANCE 966
12.2.1. ON VEHICLE REPAIRS 966
12.2.1.1. ANTIROLL BAR 966
12.2.1.2. REAR SUSPENSION LINKS TIGHTENING PROCEDURE 967
12.2.1.3. UPPER LINK REMOVAL 968
12.2.1.4. LOWER LINK REMOVAL 968
12.2.1.5. PAN HARD ROD REMOVAL 969
12.2.1.6. REAR SHOCK ABSORBER REMOVAL 969
12.2.1.7. REAR COIL SPRING REMOVAL 970
12.3. OVERHAULING 971
12.3.1. PRECAUTIONS 971
12.3.2. DISMANTLING, INSPECTION AND ASSEMBLY 971
12.3.2.1. UPPER LINK BUSH REMOVAL 971
12.3.2.2. LOWER LINK BUSH REMOVAL 972
12.3.2.3. PAN HARD ROD BUSH REMOVAL 973
12.3.2.4. SHOCK ABSORBER BOTTOM BUSH REMOVAL 975
12.3.2.5. SHOCK ABSORBER TOP REPLACEMENT 976
13. FRONT AXLE 4X2 977
13.1. GENERAL INFORMATION 983
13.1.1. TECHNICAL SPECIFICATION 983
13.1.2. CONSTRUCTION AND LAYOUT 983
13.1.3. TIGHTENING TORQUES 984
13.1.4. SPECIAL TOOLS 985
13.2. MAINTENANCE 986
13.2.1. ON VEHICLE PROCEUDRE 986
13.2.1.1. FRONT STUB AXLE ASSEMBLY 986
13.2.1.2. HUB REPLACEMENT 989
13.2.1.3. TONER RING REPLACEMENT 991
14. FRONT AXLE 4X4 993
14.1. GENERAL INFORMATION 999
14.1.1. SPECIFICATION 999
14.1.2. CONSTRUCTION 1000
14.1.3. TIGHTENING TORQUES 1001
14.1.4. SPECIAL TOOLS 1005
14.2. GENERAL SYMPTOMS AND DIAGNOSIS 1010
14.3. MAINTENANCE 1011
14.3.1. PRELIMINARY INSPECTION 1011
14.3.2. REGULAR MAINTENANCE 1011
14.4. ON VEHICLE REPAIRS 1012
14.4.1. FRONT AXLE ASSEMBLY 1012
14.4.2. ELECTRICAL DISCONNECT ASSEMBLY 1015
14.4.3. TONER RING 1016
14.5. OVERHAULING 1018
14.5.1. PRECAUTIONS 1018
14.5.2. DISMANTLING INSPECTION AND ASSEMBLY 1018
14.5.2.1. DIFFERENTIAL CASING 1018
14.5.2.2. PINION POSITION SHIM SELECTION 1023
14.5.2.3. WHEEL END ASSEMBLY 1031
14.5.2.4. FRONT AXLE DISCONNECT (FAD) 1035
14.5.2.5. CONSTANT VELOCITY SHAFT 1040
15. REAR AXLE 1044
15.1. GENERAL INFORMATION 1050
15.1.1. SPECIFICATION 1050
15.1.2. SYSTEM LAYOUT 1051
15.1.3. TIGHTENING TORQUE 1052
15.1.4. SPECIAL TOOLS 1055
15.2. GENERAL SYMPTOMS AND DIAGNOSIS 1059
15.3. MAINTENANCE 1061
15.3.1. PRELIMINARY INSPECTION 1061
15.3.2. REGULAR MAINTENANCE 1061
15.4. ON VEHICLE REPAIRS 1062
15.4.1. REAR AXLE 1062
15.4.2. AXLE SHAFT 1064
15.4.3. DIFFERENTIAL CASE 1065
15.5. OVERHAULING 1067
15.5.1. PRECAUTIONS 1067
15.5.2. DISMANTLING INSPECTION AND ASSEMBLY 1067
15.5.2.1. AXLE SHAFT 1067
15.5.2.2. DIFFERENTIAL CASING 1070
15.5.2.3. PINION POSITION SHIM SELECTION 1077
15.5.2.4. DIFFERENTIAL SHIM SELECTION 1080
15.5.2.5. LIMITED SLIP DIFFERENTIAL 1085
16. WHEELS AND TYRES 1090
16.1. GENERAL INFORMATION 1093
16.1.1. SPECIFICATIONS 1093
16.1.2. CONSTRUCTION 1094
16.1.3. TIGHTENING TORQUES 1096
16.2. GENERAL SYMPTOMS DIAGNOSIS 1097
16.2.1. DIAGNOSIS CHART 1097
16.2.2. TYRE WEAR PATTERN 1100
16.2.3. WEAR CAUSES 1102
16.2.4. TYRE VIBRATION DIAGNOSIS 1104
16.3. MAINTENANCE, INSPECTION AND TESTS 1105
16.3.1. PRELIMINARY INSPECTION 1105
16.3.2. REGULAR MAINTENANCE 1106
16.3.2.1. INFLATION 1106
16.3.2.2. WHEEL BALANCING 1106
16.3.2.3. TYRE ROTATION 1107
16.3.2.4. WHEEL RUN OUT 1108
16.3.2.5. DO'S AND DON’TS 1109
16.4. WHEEL AND TYRE REPLACEMENT 1110
16.4.1. PRECAUTIONS DURING TYRE REPLACEMENT 1110
16.4.2. TYRE REPLACEMENT 1111
16.4.3. WHEEL ASSEMBLY REPLACEMENT 1111
17. PROPELLER SHAFT 1112
17.1. GENERAL INFORMATION 1118
17.1.1. ADJUSTMENT / REPAIR DATA 1118
17.2. SYSTEM DESCRIPTION 1119
17.2.1. FOR 4X2 DRIVE 1119
17.2.2. FOR 4X4 DRIVE 1120
17.3. TIGHTENING TORQUE 1121
17.4. SPECIAL TOOLS 1122
17.5. GENERAL SYMPTOMS DIAGNOSIS 1123
17.6. MAINTENANCE, INSPECTION AND TESTS 1124
17.7. REGULAR MAINTENANCET 1124
17.8. ON VEHICLE REPAIRS 1125
17.8.1. PROPELLER SHAFT 4X2 1126
17.8.2. PROPELLER SHAFT 4X4 1127
17.9. OVERHAULING 1128
18. BRAKES 1133
18.1. GENERAL INFORMATION 1138
18.1.1. SPECIFICATIONS 1138
18.1.2. SYSTEM SCHEMATICS 1139
18.1.3. SYSTEM LAYOUT 1140
18.1.4. TIGHTENING TORQUES 1141
18.2. GENERAL SYMTOMS DIAGNOSIS 1143
18.3. MAINTENANCE, INSPECTION AND TEST 1144
18.3.1. PRELIMINARY INSPECTION 1145
18.3.1.1. FRONT BRAKE AND REAR BRAKE 1145
18.3.1.2. PARKING BRAKE 1145
18.3.1.3. BRAKE HOSES AND LINES 1145
18.3.1.4. ROAD TEST 1145
18.3.2. REGULAR MAINTAENANCE 1146
18.3.2.1. BRAKE BLEEDING PROCEDURE 1146
18.3.2.2. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) 1147
18.3.2.3. CALIPER PAD REPLACEMENT 1152
18.3.2.4. PARKING BRAKE ADJUSTMENT 1153
18.3.2.5. BRAKE FLUID DRAINING PROCEDURE 1154
18.3.2.6. BRAKE LIGHT SWITCH ADJUSTMENT 1155
18.3.2.7. BOOSTER FILTER REPLACEMENT 1156
18.3.2.8. GREASING 1157
18.3.2.9. DISC RUN-OUT MEASUREMENT PROCEDURE 1158
18.3.3. ON VEHICLE REPAIRS 1158
18.3.3.1. CALIPER ASSEMBLY WITH CARRIER 1158
18.3.3.2. BRAKE DISC 1159
18.3.3.3. PARKING BRAKE 1162
18.3.3.4. BRAKE PEDAL 1165
18.3.3.5. VACUUM TANK AND VACUUM LINES 1168
18.3.3.6. BOOSTER ASSEMBLY 1170
18.3.3.7. PARKING BRAKE (DRUM IN HAT) 1174
18.4. OVERHAULING 1176
18.4.1. PRECAUTIONS 1176
18.4.2. DISMANTLING, INSPECTION AND ASSEMBLY 1177
18.4.2.1. FRONT CALIPER ASSEMBLY 1177
18.4.2.2. REAR CALIPER ASSEMBLY 1181
19. ANTI-LOCK BRAKING SYSTEM (ABS) 1185
19.1. GENERAL INFORMATION 1191
19.1.1. NECCESITY OF ABS WITH EBD 1191
19.1.2. TECHNICAL SPECIFICATIONS 1192
19.1.3. TIGHTENING TORQUES 1193
19.1.4. SCHEMATIC OF HYDRAULIC CIRCUIT 1195
19.1.5. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 1196
19.2. COMPONENTS 1200
19.2.1. ABS ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 1201
19.2.2. WHEEL SPEED SENSOR 1204
19.2.3. ABS SYSTEM FAILURE WARNING LIGHT 1205
19.3. REPAIRS 1207
19.3.1. ABS ECU/HCU REMOVAL 1207
19.3.2. FRONT WHEEL SPEED SENSOR 1210
19.3.3. FRONT TONER RING 1211
19.3.4. REAR WHEEL SPEED SENSOR 1212
19.3.5. REAR TONER RING 1213
19.4. TROUBLE SHOOTING AND DIAGNOSIS 1214
19.4.1. ROAD TEST 1214
19.4.2. TABLE OF ABS 8.1 - FALL-BACK LEVEL 1214
19.5. ABS DIAGNOSTIC USER MANUAL 1215
20. ELECTRONIC STABILITY PROGRAM (ESP) 1228
20.1. GENERAL INFORMATION 1234
20.1.1. NECESSITY OF ESP AND TCS 1234
20.1.2. SPECIFICATIONS 1235
20.1.3. TIGHTENING TORQUES 1236
20.1.4. SYSTEM LAYOUT 1237
20.2. WORKING OF ESP 1238
20.3. COMPONENTS 1240
20.3.1. ESP ECU AND HYDRAULIC UNIT 1240
20.3.2. YAW RATE SENSOR (YRS) 1242
20.3.3. STEERING ANGLE SENSOR (SAS) 1243
20.3.4. ESP SYSTEM FAILURE WARNING LIGHT 1244
20.4. ON VEHICLE REPAIRS 1245
20.4.1. YAW RATE SENSOR REMOVAL 1245
20.4.2. STEERING ANGLE SENSOR REMOVAL 1246
20.4.3. STEERING ANGLE SENSOR CALIBRATION USING DIAGNOSTIC TOOL 1248
20.5. TROUBLESHOOTING 1256
21. STEERING 1257
21.1. GENERAL INFORMATION 1259
21.1.1. SPECIFICATIONS 1259
21.1.2. SYSTEM LAYOUT 1260
21.1.3. TIGHTENING TORQUES 1261
21.1.4. SPECIAL TOOLS 1265
21.2. GENERAL SYMPTOMS DIAGNOSIS 1266
21.3. MAINTENANCE, INSPECTION AND TEST 1273
21.3.1. PRELIMINARY INSPECTION 1273
21.3.1.1. INSPECTION OF TYRE 1273
21.3.1.2. STEERING WHEEL FREE PLAY 1273
21.3.1.3. LEAKAGES IN THE HYDRAULIC SYSTEM 1273
21.3.1.4. TEST DRIVE 1273
21.3.1.5. ROAD TEST 1273
21.3.2. REGULAR MAINTENANCE 1274
21.3.2.1. POWER STEERING OIL REPLACEMENT 1274
21.3.2.2. POWER STEERING RESERVOIR ASSY 1275
21.3.2.3. HYDRAULIC SYSTEM AIR BLEEDING 1276
21.3.2.4. TOE IN ADJSUTMENT 1277
21.3.2.5. STEERING WHEEL ALIGNMENT/CENTRALISING 1278
21.3.2.6. STEERING WHEEL PLAY 1278
21.3.2.7. POWER STEERING OIL FLUSHING PROCEDURE 1279
21.3.3. REPAIRS 1280
21.3.3.1. STEERING WHEEL 1280
21.3.3.2. STEERING COLUMN 1283
21.3.3.3. STEERING RESERVOIR AND POWER STEERING PUMP 1286
21.3.3.4. RACK AND PINION ASSEMBLY 1288
21.4. OVERHAULING 1289
21.4.1. PRECAUTIONS 1289
21.4.2. RACK AND PINION ASSEMBLY 1290
21.4.3. DISMANTLING, INSPECTION AND ASSEMBLY 1291
21.4.3.1. OUTER BALL JOINT (OBJ) 1291
21.4.3.2. BELLOW KIT 1292
21.4.3.3. INNER BALL JOINT (IBJ) 1293
21.4.3.4. FEED PIPE 1294
21.4.3.5. DO’S & DON’TS 1295
21.4.4. STEERING PUMP 1298
21.4.4.1. PRESSURE PORT CONNECTOR 1298
21.4.4.2. SUCTION PORT CONNETOR 1300
22. ELECTRICAL 1301
22.1. TECHNICAL SPECIFICATIONS 1303
22.2. GENERAL ELECTRCIAL PRECAUTIONS 1307
22.3. CHARGING & STARTING SYSTEM 1310
22.3.1. BATTERY 1310
22.3.2. ALTERNATOR 1320
22.3.3. STARTER MOTOR 1337
22.4. LIGHTING SYSTEM 1354
22.4.1. BULB SPECIFICATIONS 1354
22.4.2. TORQUE VALUE TABLE 1355
22.4.3. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS 1356
22.4.4. HEAD LAMP 1360
22.4.5. FRONT FOG LAMP WITH DRL 1365
22.4.6. FIRST and SECOND ROOF LAMP 1366
22.4.7. THIRD ROOF LAMP 1367
22.4.8. REGISTRATION PLATE LAMP 1368
22.4.9. HIGH MOUNTED STOP LAMP 1368
22.4.10. DOOR AJAR CUM PUDDLE LAMP 1369
22.4.11. GLOVE BOX LAMP 1370
22.4.12. LOAD AREA LAMP 1371
22.4.13. TAIL LAMP 1371
22.4.14. SUNVISOR MIRROR LAMP 1374
22.4.15. MOOD LAMP 1374
22.5. HORN 1375
22.6. POWER SOCKET 1380
22.7. WIPER AND WASHER SYSTEM 1383
22.7.1. FRONT AND REAR WIPER AND WASHER SYSTEM COMPONENT LOCATIONS 1383
22.7.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 1385
22.7.3. FRONT WIPER MOTOR 1386
22.7.4. FRONT WIPER ARM AND BLADE 1388
22.7.5. REAR WIPER ARM AND BLADE 1390
22.7.6. REAR WIPER MOTOR 1392
22.7.7. WIPER CARE 1394
22.7.8. WASHER BOTTLE 1395
22.7.9. WASHER PUMP 1397
22.7.10. FRONT WASHER NOZZLE 1398
22.7.11. REAR WASHER NOZZLE 1399
22.7.12. FLOAT LEVEL SENSOR 1400
22.7.13. DIAGNOSTIC INFORMATION AND PROCEDURES 1401
22.8. ELECTRICAL SWITCHES 1402
22.8.1. COMBINATION - SWITCH 1402
22.8.2. IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION 1415
22.8.3. MASTER LIGHT SWITCH 1417
22.8.4. FASCIA SWITCH 1423
22.8.5. WINDOW WINDING SWITCHES 1427
22.8.6. STEERING WHEEL SWITCHES 1433
22.8.7. BONNET SWITCH 1437
22.8.8. TAILGATE SWITCH 1438
22.8.9. DOOR SWITCHES (FRONT & REAR) 1439
22.8.10. GLOVE BOX SWITCH 1440
22.8.11. REVERSE LIGHT SWITCH 1441
22.8.12. HAND BRAKE SWITCH 1442
22.8.13. INERTIA SWITCH 1443
22.8.14. DRIVE CONTROL SWITCH (DCS) 1444
22.9. IN VEHICLE NETWORKING (IVN) 1453
22.10. WINDOW WINDING CONTROLLER 1461
22.11. BODY CONTROL MODULE (BCM) 1469
22.11.1. BCM CONNECTOR PIN SIGNALS APLICABILITY MATRIX 1471
22.11.2. BCM FUNCTIONS 1488
22.11.2.1. EXTERIOR LIGHTS 1489
22.11.2.2. INTERIOR LIGHTS 1501
22.11.2.3. WIPER WASHER 1507
22.11.2.4. VEHICLE POWER MODE 1513
22.11.2.5. CENTRAL LOCKING & RKE 1520
22.11.2.6. PERIMETRIC ALARM 1526
22.11.2.7. USER CUSTOMIZATION SETTINGS 1527
22.11.2.8. ORVM FOLD/UNFOLD 1529
22.12. IMMOBILIZER SYSTEM 1535
22.12.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 1301
22.12.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU 1539
22.12.3. IGNITION SWITCH_AT WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION (XMA, XTA) 1540
22.13. INSTRUMENT CLUSTER (XE VARIANT) 1541
22.13.1. TACHOMETER 1543
22.13.2. SPEEDOMETER 1543
22.13.3. TEMPERATURE GAUGE 1543
22.13.4. FUEL GAUGE 1543
22.13.5. TELLTALES 1544
22.13.6. DRIVER INFORMATION CENTER 1548
22.13.7. FUEL COMPUTER 1549
22.13.8. DIC SWITCH FUNCTIONS 1551
22.13.9. CONNECTION BLOCK DIAGRAM 1555
22.13.10. CONNECTOR DETAILS 1557
22.13.11. DIAGNOSTICS BRIEF 1559
22.14. INSTRUMENT CLUSTER - XM, XMA, XTA (4X2), XT (4X4) 1565
22.14.1. TACHOMETER 1567
22.14.2. FUEL GAUGE 1567
22.14.3. SPEEDOMETER 1568
22.14.4. TEMPERATURE GAUGE 1568
22.14.5. DRIVER INFORMATION SYSTEM 1569
22.14.6. XM, XT, XT (4X4) DRIVE MODE AND GEAR DISPLAY 1578
22.14.7. XMA, XMA (4X4) DRIVE MODE AND GEAR DISPLAY 1581
22.14.8. DISPLAY MESSAGES 1583
22.14.9. WARNING LAMPS 1587
22.14.10. CONNECTOR DETAILS OF XT, XM & XMA VARIANTS INSTRUMENT CLUSTER 1590
22.15. ULTRASONIC PARK ASSIST SYSTEM 1591
22.15.1. ULTRASONIC PARK ASSIST SYSTEM ARCHITECTURE 1591
22.15.2. ULTRASONIC PARK ASSIST 1592
22.15.3. ULTRASONIC PARK ASSIST OVERVIEW 1592
22.15.4. ULTRASONIC PARK ASSIST ACTIVATION PROCEDURE 1592
22.15.5. ULTRASONIC PARK ASSIST DEACTIVATION PROCEDURE 1593
22.15.6. PARK ASSIST BUTTON LED INDICATIONS (IF EQUIPPED) 1593
22.15.7. PARK ASSIST AUDIO SETTINGS 1593
22.15.8. PARK ASSIST VOLUME 1593
22.15.9. MIX WITH AUDIO 1594
22.15.10. PARK ASSIST TONE 1594
22.15.11. PARK ASSIST DELAY TIMER 1594
22.15.12. ULTRA PARK ASSIST HMI INDICATIONS 1594
22.15.13. ULTRASONIC PARK ASSIST SYSTEM LIMITATIONS 1595
22.15.14. ULTRASONIC PARK ASSIST SYSTEM MAINTENANCE 1595
22.15.15. PARK DISTANCE CONTROLLER LOCATION 1595
22.15.16. PHYSICAL IMAGES 1597
22.15.17. SENSOR FITMENT TO THE BUMPER 1598
22.15.18. PARKING DISTANCE CONTROL WITH REAR VIEW CAMERA ( IF EQUIPPED ) 1602
22.16. INFOTAINMENT SYSTEM: (If fitted) 1608
22.16.1. USB/AUX PORT 1612
22.16.2. SPEAKERS 1613
22.16.3. TWEETER 1616
22.16.4. AUDIO AMPLIFIER 1618
22.16.5. MICROPHONE 1620
22.16.6. ANTENNA 1621
22.17. GENERAL ELECTRICAL INFORMATION 1622
22.17.1. INTRODUCTION 1623
22.17.2. FUSE & RELAY BOX DETAILS 1627
22.18. CLUTCH PEDAL SENSOR 1639
23A. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) - AUTOLIV 1643
23A.1. TIGHTENING TORQUES 1649
23A.2. WORKING OF RESTRAINTS 1651
A. RESTRAINTS WITHOUT AIRBAGS 1651
B. RESTRAINTS WITH AIRBAGS 1651
23A.3. WORKING OF SRS 1651
23A.4. SYSTEM LAYOUT 1652
A. RESTRAINT WITHOUT AIRBAG 1652
B. RESTRAINT WITH AIRBAG 1652
C. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 1654
23A.5. SAFETY PRECAUTIONS 1655
23A.6. DISPOSAL OF FAULTY AIR BAG UNIT 1657
23A.7. COMPONENTS 1659
A. RESTRAINT WITHOUT AIRBAGS 1659
I. SEAT BELT 1659
II. EMERGENCY LOCKING RETRACTOR (ELR) 1659
III. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP 1659
B. RESTRAINT WITH AIRBAGS 1659
I. ECU 1659
II. SENSORS 1666
III. AIR BAGS 1668
IV. RPLL BELTS 1674
V. CLOCK SPRING 1676
VI. SRS WARNING LAMP 1679
VII. PAB DECACTIVATION SWITCH 1679
VIII. PAB INDICATOR 1681
23B. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) - BOSCH 1685
23B.0. ABBREVIATIONS 1692
23B.1. TIGHTENING TORQUES 1693
23B.2. WORKING OF RESTRAINTS 1695
A. RESTRAINTSWITHOUT AIRBAGS 1695
B. RESTRAINTSWITH AIRBAGS 1695
23B.3. WORKING OF SRS 1695
23B.4. SYSTEM LAYOUT 1696
A. RESTRAINTWITHOUT AIRBAG 1696
B. RESTRAINTWITH AIRBAG 1696
C. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 1698
23B.5. SAFETY PRECAUTIONS 1699
23B.6. DISPOSAL OF FAULTY AIR BAG UNIT 1701
23B.7. COMPONENTS 1703
A. RESTRAINTWITHOUT AIRBAGS 1703
I. SEAT BELT 1703
II. EMERGENCY LOCKING RETRACTOR (ELR) 1703
III. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP 1703
B. RESTRAINTWITH AIRBAGS 1703
I. ECU 1703
II. SENSORS 1709
III. AIR BAGS 1711
IV. RPLL BELTS 1717
V. CLOCK SPRING 1719
VI. SRS WARNING LAMP 1722
VII. PAB DECACTIVATION SWITCH 1722
VIII. PAB INDICATOR 1722
24. BODY 1728
24.1. GENERAL INFORMATION 1737
24.1.1. SPECIFICATIONS 1737
24.1.2. CONSTRUCTION 1741
24.1.3. TIGHTENING TORQUES 1742
24.2. ON VEHICLE REPAIRS 1748
24.2.1. BONNET 1748
24.2.2. FLOOR CONSOLE 1752
24.2.3. AC DUCTS IN FLOOR CONSOLE 1755
24.2.4. DASHBOARD 1756
24.2.5. FRONT BUMPER 1762
24.2.6. REAR BUMPER 1765
24.2.7. DOOR 1766
24.2.8. TAIL GATE 1775
24.2.9. MIRROR 1780
24.2.10. SEATS 1781
24.2.11. TRIMS 1787
24.2.12. LEAF SCREEN 1792
24.2.13. PANEL ASSEMBLY 1792
24.2.14. STONE GUARD 1793
24.2.15. FRONT WHEEL ARCH LINER 1793
24.2.16. FUEL FLAP MECHANISM 1794
24.2.17. GLASS 1795
24.2.18. ROOF LINER ASSEMBLY 1798
24.2.19. FRONT FENDER 1799
24.2.20. FRONT WHEEL ARCH COVER 1799
24.2.21. VALANCE COVER 1800
24.2.22. REAR DOOR CLADDING 1800
24.2.23. REAR WHEEL ARCH COVER 1801
24.2.24. LOAD FLOOR 1802
24.2.25. ROOF RAIL ASSEMBLY 1803
24.2.26. "D" PILLAR MOULDING 1803
24.3. BODY REPAIR 1804
25. HVAC 1813
25.1. GENERAL INFORMATION 1815
25.2. TIGHTENING TORQUES 1817
25.3. PRECAUTIONS 1820
25.4. HVAC SYSTEM LAYOUT AND WORKING 1822
25.5. COMPONENTS OF HVAC 1826
25.5.1. CONTROL PANEL 1827
25.5.2. FRONT HVAC UNIT 1831
25.5.3. REAR AC UNIT 1834
25.5.4. COMPRESSOR 1834
25.5.5. CONDENSER AND RECEIVER DRIER CONDENSER 1836
25.5.6. THERMISTER OR THERMO SENSOR 1836
25.5.7. TRINARY PRESSURE SWITCH 1838
25.5.8. TEMPERATURE AND MODE ACTUATOR 1839
25.5.9. AIR INLET ACTUATOR 1840
25.5.10. REAR BLOWER CONTROLLER 1842
25.6. TROUBLESHOOTING 1844
25.7. MAINTENANCE 1857
25.7.1. PRELIMINARY INSPECTION 1857
25.7.2. REGULAR MAINTENANCE 1859
25.8. ON VEHICLE REPAIRS 1865
25.8.1. CONTROL PANEL ASSEMBLY 1865
25.8.2. COMPRESSOR REMOVAL 1865
25.8.3. FRONT HVAC UNIT 1866
25.8.4. REAR AC UNIT 1867
25.8.5. BLOWER (FRONT HVAC UNIT) 1868
25.8.6. BLOWER RESISTER 1868
25.8.7. LPM (LINEAR POWER MODULE) 1869
25.8.8. WIRE MESH 1869
25.8.9. TXV (THERMAL EVAPORATION VALVE) 1870
25.8.10. PRESSURE SWITCH 1870
25.8.11. CONDENSER 1871
25.8.12. REFRIGERANT HOSES/PIPES 1872
25.8.13. REAR AC DUCTING 1874
25.8.14. CONDENSER SEALING DUCT 1877
25.9. OVERHAULING 1878
25.9.1. FRONT HVAC UNIT 1878
25.9.2. REAR AC 1882
25.9.3. COMPRESSOR 1883
25.10. DIAGNOSTICS USING BLINK CODES 1886
25.10.1. ACTIVATING DIAGNOSTICS MODE 1886
25.10.2. DISPLAYING BLINK CODES 1887
25.10.3. READING BLINK CODES 1887
25.10.4. ERASING ACTIVE FAULTS 1888
25.10.5. EXITING DIAGNOSTIC MODE 1888
25.11. FULLY AUTOMATIC TEMPERATURE CONTROL (FATC) 1889
25.11.1. INTRODUCTION 1889
25.11.2. TECHNICAL SPECIFICATION 1890
25.11.3. FATC CONTROL SCHEMATICS 1892
25.12. COMPONENTS 1893
25.12.1. FATC CONTROL PANEL DETAILS 1893
25.12.2. CONTROLS 1895
25.12.3. VF DISPLAY (VACUUM FLUORESCENT DISPLAY) 1898
25.12.4. SOLAR LOAD SENSOR 1900
25.12.5. INCAR TEMPERATURE SENSOR WITH INTEGRATED ASPIRATOR 1901
25.12.6. OUTSIDE AIR TEMPERATURE SENSOR 1904
25.12.7. LPM (LINEAR POWER MODULE) 1905

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