Table of Contents 1 953

HARRIER SERVICE MANUAL PART -1

1. ENGINE 5
1. ENGINE INDEX 6
1. GENERAL INFORMATION 10
A. ENGINE INTRODUCTION 10
B. TECHNICAL SPECIFICATION 11
C. SPECIAL TOOLS 12
D. ASSEMBLY CLEARANCES 17
E. LEAKAGE RATES 18
F. RECOMMENDED LUBRICANTS & COOLANTS 18
G. SERVICE SCHEDULE 19
2. TROUBLESHOOTING 20
3. CONSTRUCTIONAL AND SERVICE DETAILS 28
4. ENGINE TESTS AND MAINTENANCE 31
A. PRELIMINARY INSPECTION 31
B. ENGINE TESTS 31
C. REGULAR MAINTENANCE 37
i. ENGINE OIL AND FILTER CHANGE 37
ii. ENGINE COOLANT REPLACEMENT 38
iii. AIR FILTER ELEMENT REPLACEMENT 39
iv. FUEL FILTER REPLACEMENT 40
v. DRAINING WATER FROM FUEL FILTER 41
vi. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT 41
vii. DIESEL PARTICULATE FILTER (DPF) REGENERATION / CLEANING 42
5. REPAIR AND INSPECTION DETAILS 43
A. TIMING BELT 43
B. FUEL TANK 44
C. CYLINDER HEAD 44
D. VALVES 45
E. CRANK CASE 46
F. HYDRAULIC LASH ADJUSTER 47
G. VALVE GUIDES 47
H. CAMSHAFT 48
I. PISTON AND PISTON RINGS 49
J. CONNECTING ROD 50
K. CRANK SHAFT 52
L. EXHAUST PIPE 56
6. ENGINE ON VEHICLE SERVICE 57
A. ENGINE REMOVAL 57
B. ENGINE INSTALLATION 66
C. EXHAUST SYSTEM 66
D. COOLING SYSTEM 74
E. FUEL SYSTEM 77
F. TURBOCHARGER REMOVAL AND REFITMENT 77
G. TIMING BELT REMOVAL AND REFITMENT 83
H. STARTER MOTOR REMOVAL AND REFITMENT 86
I. ALTERNATOR REMOVAL AND REFITMENT 87
J. COMPRESSOR REMOVAL AND REFITMENT 87
K. HIGH PRESSURE PUMP REMOVAL AND REFITMENT 88
7. ENGINE OVERHAULING 91
A. ENGINE DIS-ASSEMBLY 91
i. ON OVERHAUL STAND 91
ii. REMOVAL OF FUEL INJECTOR AND PERIPHERAL 94
iii. REMOVAL OF EXHAUST MANIFOLD AND OTHER COMPONENTS 95
iv. REMOVAL OF ENGINE PERIPHERALS 99
v. REMOVAL OF TIMING BELT 101
vi. REMOVAL OF INTAKE MANIFOLD 105
vii. REMOVAL OF CYLINDER HEAD 106
viii. REMOVAL OF OIL SUMP 108
ix. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 108
x. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 110
xi. REMOVAL OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 111
B. ENGINE ASSEMBLY 112
i. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 112
ii. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 113
iii. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 114
iv. FITMENT OF OIL SUMP 116
v. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 117
vi. FITMENT OF INTAKE MANIFOLD 120
vii. FITMENT OF TIMING BELT 121
viii. FITMENT OF ENGINE PERIPHERALS 125
ix. FITMENT OF EXHAUST MANIFOLD AND OTHER COMPONENTS 127
x. FITMENT OF FUEL INJECTOR AND PERIPHERALS 131
xi. ON SUPPORT STAND 133
2. TRANSAXLE 135
2. TRANSAXLE INDEX 137
1. TECHNICAL SPECIFICATION 138
2. PRECAUTIONS 138
3. COMMON PROBLEM CAUSES OR PRE-DIAGNOSTIC INSPECTION 139
4. TIGHTENING TORQUES 145
5. SPECIAL TOOLS 151
6. REMOVAL OF TRANSAXLE FROM VEHICLE 153
7. INSTALLATION OF TRANSAXLE ON VEHICLE 156
8. FLUID 160
9. TRANSAXLE DISASSEMBLY ON BENCH 161
10. TRANSAXLE ASSEMBLY ON BENCH 166
11. DIFFERENTIAL BEARING REMOVAL 173
12. DIFFERENTIAL BEARING ASSEMBLY 173
13. DISASSEMBLY GEARSHIFT CONTROL CABLE 174
14.ASSEMBLY GEARSHIFT CONTROL CABLE 176
15. REMOVAL GEARSHIFT MECHANISM 176
16.ASSEMBLY GEARSHIFT MECHANISM 178
17. ASSEMBLY DIFFERENTIAL OIL SEAL 178
18. INPUT SHAFT DISASSEMBLY 179
19. INPUT SHAFT ASSEMBLY 180
20. DISASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th) 182
21. ASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th) 185
22. DISASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.) 188
23. ASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.) 191
24. REMOVAL BACKUP (REVERSE) LAMP SWITCH 194
25. ASSEMBLY BACKUP (REVERSE) LAMP SWITCH 194
3. DRIVESHAFT 195
3. DRIVESHAFT INDEX 197
1.1. GENERAL INFORMATION 199
1.2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 200
1.3. DRIVE SHAFT PARTS 201
1.4. TIGHTENING OF TORQUES 202
1.5. SPECIAL TOOLS 204
1.6. ON BENCH PROCEDURE 205
1.7. ON VEHICLE PROCEDURE 207
A. DRIVE SHAFT LH 207
B. DRIVE SHAFT RH 211
4. CLUTCH RELEASE SYSTEM 215
4. CLUTCH RELEASE SYSTEM INDEX 217
1. CLUTCH SYSTEM LAYOUT 219
2. CLUTCH SYSTEM COMPONENTS 220
3. REGULAR MAINTENANCE 221
4. CLUTCH PEDAL ASSEMBLY 222
5. BRAKE PEDAL ASSEMBLY 223
6. REMOVAL OF ACCELERATOR PEDAL 224
7. REMOVAL OF CLUTCH CONTROL BRACKET 225
8. ASSEMBLY OF CLUTCH CONTROL BRACKET 227
9. BRAKE SWITCH INSTALLATION PROCEDURE 229
5. STEERING 230
5. STEERING INDEX 232
1.1 GENERAL INFORMATION 234
A. SPECIFICATIONS 234
B. SYSTEM LAYOUT 235
C. TIGHTENING OF TORQUES 236
D. SPECIAL TOOLS 239
1.2 GENERAL SYMPTOMS DIAGNOSIS 240
1.3 MAINTENANCE, INSPECTION AND TEST 247
A. PRELIMINARY INSPECTION 247
B. REGULAR MAINTENANCE 248
C. REPAIRS 253
1.4 OVERHAULING 262
A. PRECAUTIONS 262
B. RACK AND PINION ASSEMBLY 262
C. FEED PIPE 263
D. DO'S & DONT'S 263
E. STEERING PUMP 264
6. SUSPENSION 265
6. SUSPENSION INDEX 267
1. GENERAL INFORMATION 268
2. TECHNICAL SPECIFICATIONS 271
3. TIGHTENING TORQUES 272
4. SPECIAL TOOLS 276
5. DIAGNOSIS 280
6. PRECAUTIONS 281
7. EXPLODED VIEWS OF FRONT SUSPENSION 282
8. EXPLODED VIEWS OF REAR SUSPENSION 285
9. ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY 286
10. ON BENCH FRONT SUSPENSION DISASSEMBLY 289
11. ON BENCH FRONT SUSPENSION ASSEMBLY 291
12. REMOVAL AND ASSEMBLY OF WHEEL DISC 293
13. ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB 294
14. REMOVAL OF SUBFRAME ASSEMBLY 295
15. INSTALLATION OF SUBFRAME ASSEMBLY 296
16. LCA REAR HYDRA-BUSH INSTALLATION 297
17. REMOVAL OF ANTI ROLL BAR 298
18. REMOVAL AND ASSEMBLY OF REAR DAMPER ASSEMBLY AND COIL SPRINGS 299
19. ECIE CONDITION 299
20. INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS 300
21. REAR SUSPENSION DISMANTLING OR INSTALLATION PROCESS 301
22. RTB BUSH INSTALLATION 304
23. PAN HARD ROD BUSH INSTALLATION AND REMOVAL 305
7. WHEELS & TYRES 306
7. WHEELS & TYRES INDEX 308
1. GENERAL INFORMATION 310
A. SPECIFICATIONS - FOR XZ & XT VARIANTS 310
B. SPECIFICATIONS - FOR XM & XE VARIANTS 311
C. TIGHTENING OF TORQUES 312
2. GENERAL SYMPTOMS DIAGNOSIS 313
A. DIAGNOSIS CHART 313
B. TYRE WEAR PATTERN 315
C. WEAR CAUSES 316
D. TYRE VIBRATION DIAGNOSIS 317
3. MAINTENANCE, INSPECTION AND TEST 318
A. PRELIMINARY INSPECTION 318
B. REGULAR MAINTENANCE 319
4. WHEEL AND TYRE REPLACEMENT 322
A. PRECAUTIONS DURING TYRE REPLACEMENT 322
B. TYRE REPLACEMENT 323
C. WHEEL ASSEMBLY REPLACEMENT 323
D. WHEEL REMOVAL 323
E. BALANCING WHEELS 324
F. TYRE CARE 324
8. BRAKES 325
8. BRAKES INDEX 327
1. GENERAL INFORMATION 331
2. SPECIFICATOIN 331
3. SYSTEM DETAILS 332
A. SYSTEM SCHEMATIC FOR ABS & ESP VERSION 332
B. SYSTEM LAYOUT FOR ABS & ESP VERSION 333
4. TIGHTENING TORQUES 334
5. GENERAL SYMPTOMS DIAGNOSIS 339
6. NESSECITY OF ABS WITH EBD 341
7. VACUUM BRAKE BOOSTER 341
8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 343
A. BRAKING WITHOUT ABS IN OPERATION 343
B. BRAKING WITH EBD INTO OPERATION 343
9. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU/HCU) 346
10. WHEEL SPEED SENSOR: (MONITOR SPEED) 348
11. ABS SYSTEM FAILURE WARNING LIGHT 349
12. MAINTENANCE, INSPECTION AND TEST 350
13. REAR DRUM BRAKES 351
14. REMOVAL OF SHOES 354
15. WHEEL CYLINDER SERVICING 357
16. REGULAR MAINTENANCE 359
A. BRAKE BLEEDING PROCEDURE 359
B. ABS SECONDAY CIRCUIT BLEEDING PROCEDURE(USING DIAGNOSTIC TOOL) 360
C. CALIPER PAD REPLACEMENT 361
D. PARKING BRAKE ADJUSTMENT 363
E. BRAKE FLUID DRAINING PROCEDURE 364
F. BRAKE LIGHT SWITCH ADJUSTMENT 364
G. CALIPER GREASING 365
H. DISC RUN-OUT MEASUREMENT PROCEDURE 365
17. ON VEHICLE REPAIRS 366
A. CALIPER ASSEMBLY WITH CARRIER REMOVAL 366
B. BRAKE DISC REMOVAL 367
C. PARKING BRAKE 368
D. BRAKE PEDAL 372
E. VACUUM LINES 377
F. BOOSTER ASSEMBLY 378
18. DISMANTLING, INSPECTION AND ASSEMBLY 384
A. FRONT CALIPER ASSEMBLY 384
9. ABS 389
9. ABS INDEX 391
1. GENERAL INFORMATION 393
2. COMPONENTS LAYOUT 401
3. REPAIRS 408
4. TROUBLE SHOOTING AND DIAGNOSIS 413
10. ESP 416
10. ESP INDEX 418
1. ELECTRONIC STABILITY PROGRAM(ESP) 420
1.1 GENERAL INFORMATION 420
A. NECESSITY OF ESP AND TCS 420
B. SPECIFICATIONS 421
C. TIGHTENING OF TORQUES 422
D. SYSTEM LAYOUT 423
1.2 WORKING OF ESP 424
1.3 COMPONENTS 426
1.4 ON VEHICLE REPAIRS 431
1.5 TROUBLESHOOTING 432
11. HVAC 433
11. HVAC INDEX 435
1. HVAC SYSTEM LAYOUT 436
2. TECHNICAL SPECIFICATIONS 437
3. TIGHTENING OF TORQUES 441
4. PRECAUTIONS 445
5. HVAC SYSTEM LAYOUT AND WORKING 446
6. CONTROL PANEL 449
7. HVAC UNIT COMPONENTS 451
8. COMPRESSOR 453
9. CONDENSER 454
10. RECEIVER DRIER(R.D) 454
11. ON VEHICLE INSPECTION(WITHOUT DISMANTLING HVAC UNIT 455
12. TRINARY PRESSURE SWITCH 456
13. MODE & TEMPERATURE CONTROL ACTUATOR 457
14. INSPECTION OF MODE AND TEMPERATURE ACTUATOR 458
15. TROUBLESHOOTING 460
16. MAINTENANCE 470
17. ON VEHICLE REPAIRS 476
A. AC FILTER REMOVAL AND ASSEMBLY 476
B. COMPRESSOR REMOVAL AND ASSEMBLY 476
C. CONTROL PANEL REMOVAL AND ASSEMBLY 477
D. BLOWER MOTOR REMOVAL AND ASSEMBLY 478
E. FRONT HVAC UNIT REMOVAL AND ASSEMBLY 479
F. B-PILLAR VENT REMOVAL AND ASSEMBLY 480
G. HEATER HOSE REMOVAL AND ASSEMBLY 481
H. PRESSURE SWITCH REMOVAL AND ASSEMBLY 482
I. CONDENSER REMOVAL AND ASSEMBLY 483
J. CONDENSER SEALING DUCT REMOVAL AND ASSEMBLY 483
18. DO’S AND DONT’S FOR A/C SYSTEM 484
12. FATC 486
12. FATC INDEX 488
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM 489
2. TECHNICAL SPECIFICATIONS 491
3. TIGHTENING TORQUES 497
4. PRECAUTIONS 501
5. HMI CLIMATE CONTRL DISPLAY 502
6. CONTROL PANEL 503
7. CONTROL PANEL MODULE CONNECTOR DETAILS 508
8. FATC UNIT 510
9. FATC SENSOR & ACTUATOR 512
10. COMPRESSOR 518
11. CONDENSER AND RECEIVER DRIER 519
12. TROUBLESHOOTING 520
13. MAINTENANCE 531
14. ON VEHICLE REPAIR 539
A. AC FILTER REMOVAL AND ASSEMBLY 539
B. CONTROL PANEL REMOVAL AND ASSEMBLY 539
C. BLOWER MOTOR REMOVAL AND ASSEMBLY 540
D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY 542
E. B-PILLAR VENT REMOVAL AND ASSEMBLY 543
F. COMPRESSOR REMOVAL AND ASEMBLY 544
G. HEATER HOSE REMOVAL AND ASSEMBLY 545
H. PRESSURE SWITCH REMOVAL AND ASSEMBLY 546
I. CONDENSER REMOVAL AND ASSEMBLY 546
J. CONDENSER SEALING DUCT REMOVAL AND ASSEMBLY 547
15. DO’S AND DONT’S FOR A/C SYSTEM 548
13. BODY 549
13. BODY INDEX 555
1. GENERAL INFORMATION 559
1.1 LAYOUT 559
1.2 TIGHTENING TORQUES 560
1.3 SPECIAL TOOL 563
2. ON VEHICLE REPAIRS 564
2.1 BONNET 564
2.2 ARM REST 567
2.3 FLOOR CONSOLE 567
2.4 DASHBOARD SKIN 569
2.5 GLOVE BOX 577
2.6 SIDE AIR VENTS 577
2.7 FRONT BUMPER 579
2.8 REAR BUMPER 581
2.9 FRONT DOOR 583
2.10 FRONT DOOR TRIMS 585
2.11 DOOR INNER LOCK HANDLE 587
2.12 FRONT OUTER DOOR LOCK 588
2.13 FRONT DOOR LATCH 589
2.14 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 590
2.15 REAR DOOR 591
2.16 REAR DOOR TRIM 593
2.17 REAR OUTER DOOR LOCK 594
2.18 DOOR LATCH REAR 595
2.19 TAIL GATE 596
2.20 TAIL GATE TRIM 598
2.21 ORVM 599
2.22 INNER REAR VIEW MIRROR 600
2.23 FRONT ROW SEAT 600
2.24 REAR ROW SEAT 601
2.25 FRONT SEAT BELT 603
2.26 REAR SEAT BELT 605
2.27 “A” PILLAR TRIM 606
2.28 FRONT SCUFF PLATE 607
2.29 “B” PILLAR TRIMS 607
2.30 REAR SCUFF PLATE 608
2.31 REAR QUARTER TRIM 609
2.32 “C” PILLAR TRIMS 610
2.33 GRAB HANDLE 610
2.34 SUNVISOR 611
2.35 ROOF LINEAR 611
2.36 PLENUM COVER 612
2.37 GEAR LEVER BOOT 612
2.38 BONNET INSULATION 613
2.39 GLASS 614
2.40 FUEL FILLER ASSEMBLY 615
2.41 FRONT WHEEL ARCH LINER 616
2.42 REAR WHEEL ARCH LINER 617
2.43 FRONT FENDER 619
2.44 REAR WIPER MOTOR 620
2.45 FRONT WIPER 621
14. ELECTRICAL 622
14. ELECTRICAL INDEX 628
1. TECHNICAL SPECIFICATION 631
2. GENERAL PRECAUTIONS 634
3. FUSE BOX / RELAY LOCATIONS 638
4. BATTERY 639
5. ALTERNATOR 641
6. STARTER MOTOR 642
7. LIGHTING SYSTEM 649
7.1 BULB SPECIFICATIONS 649
7.2 FASTENERS TORQUE VALUE TABLE 650
7.3 GENERAL SYMPTOMS AND DIAGNOSTICS 651
7.4 HEAD LAMP 655
7.5 DRL Assembly 659
7.6 SIDE REPEATER LAMP (LH/RH) 660
7.7 ROOF LAMP 660
7.8 HIGH MOUNTED STOP LAMP 661
7.9 TAIL LAMP 662
7.10 REAR FOG LAMP (HIGH VERSION ONLY) 665
7.11 FRONT FOG LAMP 666
7.12 REGISTRATION PLATE LAMP 667
8. HORN 668
9 WIPER & WASHER SYSTEM 670
9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT 671
9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 672
9.3 WIPER AND WIPER CARE 678
10 POWER SOCKETS 681
11 GLOW PLUG CONTROL UNIT 682
12 FUEL GAUGE AND FUEL LEVEL METER 684
13 COMBI-SWITCH 687
14. STEERING LOCK CUM IGNITION SWITCH 693
15. FASCIA SWITCHES 696
16. MIRROR SWITCH 703
17. INFOTAINMENT SYSTEM 706
17.1 USB/AUX PORT 710
17.2 SPEAKERS 712
17.3 ANTENNA 714
17.4 MICROPHONE 715
17.5 SILVER BOX 717
17.6 TWEETERS 722
18. WINDOW WINDING MODULE 725
19. POWER WINDOW SWITCHES & INHIBIT SWITCH 728
20. STEERING WHEEL SWITCHES 734
21. DOOR HANDLE SWITCH 737
22. TAILGATE HANDLE SWITCH 738
23. IGNITION KEY 739
24. INSTRUMENT CLUSTER 746
24.1 BASIC FUNCTIONAL MATRIX 751
24.2 TELL TALES MATRIX 752
24.3 DRIVER INFORMATION SYSTEM 758
24.4 REMINDER FEATURES 773
24.5 FUEL GAUGE DETAILS 776
24.6 TEMPERATURE BAR GRAPH DETAILS 777
24.7 CHIME TABLE 778
25. IMMOBILIZER SYSTEM 781
25.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 785
25.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU 786
25.3 REMINDER FEATURES 788
25.4 FUEL GAUGE DETAILS 790
25.5 TEMPERATURE BAR GRAPH DETAILS 791
25.6 CHIME TABLE 792
25.7 DISPLAY SCREEN FLOW AND SETTINGS 792
26 IMMOBILIZER SYSTEM 799
26.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 804
26.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU 805
26.3 IGNITION KEY LEARNING PROCEDURE 808
27. BODY CONTROL MODULE (BCM) 811
27.1 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 818
27.2 BCM FUNCTIONS 829
28. FUSE AND RELAY BOX DETAILS 889
28.1 BATTERY MOUNTED FUSE BOX 892
28.2 ENGINE FUSE AND RELAY BOX 892
28.3 CABIN FUSE AND RELAY BOX 895
29. REVERSE PARK ASSIST SYSTEM 898
29.1 REAR VIEW CAMERA 902
30. PASSIVE ENTRY PASSIVE START (PEPS) 914
30.1 PEPS ECU 915
30.2 START STOP SWITCH 917
30.3 ELECTRONIC STEERING COLUMN LOCK (ESCL) 919
30.4 DOOR AND TAILGATE HANDLE SWITCHES WITH HARNESS 920
30.5 LF ANTENNAS 921
15. SRS 924
15. SRS INDEX 926
1.1. WORKING OF RESTRAINTS 928
1.2. SYSTEM LAYOUT 930
1.3. SAFETY PRECAUTIONS 931
1.4. DISPOSAL OF FAULTY AIR BAG UNIT 933
1.5. SRS POST ACCIDENT PROCEDURE 934
1.6. TIGHTENING TORQUES 935
1.7. COMPONENTS 939
1.7.1. RESTRAINT WITHOUT AIRBAGS 939
1.7.2. RESTRAINT WITH AIRBAGS 939
1.7.2.1. ECU 939
1.7.2.2. SENSORS 942
1.7.2.3. AIR BAGS 945
1.7.2.4. RPLL BELTS 949
1.7.2.5. CLOCK SPRING 951

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