|
TATA SAFARI - BSVI
|
1 |
|
KRYOTEC ENGINE
|
6 |
|
1. GENERAL INFORMATION
|
9 |
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A ENGINE INTRODUCTION
|
9 |
|
B TECHNICAL SPECIFICATION
|
10 |
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C ASSEMBLY CLEARANCES
|
11 |
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D LEAKAGE RATES
|
14 |
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E SPECIAL TOOLS
|
14 |
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F RECOMMENDED LUBRICANTS AND COOLANTS (REFER OWNER'S MANUAL)
|
7 |
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2 TROUBLESHOOTING
|
18 |
|
3 CONSTRUCTIONAL AND SERVICE DETAILS
|
26 |
|
4 EXPLODED VIEW
|
31 |
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5 ENGINE TESTS AND DIAGNOSIS
|
71 |
|
A ENGINE TESTS
|
71 |
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B REGULAR MAINTENANCE
|
75 |
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i ENGINE OIL AND FILTER CHANGE
|
75 |
|
ii ENGINE COOLANT REPLACEMENT
|
76 |
|
iii AIR FILTER ELEMENT REPLACEMENT
|
77 |
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iv FUEL FILTER REPLACEMENT
|
78 |
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v DRAINING WATER FROM FUEL FILTER
|
79 |
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vi AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT
|
80 |
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vii DPF REGENERATION / CLEANING
|
81 |
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viii HYDROSTATIC LOCKED ENGINE
|
81 |
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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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H EXHAUST PIPE
|
90 |
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7 ENGINE ON VEHICLE SERVICE
|
91 |
|
A ENGINE REMOVAL
|
91 |
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B ENGINE FITMENT
|
96 |
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C CYLINDER HEAD
|
98 |
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D CYLINDER HEAD COVER
|
103 |
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E BALANCE SHAFT
|
106 |
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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 |
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J DIESEL WARNING LIGHT
|
114 |
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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 |
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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 |
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D DISASSEMBLY AND REASSEMBLY FOLLOWING INSPECTION
|
154 |
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E CYLINDER HEAD AND OIL PAN FOR INSPECTION
|
169 |
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F CYLINDER HEAD
|
177 |
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G CAMSHAFT
|
181 |
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H PISTON
|
184 |
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C635 TRANSAXLE
|
186 |
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1 TECHNICAL SPECIFICATION
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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
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204 |
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7 ASSEMLY OF TRANSAXLE ON VEHICLE
|
207 |
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8 FLUID
|
211 |
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9 TRANSAXLE DISASSEMBLY ON BENCH
|
212 |
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10 TRANSAXLE ASSEMBLY ON BENCH
|
217 |
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11 DIFFERENTIAL BEARING REMOVAL
|
224 |
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12 DIFFERENTIAL BEARING ASSEMLY
|
224 |
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13 DISASSEMBLY GEARSHIFT CONTROL CABLE
|
225 |
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14 ASSEMBLY GEARSHIFT CONTROL CABLE
|
227 |
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15 REMOVAL GEARSHIFT MECHANISM
|
231 |
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16 ASSEMBLY GEARSHIFT MECHANISM
|
231 |
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17 ASSEMBLY DIFFERENTIAL OIL SEAL
|
233 |
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18 INPUT SHAFT DISASSEMBLY
|
234 |
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19 INPUT SHAFT ASSEMBLY
|
235 |
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20 DISASSEMBLY OF OUTPUT SHAFT1 (1, 2 ,5 AND 6)
|
237 |
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21 ASSEMBLY OF OUTPUT SHAFT1 (1, 2 ,5 AND 6)
|
239 |
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22 DISASSEMBLY OF OUTPUT SHAFT2 (3, 4 AND REV.)
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243 |
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23 ASSEMBLY OF OUTPUT SHAFT2 (3, 4 AND REV.)
|
245 |
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24 REMOVAL BACKUP (REVERSE) LAMP SWITCH
|
248 |
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25 ASSEMBLY BACKUP (REVERSE) LAMP SWITCH
|
249 |
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DRIVESHAFT
|
250 |
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1. GENERAL INFORMATION
|
252 |
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2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE
|
253 |
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3. DRIVESHAFT PARTS
|
254 |
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4. TIGHTENING TORQUES
|
255 |
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5. SPECIAL TOOL
|
257 |
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6. ON BENCH PROCEDURE
|
258 |
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A. TRIPOT JOINT DISASSEMBLY
|
258 |
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B. TRIPOT JOINT ASSEMBLY
|
259 |
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C. CV JOINT OUTER DISASSEMBLY
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259 |
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7. ON VEHICLE PROCEDURE
|
260 |
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A. LH DRIVE SHAFT
|
260 |
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B. RH DRIVE SHAFT
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264 |
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6F33 TRANSAXLE
|
268 |
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1 TECHNICAL SPECIFICATION
|
270 |
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2 TIGHTENING TORQUE
|
274 |
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3 SPECIAL TOOLS
|
276 |
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4 GENERAL INFORMATION
|
277 |
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5 COMPONENTS
|
278 |
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6 DETAIL OF A/T COMPONENTS
|
280 |
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7 EXPLODED VIEWS
|
285 |
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8 REMOVAL AND RE-FITMENT
|
287 |
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9 TOWING SERVICE
|
294 |
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10 AUTO TRANSAXLE FLUID CHECK AND CHANGE INTERVAL
|
295 |
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11 REMOVAL OF TRANSAXLE FROM VEHICLE
|
297 |
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12 ASSEMBLY OF TRANSAXLE ON VEHICLE
|
300 |
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13 REMOVAL OF GEAR SHIFTING CABLE ON VEHICLE
|
303 |
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14 ASSEMBLY GEARSHIFT CONTROL CABLE
|
306 |
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15 REMOVAL GEARSHIFT MECHANISM
|
309 |
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16 ASSEMBLY GEARSHIFT MECHANISM
|
311 |
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17 OIL COOLER HOSES REMOVAL
|
312 |
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18 OIL COOLER HOSES REFITMENT
|
313 |
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19 TCU (TRANSMISSION CONTROL UNIT)
|
314 |
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DRIVESHAFT (AT)
|
315 |
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1 GENERAL INFORMATION
|
317 |
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2 GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE
|
318 |
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3 DRIVE SHAFT PARTS
|
319 |
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4 TIGHTENING TORQUES
|
320 |
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5 SPECIAL TOOL
|
323 |
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6 ON BENCH PROCEDURE
|
324 |
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7 ON VEHICLE PROCEDURE
|
329 |
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CLUTCH
|
338 |
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1 GENERAL INFORMATION
|
340 |
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2 TECHNICAL SPECIFICATION
|
340 |
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3 LUBRICANT SPECIFICATION
|
340 |
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4 CLUTCH PRESSURE PLATE
|
341 |
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5 CLUTCH DISC ASSEMBLY
|
341 |
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6 EXPLODED VIEWS
|
342 |
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7 TIGHTENING TORQUES
|
343 |
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8 SPECIAL TOOLS
|
343 |
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9 GENERAL SYMPTOMS DIAGNOSIS
|
344 |
|
A. CLUTCH GRAB / CHATTER
|
344 |
|
B. CLUTCH SLIPS
|
344 |
|
C. CLUTCH PEDAL NOISE
|
345 |
|
10 ON VEHICLE PROCEDURE
|
346 |
|
A. SPECIAL TOOL ASSEMBLY
|
346 |
|
B. DISASSEMBLY PROCEDURE
|
346 |
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C. ASSEMBLY PROCEDURE
|
348 |
|
CLUTCH RELEASE SYSTEM
|
349 |
|
1 CLUTCH SYSTEM LAYOUT
|
351 |
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2 CLUTCH SYSTEM COMPONENTS
|
352 |
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3 REGULAR MAINTENANCE
|
353 |
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4 CLUTCH PEDAL ASSEMBLY
|
354 |
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5 BRAKE PEDAL ASSEMBLY
|
355 |
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6 REMOVAL OF ACCELERATOR PEDAL
|
356 |
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7 REMOVAL OF CLUTCH CONTROL BRACKET
|
357 |
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8 ASSEMBLY OF CLUTCH CONTROL BRACKET
|
359 |
|
9 BRAKE SWITCH INSTALLTION PROCEDURE
|
361 |
|
STEERING
|
362 |
|
1 GENERAL INFORMATION
|
364 |
|
A SPECIFICATIONS
|
364 |
|
B SYSTEM LAYOUT
|
365 |
|
C TIGHTENING TORQUE
|
366 |
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D SPECIAL TOOLS
|
369 |
|
2 GENERAL SYMPTOMS DIAGNOSIS
|
370 |
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3 MAINTENANCE, INSPECTION AND TEST
|
377 |
|
A PRELIMINARY INSPECTION
|
377 |
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B REGULAR MAINTENANCE
|
378 |
|
C REPAIRS
|
383 |
|
4 OVERHAULING
|
392 |
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A PRECAUTIONS
|
392 |
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B RACK AND PINION ASSEMBLY
|
392 |
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C FEED PIPE
|
393 |
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D DO’S & DON’TS
|
393 |
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E STEERING PUMP
|
394 |
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SUSPENSION
|
395 |
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1 GENERAL INFORMATION
|
397 |
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2 TECHNICAL SPECIFICATIONS
|
400 |
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3 TIGHTENING TORQUE
|
401 |
|
4 SPECIAL TOOLS
|
406 |
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5 DIAGNOSIS
|
409 |
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6 PRECAUTIONS
|
410 |
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7 EXPLODED VIEWS OF FRONT SUSPENSION
|
411 |
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8 EXPLODED VIEWS REAR SUSPENSION
|
414 |
|
9 ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY
|
415 |
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10 ON BENCH FRONT STRUT DISASSEMBLY
|
418 |
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11 ON BENCH FRONT STRUT ASSEMBLY
|
419 |
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12 REMOVAL AND ASSEMBLY OF WHEEL DISC
|
421 |
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13 ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB
|
422 |
|
14 REMOVAL OF SUBFRAME ASSEMBLY
|
423 |
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15 INSTALLATION OF SUBFRAME ASSEMBLY
|
425 |
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16 LCA REAR HYDRA-BUSH INSTALLATION
|
426 |
|
17 REMOVAL OF ANTI ROLL BAR
|
426 |
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18 REMOVAL AND ASSEMBLY OF REAR DAMPER ASSEMBLY AND COIL SPRINGS
|
427 |
|
19 ECIE / PRELOAD CONDITION
|
428 |
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20 INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS
|
429 |
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21 REAR SUSPENSION DISMANTLING OR INSTALLATION
|
430 |
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22 RTB BUSH INSTALLATION
|
432 |
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23 PAN HARD ROD BUSH INSTALLATION AND REMOVAL
|
433 |
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24 INSTALLATION AND REMOVAL OF DAMPER BOTTOM BUSH
|
434 |
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25 SUSPENSION ECIE / PRE-LOADING CONDITION
|
435 |
|
WHEELS AND TYRES
|
436 |
|
1 GENERAL INFORMATION
|
438 |
|
A. SPECIFICATIONS FOR XZ & XT VARIANTS
|
438 |
|
B. SPECIFICATIONS FOR XM & XE VARIANTS
|
439 |
|
C. TIGHTENING TORQUES
|
440 |
|
2 GENERAL SYMPTOMS DIAGNOSIS
|
441 |
|
A. DIAGNOSIS CHART
|
441 |
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B. TYRE WEAR PATTERN
|
443 |
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C. WEAR CAUSES
|
444 |
|
D. TYRE VIBRATION DIAGNOSIS
|
445 |
|
3 MAINTENANCE, INSPECTION AND TESTS
|
446 |
|
A. PRELIMINARY INSPECTION
|
446 |
|
B. REGULAR MAINTENANCE
|
447 |
|
I.INFLATION
|
447 |
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II. WHEEL BALANCING
|
447 |
|
III. TYRE ROTATION
|
448 |
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IV.WHEEL RUN OUT
|
449 |
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V. DO'S AND DON’TS
|
449 |
|
4 WHEEL AND TYRE REPLACEMENT
|
450 |
|
A. PRECAUTIONS DURING TYRE REPLACEMENT
|
450 |
|
B. TYRE REPLACEMENT
|
451 |
|
C. WHEEL ASSEMBLY REPLACEMENT
|
451 |
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D. WHEEL REMOVAL
|
451 |
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E. BALANCING WHEELS
|
452 |
|
F. TYRE CARE
|
452 |
|
BRAKE DISC-DISC(Non EPB)
|
453 |
|
1 TECHNICAL SPECIFICATION
|
456 |
|
2 SYSTEM DETAILS
|
457 |
|
3 TIGHTENING TORQUE
|
459 |
|
4 GENERAL SYMPTOMS DIAGNOSIS
|
464 |
|
5 NECESSITY OF ABS WITH EBD
|
466 |
|
6 VACCUM BRAKE BOOSTER
|
466 |
|
7 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS
|
468 |
|
8 ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULLIC CONTROL UNIT (ECU\HCU
|
471 |
|
9 WHEEL SPEED SENSOR (MONITORS WHEEL SPEED)
|
473 |
|
10 ABS SYSTEM FAILURE WARNING LIGHT
|
474 |
|
11 MAINTAINANCE, INSPECTION AND TEST
|
475 |
|
12 REGULAR MAINTENANCE
|
476 |
|
A BRAKE BLEEDING PROCEDURE
|
476 |
|
B ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL
|
477 |
|
C CALIPER PAD REPLACEMENT.
|
478 |
|
D PARKING BRAKE ADJUSTMENT
|
479 |
|
E BRAKE FLUID DRAINING PROCEDURE
|
480 |
|
F BRAKE LIGHT SWITCH ADJUSTMENT
|
480 |
|
G CALIPER GREASING
|
480 |
|
H DISC RUN-OUT MEASUREMENT PROCEDURE
|
481 |
|
13 ON VEHICLE REPAIRS
|
482 |
|
A FRONT CALIPER ASSEMBLYWITH CARRIER
|
482 |
|
B BRAKE CALIPER ASSEMBLY DISMANTALING
|
482 |
|
C FRONT AND REAR DISC REMOVAL
|
484 |
|
D REAR CALIPER ASSEMBLYWITH CARRIER
|
485 |
|
E PARKING BRAKE
|
487 |
|
F PARKING BRAKE CABLE REMOVAL
|
488 |
|
G HAND BRAKE LEVER REMOVAL
|
489 |
|
H VACCUM LINES
|
490 |
|
I BOOSTER ASSEMBLY
|
491 |
|
J TANDEM MASTER CYLINDER (TMC) & BOOSTER ASSEMBLY
|
493 |
|
K BOOSTER NRV
|
494 |
|
L BOOSTER ASSEMBLY
|
494 |
|
14 DISMANTLING, INSPECTION AND ASSEMBLY
|
496 |
|
A FRONT CALIPER ASSEMBLY
|
496 |
|
B REAR CALIPER ASSEMBLY
|
497 |
|
BRAKE DISC-DISC(EPB)
|
499 |
|
1 TECHNICAL SPECIFICATION
|
501 |
|
2 SYSTEM DETAILS
|
502 |
|
3 TIGHTENING TORQUE
|
504 |
|
4 GENERAL SYMPTOMS DIAGNOSIS
|
508 |
|
5 NECESSITY OF ABS WITH EBD
|
510 |
|
6 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS
|
512 |
|
7 ABS 9ELECTRONIC CONTROL UNIT / HYDRAULLIC CONTROL UNIT (ECU/HCU)
|
515 |
|
8 WHEEL SPEED SENSOR (MONITORS WHEEL SPEED)
|
517 |
|
9 ABS SYSTEM FAILURE WARNING LIGHT
|
518 |
|
10 MAINTAINANCE, INSPECTION AND TEST
|
519 |
|
11 REGULAR MAINTENANCE
|
520 |
|
A BRAKE BLEEDING PROCEDURE
|
520 |
|
B ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL)
|
521 |
|
C FRONT BRAKE CALIPER PAD REPLACEMENT
|
522 |
|
D BRAKE FLUID DRAINING PROCEDURE
|
523 |
|
E BRAKE LIGHT SWITCH ADJUSTMENT
|
523 |
|
F CALIPER GREASING
|
523 |
|
G DISC RUN-OUT MEASUREMENT PROCEDURE
|
524 |
|
12 ON VEHICLE REPAIRS
|
525 |
|
A FRONT CALIPER ASSEMBLYWITH CARRIER
|
525 |
|
B BRAKE CALIPER ASSEMBLY DISMANTLING
|
525 |
|
C FRONT AND REAR BRAKE DISC REMOVAL
|
528 |
|
D REAR CALIPER ASSEMBLYWITH CARRIER
|
528 |
|
E REAR BRAKE CALIPER PAD REPLACEMENT FOR EPB CALIPER
|
529 |
|
F C667 CALIPER RECEPTACLE HOUSINGWITH CPA
|
531 |
|
G VACCUM LINES
|
532 |
|
H BOOSTER ASSEMBLY
|
533 |
|
I TANDEM MASTER CYLINDER & BOOSTER ASSY
|
535 |
|
J BOOSTER NRV
|
536 |
|
K BOOSTER ASSEMBLY
|
536 |
|
13 DISMANTLING, INSPECTION AND ASSEMBLY
|
538 |
|
A FRONT CALIPER ASSEMBLY
|
538 |
|
B REAR CALIPER ASSEMBLY
|
539 |
|
HVAC
|
542 |
|
1 HVAC SYSTEM LAYOUT
|
544 |
|
2 SPECIFICATIONS HVAC UNIT
|
545 |
|
3 SPECIAL TOOLS
|
554 |
|
4 TIGHTENING TORQUES
|
555 |
|
5 PRECAUTIONS
|
559 |
|
6 HVAC SYSTEM LAYOUT AND WORKING
|
560 |
|
7 CONTROL PANEL
|
563 |
|
8 FRONT HVAC UNIT
|
565 |
|
9 COMPRESSOR
|
567 |
|
10 CONDENSER
|
568 |
|
11 RECEIVER DRIER (R.D)
|
568 |
|
12 EVAPORATER SENSOR POSITION
|
568 |
|
13 TRINARY PRESSURE SWITCH
|
569 |
|
14 MODE & TEMPRATURE CONTROL ACTUATOR
|
570 |
|
15 INSPECTION OF MODE AND TEMPERATURE ACTUATOR
|
572 |
|
16 TROUBLESHOOTING
|
574 |
|
17 MAINTENANCE
|
584 |
|
18 ON VEHICLE REPAIRS
|
590 |
|
19 DO'S AND DON’T'S FOR A/C SYSTEM
|
601 |
|
FATC
|
602 |
|
1 FATC (FULLY AUTOMATIC TEMPERATURE CONTROL)
|
605 |
|
2 TECHNICAL SPECIFICATIONS
|
606 |
|
3 SPECIAL TOOLS
|
617 |
|
4 TIGHTENING TORQUE
|
618 |
|
5 HMI CLIMATE CONTROL DISPLAY
|
623 |
|
6 CONTROL PANEL
|
624 |
|
7 CONTROL PANEL MODULE CONNECTOR DETAILS
|
629 |
|
8 FATC UNIT
|
631 |
|
A BLOWER
|
631 |
|
B APORATOR COIL AND TXV (THERMAL EX-PANSION VALVE)
|
631 |
|
C HEATER COIL
|
632 |
|
9 FATC SENSOR & ACTUATOR
|
633 |
|
A EVAPORATER SENSOR
|
633 |
|
B TRINARY PRESSURE SWITCH
|
634 |
|
C SOLAR LOAD SENSOR
|
635 |
|
D OAT SENSOR
|
636 |
|
E INCAR SENSOR
|
637 |
|
F MODE ACTUATOR
|
637 |
|
G TEMPERATURE ACTUATOR
|
638 |
|
H MODE ACTUATOR (B-PILLAR SIDE)
|
638 |
|
I BLOWER CONTROL MODULE
|
638 |
|
10 COMPRESSOR
|
639 |
|
11 CONDENSER AND RECEIVER DRIER CONDENSER
|
640 |
|
12 RECEIVER DRIER (R.D)
|
640 |
|
13 TROUBLESHOOTING
|
641 |
|
14 MAINTENANCE
|
651 |
|
A PRELIMINARY INSPECTION
|
651 |
|
B REGULAR MAINTENANCE
|
653 |
|
15 ON VEHICLE REPAIR
|
657 |
|
A AC FILTER REMOVAL
|
657 |
|
B CONTROL PANEL REMOVAL
|
657 |
|
C BLOWER MOTOR REMOVAL
|
658 |
|
D FRONT HVAC UNIT REMOVAL
|
660 |
|
E B-PILLAR VENT
|
661 |
|
F COMPRESSOR
|
662 |
|
G HEATER HOSE
|
663 |
|
H PRESSURE SWITCH
|
664 |
|
I CONDENSER
|
665 |
|
J CONDENSER SEALING DUCT REMOVAL
|
666 |
|
K REAR AC DUCT
|
666 |
|
L REAR AC UNIT
|
667 |
|
16 DO’S AND DONT’S FOR A/C SYSTEM
|
669 |
|
BODY
|
670 |
|
1 GENERAL INFORMATION
|
674 |
|
1.1 LAYOUT
|
674 |
|
1.2 TIGHTENING TORQUES
|
675 |
|
1.3 SPECIAL TOOL
|
678 |
|
2 ON VEHICLE REPAIRS
|
679 |
|
2.1 BONNET
|
679 |
|
2.2 ARM REST
|
681 |
|
2.3 FLOOR CONSOLE
|
682 |
|
2.4 DASHBOARD SKIN
|
683 |
|
2.5 GLOVE BOX
|
691 |
|
2.6 SIDE AIR VENTS
|
692 |
|
2.7 FRONT BUMPER
|
693 |
|
2.8 REAR BUMPER
|
696 |
|
2.9 FRONT DOOR
|
698 |
|
2.10 FRONT DOOR TRIMS
|
699 |
|
2.11 DOOR INNER LOCK HANDLE
|
701 |
|
2.12 FRONT OUTER DOOR LOCK
|
702 |
|
2.13 FRONT DOOR LATCH
|
703 |
|
2.14 FRONT DOOR GLASS ANDWINDOWWINDINGMECHANISM
|
704 |
|
2.15 REAR DOOR
|
705 |
|
2.16 REAR DOOR TRIMS
|
707 |
|
2.17 REAR OUTER DOOR LOCK
|
708 |
|
2.18 DOOR LATCH REAR
|
709 |
|
2.19 TAIL GATE
|
710 |
|
2.20 TAILGATE TRIM
|
712 |
|
2.21 ORVM
|
713 |
|
2.22 INNER REAR VIEW MIRROR
|
714 |
|
2.23 FRONT ROW SEAT
|
715 |
|
2.24 REAR ROW SEAT
|
716 |
|
2.25 REAR ROW CAPTAIN SEAT (IF APPLICABLE)
|
717 |
|
2.26 THIRD ROW SEAT
|
718 |
|
2.27 “A” PILLAR TRIM
|
719 |
|
2.28 FRONT SCUFF PLATE
|
720 |
|
2.29 “B” PILLAR TRIM
|
720 |
|
2.30 REAR SCUFF PLATE
|
721 |
|
2.31 REAR QUARTER TRIM
|
722 |
|
2.32 “C” PILLAR TRIMS
|
723 |
|
2.33 “D” PILLAR TRIMS
|
724 |
|
2.34 GRAB HANDLE
|
725 |
|
2.35 SUNVISOR
|
725 |
|
2.36 ROOF CONSOLE BEZEL
|
726 |
|
2.37 ROOF LINEAR
|
726 |
|
2.38 ROOF RAIL
|
727 |
|
2.39 PLENUM COVER
|
728 |
|
2.40 GEAR LEVER BOOT
|
728 |
|
2.41 BONNET INSULATION
|
729 |
|
2.42 GLASS
|
730 |
|
2.43 FUEL FILLER ASSEMBLY
|
731 |
|
2.44 FRONTWHEEL ARCH LINER
|
732 |
|
2.45 REARWHEEL ARCH LINER
|
733 |
|
2.46 FRONT FENDER
|
735 |
|
2.47 REARWIPER MOTOR
|
736 |
|
2.48 FRONTWIPER
|
737 |
|
2.49 SUNROOF
|
738 |
|
2.50 WIND DEFLECTOR
|
739 |
|
2.51 FRONT GLASS PANEL (MOVING PANEL)
|
740 |
|
2.52 REAR GLASS PANEL (FIXED PANEL)
|
741 |
|
2.53 SUNSHADE ROLLO ASSEMBLY (SUN BLIND)
|
742 |
|
2.54 MECHANISM ELECTRIC DRIVE ASSEMBLY
|
743 |
|
2.55 ROLLO ELECTRIC DRIVE ASSEMBLY
|
743 |
|
2.56 MECHANISM MAINTENANCE
|
744 |
|
2.57 WATER CHANNEL MAINTENANCE
|
747 |
|
2.58 SUNROOF RESET PROCEDURE - INITIALIZING THE POWER SUNROOF
|
747 |
|
2.59 SUNROOF RESET PROCEDURE - SELFLEARNING THE POWER SUNROOF
|
748 |
|
ELECTRICAL
|
749 |
|
1 TECHNICAL SPECIFICATIONS
|
753 |
|
2 GENERAL PRECAUTIONS
|
756 |
|
3 FUSE BOX / RELAY LOCATIONS
|
762 |
|
4 BATTERY
|
763 |
|
5 ALTERNATOR
|
765 |
|
6 STARTER MOTOR
|
766 |
|
7 LIGHTING SYSTEM
|
771 |
|
A.BULB SPECIFICATION
|
771 |
|
B. TORQUE VALUE TABLE
|
771 |
|
C. GENERAL SYMPTOMS AND DIAGNOSTICS FOR ALL LAMPS
|
772 |
|
D. HEAD LAMP
|
776 |
|
E. DRL ASSEMBLY
|
780 |
|
F. SIDE REPEATER LAMP (LH/RH)
|
781 |
|
G. ROOF LAMP
|
781 |
|
H. HIGH MOUNTED STOP LAMP
|
784 |
|
I. TAIL LAMP
|
785 |
|
J. REAR FOG LAMP
|
787 |
|
K. FRONT FOG LAMP
|
788 |
|
L. REGISTRATION PLATE LAMP
|
789 |
|
8 HORN
|
790 |
|
9 WIPER & WASHER SYSTEM
|
792 |
|
A. FRONT WIPER AND WAHSER SYSTEM LAYOUT
|
792 |
|
B. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY
|
793 |
|
C. WIPER AND WIPER CARE
|
796 |
|
10 POWER SOCKETS
|
798 |
|
11 GLOW PLUG CONTROL UNIT
|
799 |
|
12 FUEL GAUGE AND FUEL LEVEL METER
|
801 |
|
13 COMBI-SWITCH
|
803 |
|
14 STEERING LOCK CUM IGNITION SWITCH
|
809 |
|
15 FASCIA SWITCHES
|
812 |
|
16 MIRROR SWITCH
|
818 |
|
17 INFOTAINMENT SYSTEM
|
821 |
|
A.USB/AUX PORT
|
824 |
|
B.SPEAKERS
|
825 |
|
C.ANTENNA
|
828 |
|
D.MICROPHONE
|
829 |
|
E.SILVER BOX
|
830 |
|
F.TWEETERS
|
834 |
|
G.AMPLIFIER
|
836 |
|
18 WINDOW WINDING MODULE.
|
837 |
|
19 POWERWINDOW SWITCHES & INHIBIT SWITCH
|
840 |
|
20 STEERINGWHEEL SWITCHES
|
844 |
|
21 DOOR HANDLE SWITCH
|
847 |
|
22 TAILGATE HANDLE SWITCH
|
848 |
|
23 IGNITION KEY
|
849 |
|
24 INSTRUMENT CLUSTER
|
855 |
|
A. BASIC FUNCTIONAL MATRIX
|
859 |
|
B. TELL TALES MATRIX
|
860 |
|
C. REMINDER FEATURES
|
868 |
|
D. DRIVER INFORMATION SYSTEM
|
869 |
|
E. FUEL GAUGE DETAILS
|
891 |
|
F. TEMPERATURE BAR GRAPH DETAILS
|
892 |
|
G. CHIME TABLE
|
893 |
|
25 IMMOBILIZER SYSTEM
|
895 |
|
A. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB
|
899 |
|
B. IMMOBILIZER SYSTEM STATUS IN EMS ECU
|
900 |
|
C. IGNITION KEY LEARNING PROCEDURE
|
902 |
|
D. CHECKING PAIRING STATUS
|
903 |
|
26 BODY CONTROL MODULE (BCM)
|
905 |
|
A. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX
|
912 |
|
B. BCM FEATURES
|
918 |
|
C. BCM REPLACEMENT STRATEGY
|
920 |
|
D. BCM FUNCTIONS
|
922 |
|
27 RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE)
|
923 |
|
28 FUSE AND RELAY BOX DETAILS
|
928 |
|
A. BATTERY MOUNTED FUSE BOX
|
931 |
|
B. ENGINE FUSE AND RELAY BOX
|
931 |
|
C. CABIN FUSE AND RELAY BOX
|
934 |
|
29 REVERSE PARK ASSIST SYSTEM
|
937 |
|
30 PASSIVE ENTRY PASSIVE START (PEPS)
|
947 |
|
A. PEPS ECU
|
948 |
|
B. START STOP SWITCH
|
950 |
|
C. ELECTRONIC STEERING COLUMN LOCK (ESCL)
|
951 |
|
D. DOOR AND TAILGATE HANDLE
|
953 |
|
E. LF ANTENNAS
|
954 |
|
31 TELEMATICS
|
956 |
|
SUPPLEMENTARY RESTRAINTSYSTEM (SRS)
|
959 |
|
1 WORKING OF RESTRAINTS
|
961 |
|
2 SYSTEM LAYOUT
|
963 |
|
3 SAFETY PRECAUTIONS
|
964 |
|
4 DISPOSAL OF FAULTY AIR BAG UNIT
|
966 |
|
5 SRS POST ACCIDENT PROCEDURE
|
967 |
|
6 TIGHTENING TORQUES
|
968 |
|
7 COMPONENTS
|
973 |
|
1 RESTRAINTWITHOUT AIRBAGS
|
973 |
|
2 RESTRAINTWITH AIRBAGS
|
973 |
|
8 FRONT SEAT BELT
|
984 |
|
9 SECOND ROW SEAT BELT
|
985 |
|
10 THIRD ROW SEAT BELT
|
986 |
|
11 CLOCK SPRING
|
987 |
|
TIRE PRESSURE MONITORING SYSTEM (TPMS)
|
990 |
|
1. INTRODUCTION
|
992 |
|
2. SYSTEM WORKING
|
993 |
|
3. SYSTEM LAYOUT
|
993 |
|
4. COMPONENTS
|
994 |
|
A. TPMS ECU
|
994 |
|
B. TIRE PRESSURE SENSOR
|
994 |
|
5. ON VEHICLE PROCEDURES
|
995 |
|
A. TPMS ECU REPLACEMENT PROCEDURE
|
995 |
|
B. ECU REPLACEMENT PROCEDURE PREREQUISITE
|
995 |
|
C. TPMS ECU LEARNING PROCEDURE
|
997 |
|
D. TPMS SENSOR REPLACEMENT PROCEDURE USING LF TOOL
|
999 |
|
6. TIRE REPLACEMENT
|
1000 |
|
7. MOUNTING OF THE TIRE
|
1001 |