Table of Contents 1 1232

ZEST BOLT Service Manual

1. GENERAL 8
1.1 GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS 10
1.2 PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE 12
1.3 PRECAUTIONS OF COMMON RAILSYSTEM (CR SYSTEM) 13
1.4 LIFTING, JACKING, TOWING POINTSUSING THE TWO POST LIFT 15
1.5 JACK AND TOOL BAG LOCATION IN VEHICLE 16
1.6 NUMBERING SYSTEM 17
1.6.1 CHASSIS NUMBERING SYSTEM 17
1.6.2 AGGREGATE NUMBERING SYSTEM 18
1.7 LOCATION OF CHASSIS AND AGGREGATE NUMBERS 21
1.8 CHASSIS TYPE AND SALES DESIGNATIONS 22
1.9 TECHNICAL SPECIFICATION FOR BOLT 23
1.10. TECHNICAL SPECIFICATION FOR ZEST 26
1.11 A VEHICLE DIMENSIONS 29
1.11 B VEHICLE DIMENSIONS 30
1.12 RECOMMENDED LUBRICANTS & COOLANTS 31
FOR BOLT AND ZEST (QUADRAJET) 31
FOR BOLT AND ZEST (REVOTRON) 32
FUEL, LUBRICANTS AND COOLANTS 33
1.13 SERVICE AND MAINTENANCE (BOLT / ZEST) 34
2. ENGINE (REVOTRON 1.2T) 38
2.1 GENERAL INFORMATION 48
A. ENGINE INTRODUCTION 48
B. Electronic Fuel Injection Control 49
C. TECHNICAL SPECIFICATION 50
D. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 51
E. SERVICE SCHEDULE 52
F. TIGHTENING TORQUE SPECIFICATIONS 53
G. SPECIAL TOOLS 56
2.2 TROUBLESHOOTING 58
2.3 CONSTRUCTIONAL AND SERVICE DETAILS 66
A. Intake Manifold 66
B. Cylinder Head and Cover 67
C. Cylinder Head 69
D. Cylinder Block 71
E. Moving Parts 73
F. Engine Timing 75
G. Exhaust Manifold 77
H. Fuel Injection Equipment 79
I. Lubrication Pump and Components 81
J. Engine Suspension 83
K. Air Intake System 85
L. Special Installation 88
2.4 ENGINE TESTS AND MAINTENANCE 90
A. PRELIMINARY INSPECTION 90
B. Engine Tests 92
i. Engine Compression Test 92
ii. Engine Oil Consumption Test 93
iii. Engine Oil Pressure Test 94
C. REGULAR MAINTENANCE 95
i. Engine Oil and Filter Change 95
ii. Engine Coolant Replacement 96
iii. Air Filter Element Replacement 98
iv. Spark Plug Replacement 99
v. Fuel Filter Replacement 101
vi. Air Conditioner Compressor BeltReplacement 102
vii. Alternator Belt Replacement 103
2.5 REPAIR AND INSPECTION DETAILS 106
A. Timing Belt 106
B. Cylinder Head 106
C. Valves 107
D. Cylinder Head Valve Seats 109
E. Rocker Arms and Shafts 109
F. Cylinder Head Valve Guides 110
G. Camshaft 111
H. Piston and Piston Rings 112
I. Connecting Rods 113
J. Crankshaft 115
K. Fuel Tank 117
2.6 ENGINE SYSTEM 120
A. AIR INTAKE SYSTEM 120
B. BLOW BY SYSTEM 123
C. LUBRICATION SYSTEM 124
D. EXHAUST SYSTEM 127
E. COOLING SYSTEM 129
2.7 ENGINE ON VEHICLE SERVICE PROCEDURE 134
A. Engine Removal 134
B. Engine Installation 137
2.8 ENGINE OVERHAULING: (ON OVERHAUL STAND) 140
A. Engine Dis-assembly 140
i. Removal of Intake Manifold 140
ii. Removal of Exhaust Manifold 143
iii. Removal of Oil Sump 147
iv. Removal of Sensors 147
v. Removal of Timing Belt 148
vi. Removal of Cylinder Head 151
vii. Removal of Cylinder Head Sub-Assemblies 152
viii. Removal of Cylinder Block Sub-Assemblies 154
B. Engine Assembly 158
i. Fitment of Cylinder Head Sub-Assemblies 158
ii. Fitment of Piston and Connecting rod Sub-Assemblies 160
iii. Fitment of Cylinder Block Sub-Assemblies 161
iv. Fitment of Cylinder Head on CylinderBlock 164
v. Fitment of Oil Sump 170
vi. Fitment of Engine Sensors andPeripherals 171
vii. Fitment of Exhaust Manifold andPeripherals 174
viii. Fitment of Intake Manifold and Peripherals 176
2.9 ENGINE MANAGEMENT SYSTEM 180
A. ABBREVIATIONS 182
B. AN OVERVIEW 183
C. ELECTRONIC CONTROL UNIT (ECU) 184
D. SENSORS 190
i. Manifold Air Pressure Sensor andTemperature Sensor 191
ii. Lambda Sensor 193
iii. Camshaft Position Sensor 195
iv. Knock Sensor 196
v. Crankshaft Position Sensor 197
vi. Coolant Temperature Sensor 199
vii. Boost Pressure Sensor 200
E. ACTUATORS 203
i. Ignition Coil 204
ii. WG PWM actuator 205
iii. Dump Valve 207
iv. Purge Control Valve 208
v. Fuel Injectors 210
vi. Electronic Throttle Body 211
F. SWITCH 213
i. Oil Pressure Switch 213
DIAGNOSIS TROUBLESHOOTING CODES 216
LIST OF DIAGNOSTIC TROUBLESHOOTING CODES 218
3A. ENGINE (QUADRAJET 75PS) 224
3A.1.1.GENERAL INFORMATION 229
3A.1.1.1 TECHNICALSPECIFICATIONS 229
3A.1.1.2 TIGHTENING TORQUES 230
3A.1.1.3 SPECIAL TOOLS 232
3A.1.1.4 MAINTENANCE , INSPECTION ANDTESTS 237
A. ENGINE OIL REPLACEMENT 237
B. ENGINE OIL FILTER CARTRIDGEREPLACEMENT. 238
C. AIR FILTER INSPECTION AND CLEANING 239
D. AIR FILTER ASSY – REMOVAL 240
E. FUEL FILTER – REPLACE 240
3A.1.2 ENGINE – MECHANICAL 242
3A.1.2.1 REMOVAL OF ENGINE FROMVEHICLE 242
CYLINDER HEAD ASSEMBLY 246
3A.1.2.2.1 EXPLODED VIEW 246
3A.1.2.2.2 REMOVAL OF CYLINDER HEADASSEMBLY AND OIL SUMP 246
3A.1.2.2.3 CYLINDER HEAD – OVERHAUL 254
3A.1.2.2.4 VALVE AND VALVE SPRING 257
A. EXPLODED VIEW 257
B. REMOVAL AND OVERHAUL 258
C. INSTALLATION 260
3A.1.2.2.5 CYLINDER HEAD BLOCK 261
A. HEAD GASKET CORRECTION BASED ONCYLINDER HEAD BLOCK PLANARITY. 261
B. CAMSHAFT HOUSING INSPECTION ANDMEASUREMENT 262
C. CYLIDER HEAD BLOCK ASSEMBLY -REFITTING 262
3A.1.2.2.6 SELECTION OF CYLINDER HEADGASKET 264
3A.1.2.2.7 INSTALLATION OF CYLINDER HEADASSEMBLY AND OIL SUMP 265
3A.1.2.3 ENGINE BLOCK 388
3A.1.2.3.1 DISMANTLING 388
3A.1.2.3.2 PISTON - REMOVAL & FITMENT 392
3A.1.2.3.3 ENGINE OIL PUMP - REMOVALAND FITMENT 392
3A.1.2.3.4 ENGINE BLOCK -MEASUREMENT, INSPECTION & GRADEDETERMINATION 395
3A.1.2.3.5 ENGINE BLOCK – ASSEMBLY 401
3A.1.3. ENGINE COOLING 404
A. SYSTEM DESCRIPTION 404
B. COMPONENTS 405
3A.1.4. LUBRICATING SYSTEM 406
A. COMPONENTS 406
B. CONSTRUCTION AND WORKING 406
3A.1.5 FUEL SUPPLY SYSTEM 288
3A.1.5.1 INTRODUCTION 288
3A.1.5.2 COMPONENTS 289
3A.1.5.2.1 VACUUM PUMP 289
3A.1.5.2.2 INJECTORS 289
A. IMA CLASSIFICATION 290
3A.1.5.2.3 SINGLE FUEL MANIFOLD PIPE 291
3A.1.5.2.4 FUEL FEED SYSTEM 292
A. FUEL TANK 294
B. INTANK FUEL PUMP 298
C. FUEL LEVEL SENSOR 299
E. FUEL LEVEL WARNING LIGHT 306
F. FUEL FILTER 306
G. FUEL FILLER CAP 307
H. FUEL HOSES & LINES 307
I. ASSEMBLY FILLER NECK COMPLETE 308
3A.1.6 INTAKE SYSTEM 309
WORKING 309
3.1.7 EXHAUST SYSTEM 310
A. DESCRIPTION 310
B. COMPONENTS 310
C. EXHAUST GAS RECIRCULATION (EGR). 311
D. E.G.R. SOLENOID VALVE 312
E. EXHAUST PIPE REMOVAL 313
3A.1.8 ENGINE MANAGEMENT SYSTEM 314
3A.1.8.1 SYSTEM OVERVIEW 314
3A.1.8.2 FUNCTIONAL DESCRIPTION 314
3A.1.8.3 SENSORS AND CONTROL UNIT 315
3A.1.8.4 DIESEL FUEL INJECTION SYSTEM 321
3.1.8.4.1 FUNCTION 321
3A.1.8.4.2 SYSTEM LAYOUT 322
3A.1.8.4.3 OPERATION PERFORMED BY EMS 323
3A.1.8.9: DTC Codes 328
3B. ENGINE (QUADRAJET 90PS) 336
3A.1.1.GENERAL INFORMATION 341
3A 1.1.1. TECHNICAL SPECIFICATIONS 341
3A.1.1.2 TIGHTENING TORQUES 342
3A.1.1.3 SPECIAL TOOLS 344
3A.1.1.4 MAINTENANCE , INSPECTION ANDTESTS 349
A. ENGINE OIL REPLACEMENT 349
B. ENGINE OIL FILTER CARTRIDGEREPLACEMENT 350
C. AIR FILTER INSPECTION AND CLEANING 351
D. AIR FILTER ASSY – REMOVAL 353
E. FUEL FILTER REPLACEMENT PROCEDURE 354
F. ON VEHICLE TIMING CHAIN REPLACEMENTPROCEDURE 355
3A.1.2 ENGINE – MECHANICAL 359
3A.1.2.1 REMOVAL OF ENGINE FROM VEHICLE 359
CYLINDER HEAD ASSEMBLY 363
3A.1.2.2.1 EXPLODED VIEW 363
3A.1.2.2.2 REMOVAL OF CYLINDER HEADASSEMBLY AND OIL SUMP 363
3A.1.2.2.4 CYLINDER HEAD – OVERHAUL 372
3A.1.2.2.5 VALVE AND VALVE SPRING 375
A. EXPLODED VIEW 375
B. REMOVAL AND OVERHAUL 375
C. INSTALLATION 377
3A.1.2.2.6 CYLINDER HEAD BLOCK 378
A. HEAD GASKET CORRECTION BASED ONCYLINDER HEAD BLOCK PLANARITY. 378
B. CAMSHAFT HOUSING INSPECTION ANDMEASUREMENT 379
C. CYLIDER HEAD BLOCK ASSEMBLY -REFITTING 380
3A.1.2.2.6. SELECTION OF CYLINDER HEADGASKET 381
3A.1.2.2.7 INSTALLATION OF CYLINDERHEAD ASSEMBLY AND OIL SUMP 382
3A.1.2.3 ENGINE BLOCK 388
3A.1.2.3.1 DISMANTLING 388
3A.1.2.3.2 PISTON - REMOVAL & FITMENT 392
3A.1.2.3.3 ENGINE OIL PUMP - REMOVALAND FITMENT 393
3A.1.2.3.4 ENGINE BLOCK -MEASUREMENT, INSPECTION & GRADEDETERMINATION 395
3A.1.2.3.5 ENGINE BLOCK – ASSEMBLY 401
3A.1.3. ENGINE COOLING 404
A. SYSTEM DESCRIPTION 404
B. COMPONENTS: 405
3A.1.4. LUBRICATING SYSTEM 406
A. COMPONENTS 406
B. CONSTRUCTION AND WORKING: 406
3A.1.5 FUEL SUPPLY SYSTEM 407
3A.1.5.1 INTRODUCTION 407
3A.1.5.2 COMPONENTS 408
A. IMA CLASSIFICATION 409
3A.1.5.2.3 SINGLE FUEL MANIFOLD PIPE 410
3A.1.5.2.4 FUEL FEED SYSTEM 411
A. FUEL TANK 413
B. INTANK FUEL PUMP (TANK UNIT) 417
C. FUEL LEVEL SENSOR 418
E. FUEL LEVEL 423
F. FUEL FILTER 424
G. FUEL FILLER CAP 425
H. FUEL HOSES & LINES 425
I. ASSEMBLY FILLER NECK COMPLETE 426
3A.1.6 INTAKE SYSTEM 427
3.1.7 EXHAUST SYSTEM 431
A. DESCRIPTION 431
B. COMPONENTS 431
C. EXHAUST GAS RECIRCULATION (EGR) 432
D. E.G.R. SOLENOID VALVE 433
E. EXHAUST PIPE REMOVAL 434
3A.1.8 ENGINE MANAGEMENT SYSTEM 435
3A.1.8.1 SYSTEM OVERVIEW 435
3A.1.8.2 FUNCTIONAL DESCRIPTION 435
3A.1.8.3 SENSORS 440
3A.1.8.4 DIESEL FUEL INJECTION SYSTEM 448
3.1.8.4.1 FUNCTION 448
3A.1.8.4.2 SYSTEM LAYOUT 449
3A.1.8.4.3 OPERATION PERFORMED BY EMS 450
DTC CODES 455
4. DRIVETRAIN-C 549 470
4.1.1 CLUTCH 476
4.1.1.1 HYDRAULIC CLUTCH ACTUATION LAYOUT 476
4.1.1.2. TECHNICAL SPECIFICATIONS 478
4.1.1.3 MAINTENANCE 479
A. CLUTCH ASSEMBLY REMOVAL 479
B. HYDRAULLIC ACTUATOR - REMOVAL 479
C. CLUTCH SLAVE CYLINDER BLEEDINGPROCEDURE 480
D. CLUTCH MASTER CYLINDER - REMOVAL 482
E. CLUTCH PEDAL ASSEMBLY – REMOVAL 483
F CLUTCH SWITCH ADJUSTMENTPROCEDURE 483
G EXPLODED VIEW 484
4.1.2 TRANSAXLE 487
4.1.2.1 GENERAL INFORMATION 487
A. TECHNICAL SPECIFICATIONS 487
B. CONSTRUCTION AND SYSTEMDESCRIPTION 488
C Tightening Torque 490
D. SPECIAL TOOS 491
4.1.2.2 MAINTENANCE 497
A. TRANSAXLE OIL REPLACEMENT 497
4.1.2.3 REMOVAL AND INSTALLATION OFTRANSAXLE FROM VEHICLE 497
4.1.2.4. TRANSAXLE – OVERHAUL 501
A. TRANSAXLE ASSEMBLY - DISMANTLING 501
B. FIFTH GEAR - DISMANTLING 502
C. REMOVAL OF SHAFTS, CONTROL RODSAND DIFFRENTIAL 504
D. LAY SHAFT - DISMANTLING 507
E. MAINSHAFT- DISMANTLING 508
F. MAINSHAFT – ASSEMBLY 509
G. LAYSHAFT – ASSEMBLY 510
H. TRANSAXLE AS+SEMBLYINSTALLATION 512
I. FIFTH GEAR - ASSEMBLY 513
4.1.2.5. DIFFERENTIAL ASSEMBLY –OVERHAUL 515
4 1.2.6. INPUT SHAFT SEAL REPLACEMENT 517
4.1.3.DRIVE SHAFT 517
4.1.3.1 INTRODUCTION 517
4.1.3.2.MAINTENANCE 518
A. DRIVESHAFT REMOVAL – LH SIDE: 518
B. DRIVESHAFT REMOVAL – RH SIDE: 519
C. INTERMEDIATE SHAFT 519
5. ZEST AMT (AUTOMATED MANUAL TRANSMISSION) 521
5.1 INTRODUCTION 529
5.2 SYSTEM COMPONENTS 530
5.2.1 POWER UNIT 531
5.2.1.1. ELECTRIC PUMP 531
5.2.1.2. PRESSURE ACCUMULATOR 531
5.2.1.3. OIL RESERVOIR 532
5.2.2 ELECTRO HYDRAULIC UNIT 532
5.3 HYDRAULIC DIAGRAM 533
5.4 ELECTRICAL COMPONENTS OF THE HYDRAULIC UNIT 534
5.4.1 PROPORTIONAL PRESSURE SOLENOID VALVE 534
5.4.2 ON-OFF SOLENOID VALVES FOR CONTROLLING THE POSITION SELECTION ACTUATOR 535
5.4.3 PROPORTIONAL FLOW RATE SOLENOID VALVE 535
5.5 ELECTRICAL WIRING 537
5.5.1 LINE PRESSURE SENSOR 538
5.5.2 CLUTCH RPM SENSORS 538
5.5.3 ENGAGEMENT AND SELECTION POSITION SENSORS 538
5.5.4 CSC CLUTCH ACTUATOR 538
5.5.5 PLCD CLUTCH POSITION SENSOR 539
5.5.6 MECHANICAL COMPONENTS OF THE UNIT 541
5.5.7 GEAR ENGAGEMENT AND SELECTION SHAFT 541
5.5.8 ELECTRONIC CONTROL UNIT 541
5.5.9 SYSTEM INPUT SIGNALS 544
5.6 USER INTERFACES - SYSTEM 544
5.6.1 SYSTEM OPERATION (IN THE ABSENCE OF FAULTS) 545
5.6.2 PRESSURISATION OF THE HYDRAULIC CIRCUIT 545
5.6.3 AUTOMATIC ENGAGEMENT OF THE CLUTCH DOWNHILL WITH THE ACCELERATOR PEDAL 545
5.6.4 RELEASED 545
5.6.5 VEHICLE SLOWDOWN 545
5.6.6 TURNING OFF THE ENGINE AND SYSTEM 545
5.6.7 FUNCTIONAL INTERACTION LOGICS WITH OTHER SYSTEMS 545
5.6.8 INTERACTION WITH ENGINE MANAGEMENT 545
5.6.9 ABS INTERACTION (FOR CAR VERSIONS/TRIM LEVELS WHERE PROVIDED) 546
5.6.10 SPRINT DEPARTURE 546
5.6.11 OPERATION 546
5.6.12 VEHICLE STOPPED AND ENGINE OFF 546
5.6.13 DOOR OPENING 546
5.6.14 MEASURES BEFORE KEY ON 546
5.6.15 KEY ON (+15) 546
5.6.16 ENGINE ON AND/OR VEHICLE MOVING 547
5.6.17 FIRST STARTING (+50) 547
5.6.18 STARTING THE VEHICLE FROM STATIONARY 547
5.6.19 ENGINE STARTED 547
5.6.20 CHANGE IN MANUAL MODE 547
5.6.21 GEAR CHANGE IN AUTOMATIC MODE 547
5.6.22 REQUEST FOR NEUTRAL WITH THE VEHICLE MOVING 548
5.6.23 REQUEST FOR REVERSE WITH THE VEHICLE MOVING REVERSE 548
5.6.24 REVERSE DISENGAGEMENT 548
5.7 SYSTEM SAFETY 549
5.7.1 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) 549
5.7.2 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) 549
5.7.3 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) 549
5.7.4 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) 549
5.7.5 VEHICLE STATIONARY, ENGINE RUNNING, GEARBOX IN A GEAR OTHER THAN NEUTRAL (N) KEY-OFF PROCEDURE 549
5.8 SUMMARY OF BUZZER ACTIVATION REQUESTED BY THE SYSTEM 549
5.8.1 AUTO CALIBRATIONS 549
5.8.2 CLUTCH BLEEDING 550
5.8.3 CLUTCH KISS POINT SELF TUNING 551
5.8.4 GRID SELF-TUNING 551
5.8.5 NEW ACTUATORS 553
5.9 VERIFYING AND CHECKING PROCEDURES C510 554
5.9.1 OIL LEVEL CHECK 554
5.9.2 OIL LEAK CHECK 554
5.9.3 OIL PRESSURE CHECK 554
5.9.4 ELECTRICAL PUMP SUPPLY CHECK 554
5.9.5 BRAKE PEDAL SWITCH CHECK 555
5.9.6 CLUTCH DRAG CHECK 555
5.9.7 ELECTRO HYDRAULIC SELECTION GEARBOX ACTIVATION HYDRAULIC UNIT MOUNTING REMOVAL 559
5.9.8 ELECTRO HYDRAULIC SELECTION GEARBOX ACTIVATION HYDRAULIC UNIT MOUNTING FITMENT 560
5.9.9 ELECTRO HYDRAULIC CIRCUIT RESERVOIR AND SYSTEM PUMP REMOVAL 560
5.9.10 ELECTRO HYDRAULIC CIRCUIT RESERVOIR AND SYSTEM PUMP FITMENT 562
5.9.11 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED REMOVAL 563
5.9.12 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED FITMENT 563
5.9.13 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED REMOVAL VALID FOR VERSIONS WITH ROBOTISED GEARBOX 564
5.9.14 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED FITMENT VALID FOR VERSIONS WITH ROBOTISED GEARBOX 564
5.9.15 HEAT PROTECTION BULKHEAD ON GEARBOX HYDRAULIC CIRCUIT FLUID RESERVOIR WITH ELECTRO- HYDRAULIC SELECTION REMOVAL 565
5.9.16 HEAT PROTECTION BULKHEAD ON GEARBOX HYDRAULIC CIRCUIT FLUID RESERVOIR WITH ELECTRO- HYDRAULIC SELECTION FITMENT 565
5.9.17 PIPE FROM PUMP TO HYDRAULIC SPEED SELECTION ACTUATOR UNIT REMOVAL 565
5.9.18 PIPE FROM PUMP TO HYDRAULIC SPEED SELECTION ACTUATOR UNIT FITMENT 566
5.9.19 PIPE FROM HYDRAULIC SPEED SELECTION ACTUATOR UNIT TO FLUID RESERVOIR REMOVAL 566
5.9.20 PIPE FROM HYDRAULIC SPEED SELECTION ACTUATOR UNIT TO FLUID RESERVOIR FITMENT 566
5.9.21 HYDRAULIC UNIT/ELECTRO HYDRAULIC SELECTION GEARBOX ELECTRIC PUMP ASSEMBLY WITH GEARBOX REMOVED REMOVAL 567
5.9.22 HYDRAULIC UNIT/ELECTRO HYDRAULIC SELECTION GEARBOX ELECTRIC PUMP ASSEMBLY WITH GEARBOX REMOVED FITMENT 569
5.9.23 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH REMOVAL 570
5.9.24 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH FITMENT 572
5.9.25 PRESSURE ACCUMULATOR ON HYDRAULIC ACTUATOR UNIT REMOVAL 573
5.9.26 PRESSURE ACCUMULATOR ON HYDRAULIC ACTUATOR UNIT FITMENT 573
5.9.27 PIPE FROM CLUTCH MASTER CYLINDER TO CLUTCH RELEASE ACTUATOR REMOVAL 574
5.9.28 PIPE FROM CLUTCH MASTER CYLINDER TO CLUTCH RELEASE ACTUATOR FITMENT 574
5.9.29 ODD AND EVEN GEAR ENGAGEMENT SOLENOIDS REMOVAL 575
5.9.30 ODD AND EVEN GEAR ENGAGEMENT SOLENOIDS FITMENT 575
5.9.31 GEAR SELECTION SOLENOIDS REMOVAL 576
5.9.32 GEAR SELECTION SOLENOIDS FITMENT 577
5.9.33 CLUTCH CONTROL SOLENOID REMOVAL 578
5.9.34 CLUTCH CONTROL SOLENOID FITMENT 578
5.9.35 HYDRAULIC SELECTION GEARBOX SPEED SELECTION POSITION SENSOR REMOVAL 579
5.9.36 HYDRAULIC SELECTION GEARBOX SPEED SELECTION POSITION SENSOR FITMENT 579
5.9.37 HYDRAULIC SELECTION GEARBOX SHIFT POSITION SENSOR REMOVAL 581
5.9.38 HYDRAULIC SELECTION GEARBOX SHIFT POSITION SENSOR FITMENT 581
5.10 HYDRAULIC SELECTION GEARBOX CLUTCH POSITION SENSOR 583
5.10.1 HYDRAULIC SELECTION GEARBOX CIRCUIT PRESSURE SENSOR REMOVAL 583
5.10.2 HYDRAULIC SELECTION GEARBOX CIRCUIT PRESSURE SENSOR FITMENT 583
5.10.3 HYDRAULIC SELECTION GEARBOX INPUT SHAFT SPEED SENSOR REMOVAL 584
5.10.4 HYDRAULIC SELECTION GEARBOX INPUT SHAFT SPEED SENSOR FITMENT 584
5.10.5 ELECTRO-HYDRAULIC SELECTION GEARBOX WIRING MOUNTING BRACKET REMOVAL 584
5.10.6 ELECTRO-HYDRAULIC SELECTION GEARBOX WIRING MOUNTING BRACKET FITMENT 585
5.10.7 WIRING FOR MANUAL GEARBOX HYDRAULIC SELECTION SYSTEM ON HYDRAULIC SELECTION UNIT REMOVAL 585
5.10.8 WIRING FOR MANUAL GEARBOX HYDRAULIC SELECTION SYSTEM ON HYDRAULIC SELECTION UNIT FITMENT 587
6. DRIVETRAIN-TA65 STAR 588
6.1. PRECAUTIONS 596
6.2. SPECIFICATIONS AND TIGHTENING TORQUES 597
6.2. A. CLUTCH 597
6.2. B. TRANSAXLE 600
6.3. SPECIAL TOOLS 602
6.3. A. CLUTCH 602
6.3. B. TRANSAXLE 602
6.4. DIAGNOSIS 608
6.4. A. DIAGNOSIS OF CLUTCH: 608
6.4. B. DIAGNOSIS OF TRANSAXLE 611
6.5. MAINTENANCE, ADJUSTMENT ANDTESTS 612
6.5. A PRELIMINARY INSPECTION OF CLUTCH 612
6.5. B. DRIVESHAFT 613
6.6. CLUTCH 615
A. THEORY OF DIAPHRAGM SPRING CLUTCH 615
B. CONSTRUCTIONAL DETAILS 616
C. FACTORS AFFECTING CLUTCHWEAR 616
D. CLUTCH CABLE REMOVAL ANDINSPECTION: 617
E. REMOVAL OF CLUTCH FROM THECAR: 618
F. INSTALLATION OF CLUTCH ON THECAR: 618
G. PROCEDURE FOR CLUTCH ADJUSTMENT 619
6.7. TRANSAXLE 620
A. GENERAL DESCRIPTION 620
B. EXPLODED VIEW OF DIFFERENTIAL: 627
C. EXPLODED VIEW OF SHIFTER FORK 629
D. EXPLODED VIEW OF GEAR SHIFT LINKAGE ASSEMBLY: 631
E. REMOVAL OF TRANSAXLE FROMCAR 634
F. TRANSAXLE TA65 STAR (ON BENCH)DISASSEMBLY: 635
G. INPUT SHAFT SUB ASSEMBLY: 640
H. INPUT SHAFT ASSEMBLY: 641
I. DISASSEMBLY OF LAY SHAFT: 641
J. IDNETIFICATION OF COMPONENTS 643
K. SUB ASSEMBLIES: 646
L. LAY SHAFT ASSEMBLY: 648
M. DIFFERENTIAL ASSEMBLIES: 650
N. ASSEMBLIES OF TRANSAXLE: 652
O. ASSEMBLY OF TOP COVER: 656
P: INSTALLATION OF TRANSAXLE ONTHE CAR: 660
Q: REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE: 661
6.8. DRIVE SHAFT 663
A. DRIVE SHAFT PARTS: 663
B. DISASSEMBLY AND ASSEMBLYPROCEDURE: 664
C. Disassembly and Assembly of CVJoint Assembly (Outer): 667
7. SUSPENSION 672
7.1 TECHNICAL SPECIFICATIONS AND TIGHTENING TORQUES 680
7.1.1 SPECIFICATIONS: 680
7.1.2 TIGHTENING TORQUES FOR SUSPENSION 681
7.2 SPECIAL TOOLS 682
7.3 DIAGNOSIS 683
7.4 PRECAUTIONS 684
7.5 SUSPENSION SYSTEM 685
7.6 ASSEMBLY FRONT SUSPENSION 689
A) ASSEMBLY FRONT STRUT EXPLODED VIEW 689
B) ANTI ROLL BAR MOUNTING EXPLODED VIEW 690
C) LOWER LINK EXPLODED VIEW 691
D) FRONT AXLE ASSEMBLY EXPLODED VIEW 692
7.7 FRONT SUSPENSION 693
7.7.1 REMOVAL AND INSTALLATION OFSTRUT ASSEMBLY 693
7.7.2 DISASSEMBLY AND ASSEMBLY OFFRONT STRUT 694
7.7.3 REMOVAL AND INSTALLATION OFWHEEL HUB 696
7.7.4 REMOVAL AND INSTALLATION OFSUBFRAME ASSEMBLY. 699
7.7.4.1 REMOVAL AND INSTALLATION OFANTI ROLL BAR 700
7.7.4.2 REMOVAL AND INSTALLATIONLOWER ARM BALL JOINT 701
7.7.4.3 REMOVAL AND INSTALLATION OFLOWER ARM RUBBER BUSHES 702
7.8 ASSEMBLY REAR SUSPENSION 704
A) REAR SHOCK ABSORBER AND SPRING EXPLODED VIEW 704
B) REAR HUB ASSEMBLY EXPLODED VIEW 706
C) PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW 707
7.9 REAR SUSPENSION 708
7.9.1 REMOVAL AND INSTALLATION OFREAR SHOCK ABSORBER AND COILSPRINGS: 708
7.9.1.1 REMOVAL OF REAR SHOCKABSORBER AND COIL SPRINGS: 708
7.9.1.2 DISASSEMBLY AND ASSEMBLY OFREAR SHOCK ABSORBER: 710
7.9.1.3 INSTALLATION OF REAR SHOCKABSORBER AND COIL SPRINGS: 711
7.9.2 REMOVAL AND INSTALLATION OFTORSION BEAM FROM CAR 712
7.10 WHEELS AND TYRES 717
A) TYRE INSPECTION 717
B) REPLACEMENT OF TYRES: 717
C) REPLACEMENT OF WHEELS: 717
7.10.1 HOW TO MEASURE WHEEL RUNOUT: 717
7.10.2 INFLATION OF TYRES: 718
7.10.3 TYRE ROTATION: 719
7.10.4 WHEEL REMOVAL: 719
7.10.5 TYRE MOUNTING AND DEMOUNTING: 719
7.10.6 BALANCING WHEELS: 720
7.10.7. TYRE CARE: 720
8. BRAKES 722
8.1 PRECAUTIONS 728
8.2 TECHNICAL SPECIFICATIONS 729
8.3 TIGHTENING TORQUES 731
8.4 DIAGNOSIS 732
8.5 NESSECITY OF ABS with EBD 735
8.6. BRAKE HYDRAULIC LINES 736
8.7 WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS): 739
8.8 ABS COMPONENTS 743
8.9 MAINTENANCE, ADJUSTMENTS &TEST 748
8.10 REPAIRS 762
8.10.1 FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT 763
8.10.2 REMOVAL OF FRONT BRAKE DISC 769
8.10.3 REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY 770
8.10.4 REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY 775
8.10.5 REMOVAL OF PARKING BRAKELEVER 781
8.10.6 REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE 781
8.10.7 PARKING BRAKE CABLEADJUSTMENT 782
8.10.8 REMOVAL AND REFITMENT OF ABSECU / HCU 783
8.10.9 REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR 784
8.10.10 REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR 785
8.11 DTC CODES 787
8.12 TROUBLE SHOOTING & DIAGNOSIS 789
9. STEERING 793
9.1 GENERAL INFORMATION 799
9.1.1 SPECIFICATIONS 799
9.1.2 SYSTEM LAYOUT 799
9.1.3 GENERAL DESCRIPTION 800
9.1.4 TIGHTENING TORQUES 801
9.1.5 SPECIAL TOOLS 803
9.2. MAINTENANCE, INSPECTION ANDTEST 804
9.2.1 PRELIMINARY INSPECTION 804
9.2.2 REGULAR MAINTENANCE 805
9.2.3 ON VEHICLE REPAIRS 806
9.2.3.1 STEERING WHEEL REMOVAL 806
9.2.3.2 STEERING COLUMN REMOVAL 807
9.2.3.3 INTERMEADIATE SHAFT REMOVAL 808
9.2.3.4 ECU REMOVAL 809
9.2.3.5 RACK & PINION ASSEMBLYREMOVAL 810
9.3. OVERHAULING 812
9.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 812
9.3.2 PRECAUTIONS 813
9.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 813
9.3.3.1 DISASSEMBLY OF RACK & PINON 813
9.3.3.2 INSPECTION OF DISMANTLED PARTS 814
9.3.3.3 ASSEMBLY OF RACK & PINON 814
9.3.3.4 OBJ ON-VEHICLE REMOVAL 815
9.3.3.5 DO’S & DON’TS 815
9.3.3.6 WHEEL ALIGNMENT 816
9.4. TROUBLESHOOTING AND DIAGNOSIS 818
A. GENERAL TROUBLESHOOTING 818
B. ELECTRICAL TROUBLESHOOTING 820
C. MECHANICAL TROUBLESHOOTING 821
9.5 STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS 822
9.6 STEERING SYSTEM DTC CODES. 825
9.7 (EPAS) ECU replacement and software updateprocedure in field 827
10. BODY 834
10.1 PRECAUTIONS 842
10.2 TIGHTENING TORQUES: 843
10.3 SPECIAL TOOL 843
10.4. INTERIORS 844
10.4.1 REMOVAL OF “A” PILLAR TRIM: 844
10.4.2 REMOVAL OF “A” PILLAR LOWER TRIM: 845
10.4.3 REMOVAL OF “B” PILLAR TRIMS: 845
10.4.4 REMOVAL OF 'C' PILLAR TRIM: 846
10.4.5 REMOVAL OF CENTRAL FLOORCONSOLE: 847
10.4.6 REMOVAL OF GRAB HANDLE: 848
10.4.7 REMOVAL OF SUNVISOR: 848
10.4.8 REMOVAL OF REAR SCUFF PLATE: 849
10.4.9 REMOVAL OF FRONT SEAT BELT: 850
10.4.10 REMOVAL OF REAR SEAT BELT: 851
10.4.11 REMOVAL OF REAR QUARTER TRIM: 852
10.4.12 REMOVAL AND REFITMENT OF ROOFTRIM REMOVAL: 852
10.5 SEATS 853
10.5.1 REMOVAL OF FRONT SEAT: 853
10.5.2 REMOVAL OF REAR SEAT: 854
10.6 SECURITY AND LOCKS 855
10.6.1 REMOVAL OF BONNET LOCK 855
10.6.2 REMOVAL AND REFITMENT 856
10.6.3 TAILGATE LATCH CABLE 857
10.6.4 FUEL LID CABLE REMOVAL: 857
10.7 GLASS / WINDOW / MIRROR 859
10.7.1 FIXING OF WIND SCREEN GLASS &REAR QUARTER FIXED GLASS 859
10.8 EXTERIOR TRIM 860
10.8.1 REMOVAL OF TAILGATE TRIM: 860
10.8.2 REMOVAL OF TAILGATE STRIKER: 860
10.8.3 REMOVAL OF TAILGATE BALANCER: 861
10.8.4 REMOVAL OF TAILGATE LATCH: 861
10.8.5 REMOVAL OF SPOILER: 862
10.8.6 REMOVAL OF REAR WIPER MOTOR: 862
10.8.7 REMOVEL AND REFITMANT OF FRONTWIPER 863
10.9 BUMPER AND FASCIA ASSEMBLY 865
10.9.1 R+R of front bumper 865
10.9.2 REMOVAL AND REFITMENT OF ENDMODULE: 866
10.9.3 REMOVAL AND REFITMENT OF REARBUMPER 867
10.9.4 REMOVAL OF COCKPIT SIDE COVER: 868
10.9.5 SPEAKAR GRILL SERVICING 869
10.10.6 TWEETER SERVICING 869
10.9.7 SIDE AIR VENT SERVICING 870
10.9.8 RADIO BLANK COVER SERVICING 870
10.9.9 FASCIA INSTRUMENT CLUSTER 871
10.9.10 SERVICING FASCIA CLUSTER: 872
10.9.11 GLOVE BOX SERVICING 873
10.9.12 STEERING COLUM COVER SERVICING 873
10.9.13 CLIMATE CONTROL MODULE FIXINGS 874
10.9.14 REMOVAL OF DASH BOARD 875
10.9.15 WIRE HARNESS SERVICING 877
10.10. HOOD / FENDER / DOORS 881
10.10.1 R+R OF BONNET HOOD 881
10.10.2 R+R of fender 882
10.10.3 Removal and Refitment of Front Door 883
10.10.4 Removal and Refitment of Rear Door 889
10.11 PAINT AND COATINGS 894
10.12 EXCLUSIVE DATA OF ZEST 899
10.12.1. Front Bumper 903
10.12.2. Rear Bumper 906
10.12.3. ORVM 908
10.12.4. Tailgate Garnish Trim 910
10.12.5. Trunk Striker 911
10.12.6. Trunk Lid Latch 911
10.12.7. Microphone 912
10.12.8. Headliner 913
10.12.9. Parcel Shelf 914
10.12.10. Rear Quarter Trim (RQT) 915
10.12.11. Trunk Lid Sill Cover 916
10.12.12. Wheel Arch Trim 917
10.12.13. Wheel Arch Carpet 918
10.12.14. Assembly Luggage Compartment Carpet 920
10.12.15. Trunk Lid 920
10.12.16. Tail Lamp 921
10.12.17. Tail Lamp Bulb Re-fitment 921
11. SRS 923
11.1 COMPONENTS OF SRS 929
11.2 COMPONENTS 930
11.2.1 DRIVER AIRBAG (DAB) 930
11.2.2 PASSENGER AIRBAG (PAB) MODULE 930
11.2.3 FRONT SEAT MOUNTED SIDE AIRBAGS 931
11.2.4 SRS ECU 932
11.2.5 SRS WARNING LAMP 933
11.2.6 SEAT BELT PRETENSIONERS WITHLOADLIMITERS 933
11.2.7 FRONT REMOTE SENSING UNIT (RSU)OR FRONT IMPACT SENSOR 935
11.2.8 SIDE REMOTE SENSING UNIT (RSU) ORSIDE IMPACT SENSOR (IF FITTED) 936
11.2.9 PASSENGER AIRBAG (PAB)ACTIVATION AND DEACTIVATION SWITCH( IFFITTED) 937
11.3 SRS OPERATION 938
11.4 TIGHTENING TORQUES 938
11.5 SAFETY PRECAUTIONS 938
11.6 REPAIRS 940
11.6.1 DRIVER AIRBAG (DAB) MODULE 940
11.6.2 Clock spring 942
11.6.3 PASSENGER AIRBAG (PAB) MODULE 944
11.6.4 SRS ECU 944
11.6.5 FRONT (RH) REMOTE SENSING UNIT(RSU) 945
11.6.6 FRONT (LH) REMOTE SENSING UNIT(RSU) 945
11.6.7 RETRACTOR PRETENSIONER ANDLOAD LIMITER CONFIGURATION BELTS(RPLL) 946
11.6.8 SIDE RSU OR SIDE IMPACT SENSOR 947
11.6.9 FRONT SEAT MOUNTED SIDE AIRBAG(IF FITTED) 948
11.7 SRS ECU PIN OUTS: 950
11.8 SRS ECU DTC CODES 952
11.9. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT 954
12. AIR CONDITIONING 956
12.1 PRECAUTIONS 964
12.2 TECHNICAL SPECIFICATIONS: 965
12.2.1 TIGHTENING TORQUES: 966
12.3 DIAGNOSIS 967
12.4 MAINTENANCE, INSPECTION ANDTEST 972
12.4.1 AC PERFORMANCE TEST 972
12.5. SERVICING PROCEDURE FOR BEHR 972
12.5.1 BOWDEN CABLE SERVICING (BEHR) 972
12.5.2 REMOVAL AND REFITMENT OFCABLES FROM HVAC 973
12.5.3 REMOVAL OF WIRING HARNESSCONNECTORS FROM CONTROL PANEL 973
12.5.4 SERVICING OF BLOWER ASSEMBLY 974
12.5.5 SERVICING OF HEATER ASSEMBLY 974
12.5.6 SERVICING FILTER 975
12.5.7 SERVICING OF KINEMATIC 976
12.5.8 RESISTER SERVICING 977
12.5.9 SERVICING OF THERMOSENSER/ 977
12.5.10 SERVICING OF CONDENSER 978
12.6 SERVICING PROCEDURE FORSUBROS IF FITTED 980
12.6.1 REMOVAL AND REFITMENT OFCABLES FROM HVAC 980
12.6.2 REMOVAL OF WIRING HARNESSCONNECTORS FROM CONTROL PANEL 981
12.6.3 SERVICING OF BLOWER ASSEMBLY 981
12.6.4. SERVICING OF HEATER ASSEMBLY 982
12.6.5 SERVICING FILTER 982
12.6.6 SERVICING OF KINEMATIC FOR AIRMODE 983
12.6.7 RESISTER SERVICING 984
12.6.8 SERVICING OF THERMOSENSER 984
12.6.9 SERVICING OF CONDENSER 985
12.7 SCHEMATIC DIAGRAM OF AC CYCLE. 987
12.8 LAYOUT OF HVAC SYSTEM 988
12.9 MAIN PARTS OF A.C. SYSTEM 989
12.10 HVAC CONTROLS (Air Flow Pattern) 991
12.11 EXPLODED VIEWS 993
12.11 1 EXPLODED VIEWS OF HVAC (BEHR) 993
12.11.2 EXPLODED VIEW OF HVAC (SUBROS) 994
12.12 DISCHARGING THE SYSTEM 995
12.13 SYSTEM CHARGING & EVACUATION 996
12.14 FLUSHING THE A/C SYSTEM FORCONTAMINATION OF LUBRICATING OIL 999
12.15 DO’s AND DON’T’s 1001
12.16 SAFETY TIPS FOR AC SYSTEM 1002
12.17 FUNCTION AND INSPECTION OF A.C.COMPONENTS: 1003
12.18 FULLY AUTOMATIC TEMPERATURECONTROL (FATC) 1004
12.18.1 SERVICING OF ACTUATOR FORDISTRIBUTION KINEMATICS 1004
12.18.2 SERVICING OF ACTUATOR FORTEMPERATURE KINAMATICS 1004
12.18.3 SERVICING OF THERMOSENSER/ 1004
12.18.4 LAYOUT OF FATC SYSTEM 1005
12.18.5 FATC CONTROLS (Air Flow Pattern) 1006
12.18.6 FATC control Panel 1007
12.18.7 EXPLODED VIEW OF FATC (BEHR) 1011
12.18.8 Connector details: 1013
12.18.9 FATC SENSORS AND ACTUATORS 1015
A SOLAR LOAD SENSOR: 1015
B OAT (Outside Ambient Temperature) 1018
C Evaporator Sensor 1020
D Mode Actuator 1021
E Temperature Actuator 1021
F Fresh / Recirculation: 1022
12.18.10 Diagnosis Trouble Codes 1023
13. ELECTRICAL (PART-1) 1026
13.1 TECHNICAL SPECIFICATION 1036
13.2 GENERAL PRECAUTIONS 1038
13.3 GENERAL ELECTRICAL INFORMATION 1041
13.3.1 HOW TO USE ELECTRICAL WIRING DIAGRAM 1041
13.3.2 COLOUR CODING 1044
13.3.3 SYMBOLS 1045
13.4 FUSE BOX / RELAY LOCATIONS 1053
13.5 BATTERY 1054
13.6 ALTERNATOR 1056
13.7 STARTER MOTOR 1058
13.8 LIGHTING SYSTEM 1063
13.8.1 BULB SPECIFICATIONS 1063
13.8.2 FASTENERS TORQUE VALUE TABLE 1063
13.8.3 GENERAL SYMPTOMS AND DIAGNOSTICS 1064
13.8.4 HEAD LAMP 1068
13.8.5 SIDE REPEATER LAMP 1073
13.8.6 ROOF LAMP 1074
13.8.7 HIGH MOUNTED STOP LAMP 1075
13.8.8 TAIL LAMP 1076
13.8.9 FRONT FOG LAMP 1077
13.8.10 REAR FOG LAMP 1078
13.9 HORN 1079
13.10 WIPER & WASHER SYSTEM 1082
13.10.1 FRONT AND REAR WIPER AND WAHSER SYSTEM LAYOUT 1083
13.10.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 1084
13.10.3 WIPER AND WIPER CARE 1088
13.11 ELECTRIC BUZZER (IF FITTED) 1090
13.12 POWER SOCKETS 1091
13.13 GLOW PLUG CONTROL UNIT 1092
13.14 FUEL GAUGE AND FUEL LEVEL METER 1094
13.15 COMBI-SWITCH 1095
13.16 STEERING LOCK CUM IGNITIONSWITCH 1099
13.17 FASCIA SWITCHES 1101
13.18 INFOTAINMENT SYSTEM: (Iffitted) 1105
13.19 SEAT BELT REMINDERSYSTEM 1109
13.20 WINDOW WINDING MODULE: 1111
13.21 POWER WINDOW SWITCHES 1114
13.22. STEERING WHEEL SWITCHES 1118
13.23 IGNITION E-KEY 1119
13.24 INSTRUMENT CLUSTER 1122
13.24.1 BASIC FUNCTIONAL MATRIX: 1124
13.24.2 TELL TALES MATRIX: 1125
13.24.3 DRIVER INFORMATION SYSTEM 1130
13.24.4 CONNECTOR DETAILS: 1135
13.24.5 FUEL GAUGE DETAILS: 1137
13.24.6 TEMPERATURE BAR GRAPH DETAILS: 1138
13.24.7 CHIMS TABLE: 1139
13.24.8 DISPLY SCREEN FLOW AND SETTINGS 1139
13.24.9 ENGINEERING TEST MODE (ETM) 1142
13.25 IMMOBILIZER SYSTEM: 1144
13.25.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB: 1149
13.25.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU: 1150
13.25.3 DIAGNOSTIC TROUBLE CODES FOR IMMOBILIZER 1152
13.25.4 IGNITION KEY LEARNING PROCEDURE: 1154
13.26 BODY CONTROL MODULE 1157
13.26.1 BCM CONNECTOR PIN SIGNALS APLICABILITY MATRIX: 1159
13.26.2 BCM FUNCTIONS: 1168
13.27 CLUTCH PEDAL SENSOR 1212
13.28 REVERSE PARK ASSIST SYSTEM 1216
13.28.1. Park Assist: 1220
13.28.2. Park Assist functionality overview: 1220
13.28.3. Park Assist Activation Procedure: 1220
13.28.4. Park Assist Deactivation Procedure: 1221
13.28.5. Park Assist Audio Settings: 1221
13.28.6. Park Assist Volume: 1222
13.28.7. Mix With Audio: 1222
13.28.8. Park Assist Tone: 1222
13.28.9. Park Assist Delay Timer: 1222
13.28.10. Park Assist Button LED Indications: 1223
13.28.11. Park Assist HMI Indications: 1223
13.28.12. Park Assist Limitations: 1224
13.28.13. Park Assist System maintenance: 1225
13.28.14. Park Assist System Architecture: 1225
13.28.15. ECU to Sensor Electrical Interface: 1226
13.28.16. ECU to Park Assist Switch Electrical Interface: 1226
13.28.17. ECU Mounting: 1226
13.28.18. Physical Images 1227
13.28.19. Sensor Fitment to the bumper: 1228
13.28.20. List of Diagnosis Troubleshooting Codes for Reverse Park Assist System (RPAS): 1230

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