Table of Contents 1 1265

NEXON

1. GENERAL 6
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS 9
1.2. PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE 10
1.3. PRECAUTIONS OF COMMON RAIL SYSTEM (CR SYSTEM) 11
1.4. VEHICLE JACKING AND LIFTING POINTS 13
1.5. JACK, AND TOOL BAG LOCATION 14
1.6. NUMBERING SYSTEM 15
1.6.1. CHASSIS NUMBERING SYSTEM 15
1.6.2. AGGREGATE NUMBERING SYSTEM 17
1.7. CHASSIS TYPE AND SALES DESIGNATIONS 18
1.8. TECHNICAL SPECIFICATIONS (PETROL) 19
1.9. TECHNICAL SPECIFICATIONS (DIESEL) 22
1.10. VEHICLE DIMENSIONS 25
1.11. RECOMMENDED LUBRICANTS & COOLANTS 26
1.12. SERVICE AND MAINTENANCE 28
2. 1.2L REVOTRON ENGINE 33
1.1. GENERAL INFORMATION 39
A. ENGINE INTRODUCTION 39
B. ELECTRONIC CONTROL UNIT 40
C. TECHNICAL SPECIFICATION 41
D. SPECIAL TOOLS 42
E. ASSEMBLY CLEARANCES 45
F. SEALANTS 45
G. LEAKAGE RATES 46
H. RECOMMENDED LUBRICANTS & COOLANTS 46
I. SERVICE SCHEDULE 47
1.2. TROUBLESHOOTING 48
1.3. CONSTRUCTIONAL AND SERVICE DETAILS 56
A. ENGINE LIFTING HOOKS 56
B. INTAKE MANIFOLD 58
C. CYLINDER HEAD COVER 60
D. CYLINDER HEAD-A 62
E. CYLINDER HEAD-B 64
F. CYLINDER BLOCK 66
G. LUBRICATION PUMP AND COMPONENTS 68
H. PISTON, CRANKSHAFT AND COMPONENTS 71
I. ENGINE TIMING 74
J. TURBOCHARGER, CATCON AND COMPONENTS 76
K. FUEL INJECTION EQUIPMENT 79
L. AIR FILTER, SNORKEL AND BLOW-BY PIPE 81
M. WATER PUMP, THERMOSTAT AND COMPONENTS 83
N. STARTER MOTOR AND ALTERNATOR 86
O. COMPRESSOR, AUTO-TENSIONER AND BELT 88
P. ENGINE SUSPENSION 90
Q. INTERCOOLER AND HOSES 93
1.4. ENGINE TESTS AND MAINTENANCE 95
A. PRELIMINARY INSPECTION 95
B. ENGINE TESTS 96
I. ENGINE COMPRESSION TEST 96
II. ENGINE OIL CONSUMPTION TEST 97
III. ENGINE OIL PRESSURE TEST 98
C. REGULAR MAINTENANCE 99
I. ENGINE OIL AND FILTER CHANGE 99
II. ENGINE COOLANT REPLACEMENT 101
III. AIR FILTER ELEMENT REPLACEMENT 102
IV. SPARK PLUG REPLACEMENT 103
V. AIR CONDITIONER COMPRESSOR AND ALTERNATOR BELT REPLACEMENT 106
1.5. REPAIR AND INSPECTION DETAILS 107
A. ACCESSORY DRIVING BELT 107
B. TIMING CHAIN 107
C. CYLINDER HEAD 107
D. VALVES 108
E. CYLINDER HEAD VALVE SEATS 110
F. ROCKER ARM AND SHAFTS 111
G. HYDRAULIC LASH ADJUSTER 111
H. CAMSHAFT 112
I. PISTON AND PISTON RINGS 113
J. CONNECTING RODS 114
K. CRANKSHAFT 116
L. CRANK CASE 118
M. FUEL TANK 119
N. CANISTER PURGE VALVE 119
O. CANISTER 120
1.6. ENGINE SYSTEM 121
A. AIR INTAKE SYSTEM 121
B. BLOW BY SYSTEM 124
C. LUBRICATION SYSTEM 125
D. EXHAUST SYSTEM 129
E. COOLING SYSTEM 132
F. FUEL SYSTEM 135
1.7. ENGINE ON VEHICLE SERVICE PROCEDURE 138
A. ENGINE REMOVAL AND INSTALLATION 138
B. AIR FILTER ASSEMBLY 144
C. INJECTION SYSTEM 145
D. SPARK PLUG 146
E. EXHAUST SYSTEM 147
F. FUEL SYSTEM 153
G. COOLING SYSTEM 159
H. REMOVAL OF ACCESSORIES 165
1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 166
A. ENGINE DIS-ASSEMBLY 166
I. REMOVAL OF INTAKE MANIFOLD 166
II. REMOVAL OF EXHAUST MANIFOLD 168
III. REMOVAL OF OIL SUMP 172
IV. REMOVAL OF SENSORS 173
V. REMOVAL OF ACCESSORIES 174
VI. REMOVAL OF TIMING CHAIN 178
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT 181
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 183
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 185
B. ENGINE ASSEMBLY 190
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES 190
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 194
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES 197
IV. ASSEMBLY OF CYLINDER HEAD ON CYLINDER BLOCK 199
V. ASSEMBLY OF TIMING CHAIN 201
VI. FITMENT OF CYLINDERHEAD COVER AND PERIPHERALS 205
VII. ASSEMBLY OF SENSORS 208
VIII. ASSEMBLY OF OIL SUMP 209
IX. ASSEMBLY OF EXHAUST MANIFOLD 210
X. ASSEMBLY OF INTAKE MANIFOLD 213
1.9. ENGINE MANAGEMENT SYSTEM 215
A. ABBREVIATIONS 215
B. AN OVERVIEW 216
C. ELECTRONIC CONTROL UNIT 217
D. SENSORS 224
I. T-MAP SENSOR 225
II. LAMBDA SENSOR 226
III. CAMSHAFT POSITION SENSOR 228
IV. KNOCK SENSOR 229
V. CRANKSHAFT POSITION SENSOR 231
VI. COOLANT TEMPERATURE SENSOR 232
E. ACTUATORS 234
I. IGNITION COIL 235
II. PURGE CONTROL VALVE 236
III. SOLENOID VALVE (OCV) 237
IV. FUEL INJECTOR 238
V. ELECTRONIC THROTTLE BODY 239
F. SWITCH 241
I. OIL PRESSURE SWITCH 241
II. THROTTLE PEDAL SENSOR 242
III. CLUTCH SWITCH 243
IV. BRAKE SWITCH 244
V. WHEEL SPEED SENSOR 245
VI. ELECTRONIC VACUUM REGULATING VALVE 246
VII. START STOP SWITCH 247
VIII. AC PRESSURE SENSOR 248
3. 1.5L REVOTORQ ENGINE 250
1.1. GENERAL INFORMATION 256
A. ENGINE INTRODUCTION 256
B. TECHNICAL SPECIFICATION 257
C. SPECIAL TOOLS 258
D. ASSEMBLY CLEARANCES 262
E. LEAKAGE RATES 263
F. RECOMMENDED LUBRICANTS AND COOLANTS 263
G. SERVICE SCHEDULE 264
1.2. TROUBLESHOOTING 265
1.3. CONSTRUCTIONAL AND SERVICE DETAILS 269
A. ENGINE LIFTING HOOK 269
B. INTAKE MANIFOLD AND FUEL INJECTION SYSTEM 271
C. LUBRICATION SYSTEM 274
D. AIR FILTER, SNORKEL, BLOW BY PIPE 277
E. STARTER MOTOR, COMPRESSOR AND ALTERNATOR 280
F. TIMING BELT, AUTO TENSIONER, WATER PUMP 283
G. EXHAUST MANIFOLD, CATCON, TURBOCHARGER 286
H. CYLINDER HEAD AND COMPONENTS 288
I. PISTON, CRANKSHAFT AND COMPONENTS 291
J. ENGINE SUSPENSION 293
K. EGR VALVE, THERMOSTAT AND COMPONENTS 296
L. CRANKCASE AND COMPONENTS 300
1.4. ENGINE TESTS AND MAINTENANCE 302
A. PRELIMINARY INSPECTION 302
B. ENGINE TESTS 302
C. REGULAR MAINTENANCE 307
I. ENGINE OIL AND FILTER CHANGE 307
II. ENGINE COOLANT REPLACEMENT 308
III. AIR FILTER ELEMENT REPLACEMENT 309
IV. FUEL FILTER REPLACEMENT 310
V. DRAINING WATER FROM PRE-FILTER 311
VI. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT 312
1.5. REPAIR AND INSPECTION DETAILS 314
A. TIMING BELT 314
B. FUEL TANK 314
C. CYLINDER HEAD 315
D. VALVES 315
E. VALVE SEATS 317
F. CRANKCASE 318
G. VALVE SEAT INSERT 319
H. HYDRAULIC LASH ADJUSTER 319
I. VALVE GUIDES 320
J. CAMSHAFT 321
K. PISTON AND PISTON RINGS 322
L. CONNECTING ROD 323
M. CRANKSHAFT 325
1.6. ENGINE SYSTEM 327
A. AIR INTAKE SYSTEM 327
B. EXHAUST SYSTEM 330
C. COOLING SYSTEM 334
D. LUBRICATION SYSTEM 337
E. EXHAUST GAS RECIRCULATION SYSTEM 341
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM 343
G. VACUUM MANAGEMENT SYSTEM 344
H. FUEL SYSTEM 345
1.7. ENGINE ON VEHICLE SERVICE PROCEDURE 351
A. ENGINE REMOVAL 351
B. ENGINE INSTALLATION 359
C. EXHAUST SYSTEM 360
D. COOLING SYSTEM 364
E. FUEL SYSTEM 370
F. TURBOCHARGER REMOVAL AND REFITMENT 379
G. TIMING BELT REMOVAL AND REFITMENT 381
H. STARTER MOTOR REMOVAL AND REFITMENT 383
I. ALTERNATOR MOTOR REMOVAL AND REFITMENT 385
J. COMPRESSOR MOTOR REMOVAL AND REFITMENT 386
K. HIGH PRESSURE PUMP REMOVAL AND REFITMENT 387
1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 390
A. ENGINE DIS-ASSEMBLY 390
I. ON OVERHAUL STAND 390
II. REMOVAL OF INTAKE MANIFOLD 394
III. REMOVAL OF EGR VALVE & OIL COOLER 396
IV. REMOVAL OF EXHAUST MANIFOLD 397
V. REMOVAL OF EVRV AND THERMOSTAT 398
VI. REMOVAL OF OIL SUMP 400
VII. REMOVAL OF TIMING BELT 401
VIII. REMOVAL OF CYLINDER HEAD 406
IX. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 407
X. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 410
XI. PISTON CONNECTING ROD DIS-ASSEMBLY 413
B. ENGINE ASSEMBLY 419
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 419
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 420
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 421
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 423
V. FITMENT OF TIMING BELT 425
VI. FITMENT OF ENGINE SUPPORT 430
VII. FITMENT OF OIL SUMP 430
VIII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 432
IX. FITMENT OF INTAKE MANIFOLD 436
X. FITMENT OF PERIPHERALS 438
1.9. ENGINE MANAGEMENT SYSTEM 441
A. ABBREVIATIONS 441
B. AN OVERVIEW 442
C. ELECTRONIC CONTROL UNIT (ECU) 443
D. EMS SENSORS 448
I. CRANK POSITION SENSOR 448
II. WHEEL SPEED SENSOR 449
III. CAMSHAFT POSITION SENSOR 450
IV. AIR MASS FLOW SENSOR 451
V. VENTURI 452
VI. RAIL PRESSURE SENSOR 453
VII. THROTTLE PEDAL SENSOR 454
VIII. WATER IN FUEL SENSOR 455
IX. CLUTCH SWITCH 455
X. OIL PRESSURE SWITCH 456
XI. BRAKE SWITCH 458
XII. COOLANT TEMPERATURE SENSOR 459
XIII. GLOW PLUG 460
XIV. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) 461
XV. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) 462
XVI. START STOP SWITCH 463
XVII. AC PRESSURE SENSOR 464
4. CLUTCH 466
1.1. GENERAL INFORMATION 469
1.2. TECHNICAL SPECIFICATIONS 472
A. CLUTCH DISC ASSEMBLY 472
B. SELF ADJUSTING CLUTCH COVER ASSEMBLY 473
C. SINGLE MASS FLYWHEEL 474
1.3. TIGHTENING TORQUES 476
1.4. SPECIAL TOOLS 478
1.5. MAINTENANCE, INSPECTION AND TESTS 479
1.5.1. PRELIMINARY MAINTENANCE 479
1.5.2. REULAR MAINTENANCE 480
1.6. GENERAL SYMPTOMS DIAGNOSIS 482
1.7. TROUBLE SHOOTING FOR SAC ASSEMBLY 484
1.8. PRECAUTION FOR SAC ASEMBLY 485
1.9. EXPLODED VIEWS 488
1.10. ON VEHICLE PROCEDURES 491
A. CLUTCH PEDAL ASSEMBLY REMOVAL 491
B. CONTROL BRACKET ASSEMBLY REMOVAL 492
C. SELF ADJUSTING CLUTCH ASSEMBLY REMOVAL 493
D. CLUTCH MASTER CYLINDER REMOVAL 494
E. FLYWHEEL REMOVAL 496
5. TRANSAXLE-MT 497
1.1. GENERAL INFORMATION 500
1.2. TECHNICAL SPECIFICATIONS 501
1.3. PRECAUTIONS 501
1.4. TIGHTENING TORQUES 502
1.5. SPECIAL TOOLS 508
1.6. DIAGNOSIS 512
1.7. SECTION VIEWS 513
1.8. EXPLODED VIEWS 516
1.9. REMOVAL OF TRANSAXLE FROM VEHICLE 523
1.10. INSTALLATION OF TRANSAXLE ON VEHICLE 524
1.11. TRANSAXLE DISASSEMBLY ON BENCH 525
A. INPUT SHAFT DISASSEMBLY & ASSEMBLY 529
B. LAY SHAFT DISASSEMBLY & ASSEMBLY 533
C. DIFFERENTIAL DISASSEMBLY & ASSEMBLY 537
D. SHIFTER SHAFTS 540
E. INDENTIFICATION OF ENGAGING GEARS 540
1.12. TRANSAXLE ASSEMBLY ON BENCH 541
1.13. INSTRUCTION FOR ASSEMBLY & DISASSEMBLY OF CABLE ON TRANSAXLE 546
1.14. REMOVAL OF GEAR SHIFTER HOUSING, GEAR SHIFTER & SELECTOR CABLE 547
6. TRANSAXLE-AMT 549
1. TRANSAXLE 553
1. GENERAL INFORMATION 556
2. TECHNICAL SPECIFICATIONS 557
3. PRECAUTIONS 558
4. TIGHTENING TORQUES 559
5. SPECIAL TOOL 565
6. DIAGNOSIS 569
7. SECTION VIEWS 570
8. EXPLODED VIEW TRANSAXLE 572
9. REMOVAL OF TRANSAXLE FROMVEHICLE (FOR PETROL VERSION) 583
10. INSTALLATION OF TRANSAXLE ONVEHICLE (FOR PETROL VERSION) 586
11. REMOVAL OF TRANSAXLE FROMVEHICLE (FOR DIESEL VERSION) 586
12. INSTALLATION OF TRANSAXLE ONVEHICLE (FOR DIESEL VERSION) 590
13. TRANSAXLE DISASSEMBLY ON BENCH 590
14. TRANSAXLE ASSEMBLY ON BENCH 606
2. CLUTCH 611
1. GENERAL INFORMATION 614
2 TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES 614
3. DIAGNOSIS 617
4. CLUTCH 619
5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE 622
3. DRIVESHAFT 623
1. GENERAL INFORMATION 626
2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 628
3. DRIVESHAFT PARTS 629
4. TIGHTENING TORQUES 630
5. ON BENCH PROCEDURE 632
A. TRIPOT JOINT DISASSEMBLY 632
B. TRIPOT JOINT ASSEMBLY 633
C. CV JOINT OUTER DISASSEMBLY 634
6. ON VEHICLE PROCEDURE 635
A. DRIVE SHAFT REMOVAL 635
B. INTERMEDIATE DRIVE SHAFT REMOVAL 636
4. AMT KIT 637
1. AMT-KIT LOCATION ON VEHICLE(LAYTOUT) 640
2. NOMENCLATURE FOR AMT KIT 641
3. TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS 642
4. EXPLODED VIEW AMT KIT 643
5. GEAR SHIFT PIN CONFIGURATION 645
6. PRECAUTIONS 646
7. MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT ON BENCH 647
8. TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT ON BENCH 649
9. DC MOTOR REMOVAL AND RE-FITMENT ON BENCH 653
10. CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT ON BENCH 654
11. HYDRAULIC OIL ACCUMLATOR REMOVAL AND RE-FITMENT ON BENCH 654
12. POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH 654
13. SPECIAL TOOLS 656
5. CONSOLE 658
1. AUTOMATED MANUAL TRANSMISSION(AMT) GEARBOX SHIFTER AND SHIFTINGMECHANISM 658
2. DRIVING MODES 658
3. GEAR SHIFTER CENTER CONSOLEREMOVAL AND RE-FITMENT ON VEHICLE 660
6. COMPONENT REPLACEMENT MANUAL 663
1. Document Scope 666
2. Intended Audience 666
3. Terminologies 666
4. Confidentiality 666
5. Contacts at Tata Motors 666
6. Routine Procedure for Component Replacement 667
6.1 Matrix of Routine Procedure for Component Replacement 667
6.2 Routine Procedure for TCU replacement 668
6.3 Routine Procedure for Actuation system replacement 669
6.4 Routine Procedure for Gear Box replacement 670
6.5 Routine Procedure for Pump/Accumulator/Clutch Actuator Replacement 671
6.6 Routine Procedure for Valve bock and TCU replacement 672
6.7 Routine Procedure for Clutch Sensor replacement 673
6.8 Routine Procedure for Clutch replacement 675
6.9 Routine Procedure for Primary shaft speed sensor replacement 675
6.10 Routine Procedure for Rubber Bellow replacement 676
6.11 Routine Procedure for Reservoir replacement 676
6.12 Routine Procedure for Gear Shift Lever replacement 677
6.13 Routine Procedure for Electric Motor replacement 677
6.14 TCU programming (Flashing) 678
6.15 Routine Procedure for AMT Kit replacement 679
7. DRIVESHAFT 681
1.1. GENERAL INFORMATION 684
1.2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 686
1.3. DRIVESHAFT PARTS 687
1.4. TIGHTENING TORQUES 688
1.5. ON BENCH PROCEDURE 690
A. TRIPOT JOINT DISASSEMBLY 690
B. TRIPOT JOINT ASSEMBLY 691
C. CV JOINT OUTER DISASSEMBLY 692
1.6. ON VEHICLE PROCEDURE 693
A. DRIVE SHAFT REMOVAL 693
B. INTERMEDIATE DRIVE SHAFT REMOVAL 694
C. TURNING NOISE REPAIR (1.5CRAIL) PROCEDURE 695
8. SUSPENSION 697
1.1. GENERAL INFORMATION 700
1.2. TECHNICAL SPECIFICATION 704
1.3. TIGHTENING TORQUES 705
1.4. SPECIAL TOOLS 710
1.5. DIAGNOSIS 716
1.6. PRECAUTIONS 717
1.7. EXPLODED VIEWS FRONT SUSPENSION 718
1.8. EXPLODED VIEWS REAR SUSPENSION 722
1.9. ON VEHICLE PROCEDURE 725
1.9.1. REMOVAL OF FRONT STRUT ASSEMBLY 725
1.9.2. DISASSEMBLY OF FRONT STRUT 726
1.9.3. REMOVAL OF WHEEL HUB 727
1.9.4. REMOVAL OF SUBFRAME ASSEMBLY 730
1.9.5. REMOVAL OF REAR SHOCK ABSORBER AND COIL SPRINGS 734
1.9.6. REMOVAL OF TORSION BEAM 737
1.10. WHEELS AND TYRES 741
1.10.1. HOW TO MEASURE WHEEL RUNOUT 741
1.10.2. INFLATION OF TYRES 742
1.10.3. TYRE ROTATION 743
1.10.4. WHEEL REMOVAL 743
1.10.5. TYRE MOUNTING AND DEMOUNTING 743
1.10.6. BALANCING WHEELS 744
1.10.7. TYRE CARE. 744
9. STEERING 745
1.1. GENERAL INFORMATION 748
1.1.1. SPECIFICATIONS 748
1.1.2. SYSTEM LAYOUT 748
1.1.3. GENERAL DISCRIPTION 749
1.1.4. TIGHTENING TORQUES 750
1.1.5. SPECIAL TOOLS 752
1.2. MAINTENANCE, INSPECTION AND TEST 753
1.2.1. PRELIMINARY INSPECTION 753
1.2.2. REGULAR MAINTENANCE 754
1.2.3. ON VEHICLE REPAIRS 756
1.2.3.1. STEERING WHEEL REMOVAL 756
1.2.3.2. STEERING COLUMN REMOVAL 757
1.2.3.3. INTERMEDIATE SHAFT REMOVAL 758
1.2.3.4. RACK & PINION ASSEMBLY REMOVAL 758
1.3. OVERHAULING 760
1.3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY 760
1.3.2. PRECAUTIONS 761
1.3.3. DISMANTLING, INSPECTION & ASSEMBLY 761
1.3.3.1. DISASSEMBLY OF RACK & PINOIN 761
1.3.3.2. INSPECTION OF DISMANTLED PARTS 762
1.3.3.3. ASSEMBLY OF RACK & PINOIN 762
1.3.3.4. OBJ ON VEHICLE REMOVAL 764
1.3.3.5. DO'S & DON’T'S 764
1.3.3.6. WHEEL ALIGNMENT 765
1.4. TROUBLESHOOTING AND DIAGNOSIS 767
1.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS 771
1.6. TUNING DATA SELECTION FOR ECU-TML EOL PROCEDURE 774
1.7. CONFIGURATION SELECTION 774
10. BRAKE 776
1.1 PRECAUTIONS 780
1.2 TECHNICAL SPECIFICATIONS 781
1.3 TIGHTENING TORQUES 783
1.4 DIAGNOSIS 784
1.5 NESSECITY OF ABS WITH EBD 787
1.6 BRAKE HYDRAULIC LINES 788
1.7 VACUUM BRAKE BOOSTER 789
1.8 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 790
1.9 ABS COMPONENTS 794
1.9.1 ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 795
1.9.2 HYDRAULIC CONTROL UNIT 796
1.9.3 WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED) 797
1.9.4 ABS SYSTEM FAILUREWARNING LIGHT 798
1.10 MAINTENANCE, ADJUSTMENTS & TEST 799
1.10.1 FRONT BRAKE MAINTENANCE 799
1.10.2 REAR BRAKE MAINTENANCE 801
1.10.3 BRAKE TROUBLE SHOOTING 806
1.10.4 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO 807
1.11 BRAKE PEDAL ASSEMBLY 809
1.12 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 810
1.13 REPAIRS 811
1.13.1 FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT 812
1.13.2 REMOVAL OF FRONT BRAKE DISC 817
1.13.3 REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY 818
1.13.4 REAR BRAKE ASSEMBLY 820
1.13.5 REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY 821
1.13.6 REMOVAL OF PARKING BRAKE LEVER 827
1.13.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE 828
1.13.8 PARKING BRAKE CABLE ADJUSTMENT 830
1.13.9 REMOVAL AND REFITMENT OF ABS ECU / HCU 831
1.13.10 REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR 832
1.13.11 REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR 833
1.14 TROUBLE SHOOTING & DIAGNOSIS 834
1.15 ABS ECU CONNECTOR 836
11. BODY 838
1.1. GENERAL INFORMATION 842
1.2. TIGHTENING TORQUES 843
1.3. SOECIAL TOOLS 846
1.4. ON VEHICLE PROCEDURES 847
1.4.1. BONNET 847
1.4.2. FLOOR CONSOLE 849
1.4.3. DASHBOARD SKIN 851
1.4.4. GLOVE BOX 859
1.4.5. SIDE AIR VENTS 860
1.4.6. FRONT BUMPER 861
1.4.7. REAR BUMPER 862
1.4.8. FRONT DOOR 863
1.4.9. FRONT DOOR TRIMS 865
1.4.10. DOOR INNER LOCK HANDLE 866
1.4.11. FRONT OUTER DOOR LOCK 867
1.4.12. FRONT DOOR LATCH 868
1.4.13. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 870
1.4.14. REAR DOOR 871
1.4.15. REAR DOOR TRIM 872
1.4.16. REAR OUTER DOOR LOCK 873
1.4.17. DOOR LATCH REAR 874
1.4.18. TAIL GATE 875
1.4.19. TAIL GATE LATCH CABLE 877
1.4.20. TAIL GATE TRIM 878
1.4.21. ORVM 879
1.4.22. INNER REAR VIEW MIRROR 879
1.4.23. FRONT ROW SEAT 880
1.4.24. REAR ROW SEAT 881
1.4.25. FRONT SEAT BELT 882
1.4.26. REAR SEAT BELT 884
1.4.27. “A” PILLAR TRIMS 885
1.4.28. FRONT SCUFF PLATE 886
1.4.29. “B” PILLAR TRIMS 886
1.4.30. “C” PILLAR TRIMS 887
1.4.31. GRAB HANDLE 888
1.4.32. SUNVISOR 889
1.4.33. ROOF LINER 889
1.4.34. PLENUM COVER 890
1.4.35. GEAR LEVER BOOT 890
1.4.36. BONNET INSULATION 890
1.4.37. GLASS 891
1.4.38. FUEL FILLER ASSEMBLY 892
1.4.39. FRONT WHEEL ARCH LINER 893
1.4.40. REAR WHEEL ARCH LINER 894
1.4.41. FRONT FENDER 895
1.4.42. REAR WIPER MOTOR 897
1.4.43. FRONT WIPER 898
12. ELECTRICAL 899
1.1 TECHNICAL SPECIFICATION 905
1.2 GENERAL PRECAUTIONS 907
1.3 FUSE BOX / RELAY LOCATIONS 911
1.4 BATTERY 912
1.5 ALTERNATOR 914
1.6 STARTER MOTOR 917
1.7 LIGHTING SYSTEM 924
1.7.1 BULB SPECIFICATIONS 924
1.7.2 FASTENERS TORQUE VALUE TABLE 925
1.7.3 GENERAL SYMPTOMS AND DIAGNOSTICS 926
1.7.4 HEAD LAMP 930
1.7.5 SIDE REPEATER LAMP 936
1.7.6 ROOF LAMP 936
1.7.7 HIGH MOUNTED STOP LAMP 937
1.7.8 TAIL LAMP 939
1.7.9 REAR FOG LAMP 942
1.7.10. FRONT FOG LAMP 943
1.7.11. REGISTRATION PLATE LAMP 944
1.7.12. REVERSE LAMP 945
1.8 HORN 946
1.9 WIPER & WASHER SYSTEM 948
1.9.1 FRONT AND REAR WIPER AND WAHSER SYSTEM LAYOUT 949
1.9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 950
1.9.3 WIPER AND WIPER CARE 955
1.10. POWER SOCKETS 958
1.11. GLOW PLUG CONTROL UNIT 959
1.12. FUEL GAUGE AND FUEL LEVEL METER 962
1.13. COMBI-SWITCH 965
1.14. STEERING LOCK CUM IGNITION SWITCH 971
1.15. FASCIA SWITCHES 974
1.16. HAZARD SWITCH 982
1.17. MIRROR SWITCH 983
1.18. INFOTAINMENT SYSTEM 986
1.18.1. USB/AUX PORT 990
1.18.2. SPEAKERS 991
1.18.3. ANTENNA 993
1.18.4. MICROPHONE 994
1.18.5. SILVER BOX 995
1.18.6. TWEETER 1001
1.19. WINDOW WINDING MODULE 1003
1.20. POWER WINDOW SWITCHES 1006
1.21. STEERING WHEEL SWITCHES 1011
1.22. DOOR HANDLE SWITCH 1014
1.23. TAILGATE HANDLE SWITCH 1015
1.24. IGNITION KEY 1016
1.25. INSTRUMENT CLUSTER 1023
1.25.1. BASIC FUNCTIONAL MATRIX 1026
1.25.2. TELL TALES MATRIX 1027
1.25.3. DRIVER INFORMATION SYSTEM 1033
1.25.4. REMINDER FEATURES 1038
1.25.5. FUEL GAUGE DETAILS 1040
1.25.6. TEMPERATURE BAR GRAPH DETAILS 1041
1.25.7. CHIME TABLE 1042
1.25.8. DISPLAY SCREEN FLOW AND SETTINGS 1042
1.26. IMMOBILIZER SYSTEM (IF APPLICABLE) 1048
1.26.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 1052
1.26.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU 1053
1.26.3. IGNITION KEY LEARNING PROCEDURE 1056
1.27. BODY CONTROL MODULE (BCM) 1059
1.27.1. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 1065
1.27.2. BCM FUNCTIONS 1075
1.28. CLUTCH PEDAL SENSOR 1111
1.29. FUSE AND RELAY BOX DETAILS 1114
1.29.1. BATTERY MOUNTED FUSE BOX (BDU) 1117
1.29.2. ENGINE FUSE AND RELAY BOX 1117
1.29.3. CABIN FUSE AND RELAY BOX 1121
1.29.4. CIRCUIT SCHMATICS 1122
1.29.5. DTCs 1122
1.30. REVERSE PARK ASSIST SYSTEM 1123
1.30.1. REAR VIEW CAMERA 1126
1.30.2. ECU TO SENSOR ELECTRICAL INTERFACE 1129
1.30.3. ECU MOUNTING 1130
1.30.4. PHYSICAL IMAGES 1131
1.30.5. SENSOR FITMENT TO THE BUMPER 1132
1.31. PASSIVE ENTRY PASSIVE START (PEPS) 1134
1.31.1. PEPS ECU 1135
1.31.2. START STOP SWITCH 1137
1.31.3. ELECTRONIC STEERING COLUMN LOCK (ESCL) 1139
1.31.4. DOOR HANDLE SWITCHES WITH HARNESS 1140
1.31.5. LF ANTENNAS 1141
13. HVAC 1143
1.1 GENERAL INFORMATION 1146
1.1.1. SPECIFICATIONS 1146
1.1.2. TIGHTENING TORQUES 1148
1.1.3. PRECAUTIONS 1154
1.1.4. HVAC SYSTEM LAYOUT & WORKING 1155
1.1.5. COMPONENTS OF HVAC 1158
1.1.5.1. CONTROL PANEL 1158
1.1.5.2. HVAC UNIT 1160
1.1.5.3. COMPRESSOR 1163
1.1.5.4. CONDENSOR & RECEIVER DRIER 1164
1.1.5.5. THERMISTOR / THERMO SENSOR 1164
1.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR 1167
1.1.5.7. AIR INLET ACTUATOR 1168
1.1.6. TROUBLESHOOTING 1169
1.2 MAINTAINANCE 1183
1.2.1. PRELIMINARY INSPECTION 1183
1.2.2. REGULAR MAINTENANCE 1185
1.3 ON VEHICLE REPAIR 1191
1.3.1. CONTROL PANEL ASSEMBLY 1191
1.3.2. COMPRESSOR 1196
1.3.3. BLOWER 1196
1.3.4. BLOWER RESISTER 1197
1.3.5. FILTER 1197
1.3.6. TXV 1200
1.3.7. PRESSURE SENSOR / SWITCH 1200
1.3.8. HVAC UNIT 1201
1.3.9. CONDENSOR SEALING DUCT 1201
1.3.10. CONDENSOR 1202
1.3.11. REFRIGERANT HOSES 1203
1.3.12. DO's & DON’T's 1204
14. FATC 1205
1.1. GENERAL INFORMATION 1208
1.2. TECHNICAL SPECIFICATIONS 1210
1.3. TIGHTENING TORQUES 1212
A. FOR PETROL VERIENT 1212
B. FOR DIESEL VERIENT 1215
1.4. FRONT HVAC UNIT 1218
1.5. COMPRESSOR 1220
1.6. CONDENSER AND RECEIVER DRIER 1221
1.7. FATC CONTROL PANEL 1222
1.8. HMI CLIMATE CONTROL DISPLAY 1226
1.9. CONTROL PANEL CONNECTOR DETAILS 1227
1.10. FATC SENSOR & ACTUATOR 1229
A. SOLAR LOAD SENSOR 1229
B. OAT SENSOR 1230
C. INCAR SENSOR 1230
D. EVAPORATOR SENSOR 1231
E. MODE ACTUATOR 1231
F. BLOWER CONTROL MODULE 1232
1.11. FRONT HVAC BLOWER ASSEMBLY 1234
1.12. REAR BLOWER SWITCH 1234
1.13. REAR BLOWER ASSEMBLY 1235
1.14. OVERHAULING FRONT FATC UNIT 1237
15. SRS 1242
1.1. WORKING OF RESTRAINTS 1245
1.2. SYSTEM LAYOUT 1246
1.3. SAFETY PRECAUTIONS 1247
1.4. DISPOSAL OF FAULTY AIR BAG UNIT 1249
1.5. SRS POST ACCIDENT PROCEDURE 1250
1.6. TIGHTENING TORQUES 1251
1.7. COMPONENTS 1252
1.7.1. RESTRAINT WITHOUT AIRBAGS 1252
1.7.2. RESTRAINT WITH AIRBAGS 1252
1.7.2.1. ECU 1252
1.7.2.2. SENSORS 1255
1.7.2.3. AIRBAGS 1257
1.7.2.4. RPLL BELTS 1259
1.7.2.5. CLOCK SPRING 1261

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