Table of Contents 1 1427

NANO

NANO 1
NANO MY13 1
1. GENERAL 7
1.1 AN OVERVIEW - NANO 15
1.2 ABBREVIATIONS 16
1.3 LIFTING, JACKING, TOWING POINTS 19
1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS 22
1.5 AGGREGATE NUMBERING SYSTEM 23
1.6 TECHNICAL SPECIFICATIONS 26
1.7 VEHICLE DIMENSIONS 28
1.8 FUEL, LUBRICANTS & COOLANTS 29
1.9 SERVICE SCHEDULE 32
2. PRECAUTIONS 35
2.1 GENERAL SAFETY PRECAUTIONS 41
2.2 GENERAL SERVICE PRECAUTIONS 45
3. ENGINE 47
3.1 GENERAL INFORMATION 55
3.1.1 TECHNICAL SPECIFICATIONS 57
3.1.2 FEATURES OF 273 MPFI ENGINE 58
3.1.3 TIGHTENING TORQUE 59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 65
3.2 ON VEHICLE PROCEDURES 69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 71
3.2.2 ENGINE OIL REPLACEMENT 73
3.2.3 OIL FILTER REPLACEMENT 74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 75
3.2.5 FUEL FILTER REPLACEMENT 76
3.2.6 TAPPET SETTING 77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 86
3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE 89
3.3 ENGINE MECHANICAL 91
PRELIMINARY INSPECTION OF ENGINE 93
REMOVAL OF ENGINE FROM VEHICLE 95
3.3.1 CYLINDER HEAD 99
3.3.1.1 GENERAL DESCRIPTION 101
3.3.1.2 EXPLODED VIEW 102
3.3.1.3 CYLINDER HEAD OVERHAUL 104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 108
3.3.1.6 INSPECTION & REPAIR DATA 111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 118
3.3.2 ENGINE BLOCK 123
3.3.2.1 GENERAL DESCRIPTION 125
3.3.2.2 EXPLODED VIEW 126
3.3.2.3 ENGINE BLOCK OVERHAUL 128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 128
3.3.2.5 INSPECTION & REPAIR DATA 133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 156
3.3.2.8 ENGINE TESTING 158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 158
3.4 ACCELERATOR 159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 161
3.4.2 SYSTEM MAINTENANCE 163
3.5 COOLING SYSTEM 167
3.5.1 GENERAL DESCRIPTION 169
3.5.2 SYSTEM SCHEMATICS 169
3.5.3 EXPLODED VIEWS 170
3.5.4 SPECIFICATIONS 172
3.5.5 SYSTEM COMPONENTS 173
3.5.6 SYSTEM MAINTENANCE 174
3.6 LUBRICATION SYSTEM 183
3.6.1 GENERAL DESCRIPTION 185
3.6.2 SYSTEM SCHEMATICS 185
3.6.3 SPECIFICATIONS 186
3.6.4 SYSTEM MAINTENANCE 187
3.7 FUEL SYSTEM 199
3.7.1 GENERAL DESCRIPTION 201
3.7.2 SYSTEM SCHEMATICS 201
3.7.3 EXPLODED VIEWS 202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 203
3.7.5 SYSTEM COMPONENTS 204
3.7.6 SYSTEM MAINTENANCE 208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 218
3.8 INTAKE SYSTEM 221
3.8.1 GENERAL DESCRIPTION 223
3.8.2 EXPLODED VIEWS 224
3.8.3 SYSTEM MAINTENANCE 225
3.9 EXHAUST SYSTEM 231
3.9.1 GENERAL DESCRIPTION 233
3.9.2 EXPLODED VIEWS 234
3.9.3 TIGHTENING TORQUE 235
3.9.4 SYSTEM COMPONENTS 236
3.9.5 SYSTEM MAINTENANCE 238
3.10 IGNITION SYSTEM 243
3.10.1 GENERAL DESCRIPTION 245
3.10.2 SYSTEM SCHEMATICS 245
3.10.3 SYSTEM MAINTENANCE 246
3.11 ENGINE MANAGEMENT SYSTEM 251
ABBREVIATIONS 251
AN OVERVIEW 254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 255
3.11.1.1 ECU BLOCK DIAGRAM 256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 257
3.11.1.3 ECU HANDLING AND CARE 258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 259
3.11.2 SENSORS 260
3.11.2.1 CRANK SHAFT POSITION SENSOR 260
3.11.2.2 COOLANT TEMPERATURE SENSOR 261
3.11.2.3 T-MAP SENSOR 263
3.11.2.4 KNOCK SENSOR 264
3.11.2.5 THROTTLE POSITION SENSOR 265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 268
3.11.2.7 VEHICLE SPEED SENSOR 269
3.11.3 ACTUATORS 271
3.11.3.1 CANISTER PURGE VALVE 271
3.11.3.2 FUEL INJECTOR 272
3.11.3.3 IGNITION COIL 274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 277
3.11.3.5 COMPONENT FITMENT DATA 279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 283
3.11.4.1 DTC LIST 283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 293
3.11.4.3 BLINK CODE 308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 310
3.11.5.1 REPAIRING STEPS 310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 311
3.11.5.3 SENSOR AND ACTUATOR TESTING 312
3.11.5.4 EMERGENCY SERVICE TIPS 314
4. DRIVETRAIN 315
4.1 CLUTCH 321
4.1.1 GENERAL INFORMATION 323
4.1.1.1 TECHNICAL SPECIFICATIONS 323
4.1.1.2 CONSTRUCTION 326
4.1.1.3 PRECAUTIONS 328
4.1.1.4 TIGHTENING TORQUES 329
4.1.1.5 SPECIAL TOOLS 330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 331
4.1.1.7 TROUBLE SHOOTING 334
4.1.1.8 MAINTENANCE AND REPAIR 335
A. PRELIMINARY INSPECTION 335
B. CLUTCH SLIPPAGE TEST 335
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST 335
D. CLUTCH PEDAL PLAY ADJUSTMENT 335
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT 336
4.1.2 OVERHAUL 337
EXPLODED VIEWS 337
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 340
B. CLUTCH ACTUATION MECHANISM OVERHAUL 341
C. CLUTCH CABLE REPLACEMENT 344
4.2 TRANSAXLE TA-59 347
4.2.1 GENERAL INFORMATION 349
4.2.1.1 TECHNICAL SPECIFICATION 349
4.2.1.2 CONSTRUCTION 349
4.2.1.3 PRECAUTIONS 350
4.2.1.4 TIGHTENING TORQUES 351
4.2.1.5 SPECIAL TOOLS 354
4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 358
4.2.1.7 TRANSAXLE OIL REPLACEMENT 359
4.2.2 OVERHAUL 360
4.2.2.1 EXPLODED VIEWS 360
4.2.2.2 COMPONENT IDENTIFICATION 367
4.2.2.3 PRECAUTIONS 369
4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE 369
4.2.2.5 TRANSAXLE DISMANTLING 372
4.2.2.6 INPUT SHAFT ASSEMBLY 376
4.2.2.7 LAY SHAFT ASSEMBLY 381
4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK 387
4.2.2.9 DIFFERENTIAL ASSEMBLY 390
4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY 394
4.2.2.11 REAR HALF HOUSING ASSEMBLY 400
4.2.2.12 FRONT HALF HOUSING 402
4.2.2.13 TRANSAXLE ASSEMBLY 404
A. SHIM SELECTION 404
B. ASSEMBLING THE TRANSAXLE 405
4.2.2.14 GEAR SHIFTER LINKAGE 409
A. GEAR SHIFTER CABLE REPLACEMENT 409
B. GEAR SHIFTER ADJUSTMENT 410
4.3 DRIVESHAFT 411
4.3.1 GENERAL INFORMATION 413
4.3.1.1 TIGHTENING TORQUE 413
4.3.1.2 SPECIAL TOOL 414
4.3.1.3 CONSTRUCTIONAL DETAILS 415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 415
4.3.1.5 COMPONENT DESCRIPTION 416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 417
4.3.2 ON VEHICLE REPAIRS 418
4.3.2.1 PRECAUTIONS 418
4.3.2.2 REMOVAL FROM VEHICLE 420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 423
5. SUSPENSION SYSTEM 429
5.1 GENERAL INFORMATION 435
5.1.1 TECHNICAL SPECIFICATIONS 435
5.1.2 TIGHTENING TORQUES 436
5.1.3 SPECIAL TOOLS 439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 446
5.2 ON VEHICLE REPAIRS 449
5.2.1 FRONT SUSPENSION COMPONENTS 449
5.2.1.1 STRUT 449
5.2.1.2 ANTI-ROLL BAR 455
5.2.1.3 LOWER ARM 456
5.2.1.4 WHEEL BEARING 458
5.2.2 REAR SUSPENSION COMPONENTS 461
5.2.2.1 SHOCK ABSORBER 462
5.2.2.2 COIL SPRING 463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 464
5.2.2.4 SEMI TRAILING ARM 465
5.2.3 WHEEL HUB AND WHEEL BEARING 468
5.3 WHEELS AND TYRES 473
5.3.1 GENERAL INFORMATION 473
5.3.1.1 TECHNICAL SPECIFICATIONS 473
5.3.1.2 TIGHTENING TORQUE 474
5.3.1.3 EXPLODED VIEW 475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 476
5.3.2 ON VEHICLE REPAIRS 477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 479
5.3.2.3 WHEEL BALANCING 480
5.3.2.4 WHEEL RUNOUT 481
5.3.2.5 TYRE REPLACEMENT 482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 483
5.3.2.8 TYRE DIAGNOSIS 484
6. BRAKE SYSTEM 493
6.1 GENERAL INFORMATION 499
6.1.1 TECHNICAL SPECIFICATIONS 499
6.1.2 TIGHTENING TORQUES 500
6.1.3 SPECIAL TOOLS 504
6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 507
6.2.1 FRONT DRUM BRAKES 507
6.2.2 REAR DRUM BRAKES 508
6.2.3 AUTO INCREMENTAL BRAKE 509
6.2.4 TANDEM MASTER CYLINDER (TMC) 510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 511
6.2.6 WHEEL CYLINDER 514
6.2.7 PARKING BRAKES 515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 523
6.4 ON VEHICLE REPAIRS 530
6.4.1 FRONT BRAKE COMPONENTS 531
6.4.2 FRONT BRAKE DRUM 532
6.4.3 FRONT BRAKE SHOES 534
6.4.4 FRONT BRAKE BACK PLATE 539
6.4.5 REAR BRAKE COMPONENTS 540
6.4.6 REAR BRAKE DRUM 541
6.4.7 REAR BRAKE SHOES 542
6.4.8 REAR BRAKE BACK PLATE 544
6.4.9 TMC 546
6.4.10 WHEEL CYLINDER 555
6.4.11 PARKING BRAKES 561
6.4.12 VACUUM BRAKE BOOSTER 564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 565
6.4.14 VACUUM LINES 567
7. STEERING 569
7.1 GENERAL INFORMATION 575
7.1.1 TECHNICAL SPECIFICATIONS 575
7.1.2 TIGHTENING TORQUES 576
7.1.3 SPECIAL TOOLS 578
7.1.4 EXPLODED VIEWS 579
7.1.5 SCHEMATIC OF STEERING SYSTEM 581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 583
7.3 ON VEHICLE REPAIRS 584
7.3.1 STEERING WHEEL 586
7.3.2 STEERING COLUMN ASSEMBLY 587
7.3.3 STEERING UPPER COLUMN 589
7.3.4 INTERMEDIATE SHAFT 589
7.3.5 STEERING RACK AND PINION ASSEMBLY 590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 592
7.3.7 WHEEL ALIGNMENT 601
7.3.8 TROUBLESHOOTING AND DIAGNOSIS 603
8. ELECTRICAL 607
8.1 TECHNICAL SPECIFICATION 613
8.2 GENERAL PRECAUTIONS 614
8.3 BATTERY 617
8.4 ALTERNATOR 620
8.5 STARTER MOTOR 641
8.6 LIGHTING SYSTEM 659
8.7 HORN 675
8.8 WIPER SYSTEM 677
8.9 FLASHER 686
8.10 FOG LAMP CONTROLLER 687
8.11 BRAKE LAMP CHECK 689
8.12 POWER SOCKET 689
8.13 CIGARETTE LIGHTER (IF EQUIPPED) 690
8.14 CENTRAL DOOR LOCKING 691
8.15 POWER WINDOW SYSTEM 694
8.16 INSTRUMENT CLUSTER 697
8.17 ELECTRICAL SWITCHES 700
8.18 ACCESSORY CONNECTORS 710
8.19 FUSE BOX/RELAY LOCATION & DETAILS 715
8.20 ELECTRIC WIRING AND FITMENT SCHEMATICS 716
8.20.1 HARNESS & CONNECTOR DESCRIPTION 716
8.20.2 UNDERSTANDING THE CIRCUIT SCHEMATIC 718
8.20.3 CONNECTOR CODE/PIN NO./CONNECTOR LAYOUT 719
8.20.4 ELECTRICAL SYMBOLS 720
9. BODY 721
9.1 GENERAL INFORMATION 727
9.1.1 TECHNICAL SPECIFICATIONS 727
9.1.2 TIGHTENING TORQUE 728
9.2 ON VEHICLE REPAIRS 732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 732
9.2.2 FRONT BUMPER 733
9.2.3 FENDER (SIDE BONNET) 734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 735
9.2.5 FRONT DOOR 739
9.2.6 REAR DOOR 750
9.2.7 REAR SHELF 759
9.2.8 TAILGATE 759
9.2.9 REAR BUMPER 760
9.2.10 DASHBOARD 762
9.2.11 CENTER CONSOLE 765
9.2.12 SEATS & BELTS 766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 776
9.2.14 SUN VISOR 776
9.2.15 TRIMS 777
9.2.16 FLOOR CARPET 778
9.2.17 WINDSHIELD 781
9.3 PAINT CARE 783
9.4 BODY REPAIR DATA 786
9.5 TROUBLESHOOTING AND DIAGNOSIS 791
10. HVAC 793
10.1 GENERAL INFORMATION 799
10.1.1 TECHNICAL SPECIFICATIONS 799
10.1.2 TIGHTENING TORQUES 800
10.1.3 GENERAL PRECAUTIONS 802
10.1.4 SYSTEM LAYOUTS 804
10.1.5 COMPONENT DESCRIPTION 808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 825
10.2.3 FLUSHING OF AC SYSTEM 830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 832
10.2.5 A/C SYSTEM PERFORMANCE TEST 834
10.2.6 LEAK TEST SYSTEM 834
10.3 ON VEHICLE REPAIRS 835
10.3.1 CONTROL PANEL ASSEMBLY 836
10.3.2 A/C COMPRESSOR 837
10.3.3 HVAC UNIT 848
10.3.4 BLOWER UNIT 852
10.3.5 BLOWER RESISTER 852
10.3.6 FILTER 853
10.3.7 EVAPORATOR AND EXPANSION VALVE 854
10.3.8 HEATER ASSEMBLY 856
10.3.9 KINEMATICS 857
10.3.10 PRESSURE SWITCH 857
10.3.11 CONDENSER ASSEMBLY 858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 862
10.3.14 REFRIGERANT LINES 863
10.3.15 HEATER LINES 865
NANO AMT 867
1. GENERAL 7
1.1 AN OVERVIEW - NANO 15
1.2 ABBREVIATIONS 16
1.3 LIFTING, JACKING, TOWING POINTS 19
1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS 22
1.5 AGGREGATE NUMBERING SYSTEM 23
1.6 TECHNICAL SPECIFICATIONS 26
1.7 VEHICLE DIMENSIONS 28
1.8 FUEL, LUBRICANTS & COOLANTS 29
1.9 SERVICE SCHEDULE 32
2. PRECAUTIONS 35
2.1 GENERAL SAFETY PRECAUTIONS 41
2.2 GENERAL SERVICE PRECAUTIONS 45
3. ENGINE 47
3.1 GENERAL INFORMATION 55
3.1.1 TECHNICAL SPECIFICATIONS 57
3.1.2 FEATURES OF 273 MPFI ENGINE 58
3.1.3 TIGHTENING TORQUE 59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 65
3.2 ON VEHICLE PROCEDURES 69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 71
3.2.2 ENGINE OIL REPLACEMENT 73
3.2.3 OIL FILTER REPLACEMENT 74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 75
3.2.5 FUEL FILTER REPLACEMENT 76
3.2.6 TAPPET SETTING 77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 86
3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE 89
3.3 ENGINE MECHANICAL 91
PRELIMINARY INSPECTION OF ENGINE 93
REMOVAL OF ENGINE FROM VEHICLE 95
3.3.1 CYLINDER HEAD 99
3.3.1.1 GENERAL DESCRIPTION 101
3.3.1.2 EXPLODED VIEW 102
3.3.1.3 CYLINDER HEAD OVERHAUL 104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 108
3.3.1.6 INSPECTION & REPAIR DATA 111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 118
3.3.2 ENGINE BLOCK 123
3.3.2.1 GENERAL DESCRIPTION 125
3.3.2.2 EXPLODED VIEW 126
3.3.2.3 ENGINE BLOCK OVERHAUL 128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 128
3.3.2.5 INSPECTION & REPAIR DATA 133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 156
3.3.2.8 ENGINE TESTING 158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 158
3.4 ACCELERATOR 159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 161
3.4.2 SYSTEM MAINTENANCE 163
3.5 ENGINE COMPONENTS 869
3.5.1 RADIATOR LOCATION ON VEHICLE 873
3.5.2 TECHNICAL SPECIFICATIONS 874
3.5.3 RADIATOR REMOVAL AND RE-FITMENT ON VEHICLE 875
3.5.4 RADIATOR FAN REMOVAL AND RE-FITMENT ON VEHICLE 884
3.5.5 COOLANT TANK REMOVAL AND RE-FITMENT ON VEHICLE 888
3.5.6 OIL FILTER REMOVAL AND RE-FITMENT ON VEHICLE 890
3.5.7 CATCON REMOVAL AND RE-FITMENT PROCEDURES ON VEHICLE 895
3.5.8 ELECTRONIC THROTTLE CONTROL BODY ORIENTATION 903
3.5.9 THERMOSTAT 904
3.6 LUBRICATION SYSTEM 183
3.6.1 GENERAL DESCRIPTION 185
3.6.2 SYSTEM SCHEMATICS 185
3.6.3 SPECIFICATIONS 186
3.6.4 SYSTEM MAINTENANCE 187
3.7 FUEL SYSTEM 199
3.7.1 GENERAL DESCRIPTION 201
3.7.2 SYSTEM SCHEMATICS 201
3.7.3 EXPLODED VIEWS 202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 203
3.7.5 SYSTEM COMPONENTS 204
3.7.6 SYSTEM MAINTENANCE 208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 218
3.8 INTAKE SYSTEM 221
3.8.1 GENERAL DESCRIPTION 223
3.8.2 EXPLODED VIEWS 224
3.8.3 SYSTEM MAINTENANCE 225
3.9 EXHAUST SYSTEM 231
3.9.1 GENERAL DESCRIPTION 233
3.9.2 EXPLODED VIEWS 234
3.9.3 TIGHTENING TORQUE 235
3.9.4 SYSTEM COMPONENTS 236
3.9.5 SYSTEM MAINTENANCE 238
3.10 IGNITION SYSTEM 243
3.10.1 GENERAL DESCRIPTION 245
3.10.2 SYSTEM SCHEMATICS 245
3.10.3 SYSTEM MAINTENANCE 246
3.11 ENGINE MANAGEMENT SYSTEM 251
ABBREVIATIONS 253
AN OVERVIEW 254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 255
3.11.1.1 ECU BLOCK DIAGRAM 256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 257
3.11.1.3 ECU HANDLING AND CARE 258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 259
3.11.2 SENSORS 260
3.11.2.1 CRANK SHAFT POSITION SENSOR 260
3.11.2.2 COOLANT TEMPERATURE SENSOR 261
3.11.2.3 T-MAP SENSOR 263
3.11.2.4 KNOCK SENSOR 264
3.11.2.5 THROTTLE POSITION SENSOR 265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 268
3.11.2.7 VEHICLE SPEED SENSOR 269
3.11.3 ACTUATORS 271
3.11.3.1 CANISTER PURGE VALVE 271
3.11.3.2 FUEL INJECTOR 272
3.11.3.3 IGNITION COIL 274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 277
3.11.3.5 COMPONENT FITMENT DATA 279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 283
3.11.4.1 DTC LIST 283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 293
3.11.4.3 BLINK CODE 308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 310
3.11.5.1 REPAIRING STEPS 310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 311
3.11.5.3 SENSOR AND ACTUATOR TESTING 312
3.11.5.4 EMERGENCY SERVICE TIPS 314
4. DRIVETRAIN 315
4.1 CLUTCH 906
4.1.1 GENERAL INFORMATION 906
4.1.1.1 TECHNICAL SPECIFICATION 906
4.1.1.2 CONSTRUCTION 909
4.1.1.3 PRECAUTIONS 911
4.1.1.4 TIGHTENING TORQUES 912
4.1.1.5 SPECIAL TOOLS 913
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 914
4.1.1.7 TROUBLE SHOOTING 916
4.1.1.8 MAINTENANCE AND REPAIRS 917
4.1.2 OVERHAULING 918
4.1.2.1 EXPLODED VIEW 918
4.1.2.2 PROCEDURE 919
4.1.2.2.1 REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 919
4.1.2.2.2 CLUTCH ACTUATION MECHANISM OVERHAUL 920
4.2 5-SPEED TRANSAXLE 923
4.2.1 GENERAL INFORMATION 923
4.2.1.1 TECHNICAL SPECIFICATION 923
4.2.1.2 PRECAUTIONS 924
4.2.1.3 TIGHTENING TORQUES 925
4.2.1.4 SPECIAL TOOLS 929
4.2.1.5 GENERAL SYMPTOMS AND DIAGNOSIS 932
4.2.1.6 TRANSAXLE OIL REPLACEMENT 933
4.2.2 OVERHAULING (EXPLOADED VIEWS) 934
4.2.2.1 TRANSAXLE HOUSING 934
4.2.2.2 INPUT SHAFT AND LAY SHAFT 936
4.2.2.3 SHIFER SHAFT AND SHIFTER SLEEVE 937
4.2.2.4 DIFFERENTIAL 938
4.2.2.5 TOP COVER ASSEMBLY 939
4.2.2.6 SHIFTER LINKAGE 940
4.2.3 COMPONENT IDENTIFICATION 941
4.2.3.1 SHIFTER SHAFTS 941
4.2.3.2 SHIFTER FORKS (DOGS) 941
4.2.3.3 SHIFTER SLEEVE 942
4.2.4 REMOVAL OF TRANSAXLE 944
4.2.5 TRANSAXLE DISMANTLING 945
4.2.6 INPUT SHAFT ASSEMBLY 949
4.2.7 LAY SHAFT ASSEMBLY 952
4.2.8 SHIFTER SHAFT AND SHIFTER FORK 956
4.2.9 REVERSE GEAR SHIFTER BRACKET ASSEMBLY 959
4.2.10 DIFFERENTIAL ASSEMBLY 960
4.2.11 TOP COVER ASSEMBLY 963
4.2.12 REAR HALF HOUSING ASSEMBLY 966
4.2.13 FRONT HALF HOUSING ASSEMBLY 967
4.2.14 TRANSAXLE ASSEMBLY 969
4.2.14.1 SHIM SELECTION 969
4.2.14.2 ASSEMBLING THE TRANSAXLE 970
4.3 DRIVESHAFT 411
4.3.1 GENERAL INFORMATION 413
4.3.1.1 TIGHTENING TORQUE 413
4.3.1.2 SPECIAL TOOL 414
4.3.1.3 CONSTRUCTIONAL DETAILS 415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 415
4.3.1.5 COMPONENT DESCRIPTION 416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 417
4.3.2 ON VEHICLE REPAIRS 418
4.3.2.1 PRECAUTIONS 418
4.3.2.2 REMOVAL FROM VEHICLE 420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 423
4.4 AMT KIT 974
4.4.1 AMT KIT LOCATION ON VEHICLE 975
4.4.2 ABBREVIATION LIST 976
4.4.3 PRECAUTION (DO’S AND DON’TS) 977
4.4.4 TECHNICAL SPECIFICATIONS 979
4.4.5 TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS 980
4.4.6 TOOLS 982
4.4.7 AMT UNIT REMOVAL AND INSTALLATION PROCEDURES ON VEHICLE 984
4.4.8 MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT ON BENCH 991
4.4.9 TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT ON BENCH 994
4.4.10 OIL TANK REMOVAL AND RE-FITMENT ON BENCH 998
4.4.11 DC MOTOR REMOVAL AND RE-FITMENT ON BENCH 1000
4.4.12 CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT ON BENCH 1001
4.4.13 HYDRAULIC OIL ACCUMLATOR 1001
4.4.14 POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH 1002
4.5 GEAR SHIFTER CONSOLE 1004
4.5.1 AMT GEARBOX SHIFTER AND SHIFTING MECHANISM 1004
4.5.2 GEAR SHIFTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE 1006
5. SUSPENSION SYSTEM 429
5.1 GENERAL INFORMATION 435
5.1.1 TECHNICAL SPECIFICATIONS 435
5.1.2 TIGHTENING TORQUES 436
5.1.3 SPECIAL TOOLS 439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 446
5.2 ON VEHICLE REPAIRS 449
5.2.1 FRONT SUSPENSION COMPONENTS 449
5.2.1.1 STRUT 449
5.2.1.2 ANTI-ROLL BAR 455
5.2.1.3 LOWER ARM 456
5.2.1.4 WHEEL BEARING 458
5.2.2 REAR SUSPENSION COMPONENTS 461
5.2.2.1 SHOCK ABSORBER 462
5.2.2.2 COIL SPRING 463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 464
5.2.2.4 SEMI TRAILING ARM 465
5.2.3 WHEEL HUB AND WHEEL BEARING 468
5.3 WHEELS AND TYRES 473
5.3.1 GENERAL INFORMATION 473
5.3.1.1 TECHNICAL SPECIFICATIONS 473
5.3.1.2 TIGHTENING TORQUE 474
5.3.1.3 EXPLODED VIEW 475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 476
5.3.2 ON VEHICLE REPAIRS 477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 479
5.3.2.3 WHEEL BALANCING 480
5.3.2.4 WHEEL RUNOUT 481
5.3.2.5 TYRE REPLACEMENT 482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 483
5.3.2.8 TYRE DIAGNOSIS 484
6. BRAKE SYSTEM 493
6.1 GENERAL INFORMATION 499
6.1.1 TECHNICAL SPECIFICATIONS 499
6.1.2 TIGHTENING TORQUES 500
6.1.3 SPECIAL TOOLS 504
6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 507
6.2.1 FRONT DRUM BRAKES 507
6.2.2 REAR DRUM BRAKES 508
6.2.3 AUTO INCREMENTAL BRAKE 509
6.2.4 TANDEM MASTER CYLINDER (TMC) 510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 511
6.2.6 WHEEL CYLINDER 514
6.2.7 PARKING BRAKES 515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 523
6.4 ON VEHICLE REPAIRS 530
6.4.1 FRONT BRAKE COMPONENTS 531
6.4.2 FRONT BRAKE DRUM 532
6.4.3 FRONT BRAKE SHOES 542
6.4.4 FRONT BRAKE BACK PLATE 539
6.4.5 REAR BRAKE COMPONENTS 540
6.4.6 REAR BRAKE DRUM 541
6.4.7 REAR BRAKE SHOES 542
6.4.8 REAR BRAKE BACK PLATE 544
6.4.9 TMC 546
6.4.10 WHEEL CYLINDER 555
6.4.11 PARKING BRAKES 561
6.4.12 VACUUM BRAKE BOOSTER 564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 565
6.4.14 VACUUM LINES 567
7. STEERING 569
7.1 GENERAL INFORMATION 575
7.1.1 TECHNICAL SPECIFICATIONS 575
7.1.2 TIGHTENING TORQUES 576
7.1.3 SPECIAL TOOLS 578
7.1.4 EXPLODED VIEWS 579
7.1.5 SCHEMATIC OF STEERING SYSTEM 581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 583
7.3 ON VEHICLE REPAIRS 584
7.3.1 STEERING WHEEL 586
7.3.2 STEERING COLUMN ASSEMBLY 587
7.3.3 STEERING UPPER COLUMN 589
7.3.4 INTERMEDIATE SHAFT 589
7.3.5 STEERING RACK AND PINION ASSEMBLY 590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 592
7.3.7 WHEEL ALIGNMENT 601
7.3.8 TROUBLESHOOTING AND DIAGNOSIS 603
8. ELECTRICAL 1010
8.1 EMS ECU AND AMT TCU CONNECTOR’S REMOVAL AND RE-FITMENT ON VEHICLE 1012
8.1.1 PARTS LIST 1012
8.1.2 EMS ECU CONNECTOR REMOVAL AND RE-FIMENT ON VEHICLE 1014
8.1.3 AMT TCU UNIT CONNECTOR’S REMOVAL AND RE-FIMENT ON VEHICLE 1019
8.2 FOG LAMP REMOVAL AND RE-FITMENT ON VEHICLE 1023
8.3 HORN REMOVAL AND RE-FITMENT ON VEHICLE 1026
8.4 AMBIENT TEMPERATURE SENSOR REMOVAL AND RE-FITMENT ON VEHICLE 1029
8.5 TRANSMISSION INPUT SPEED SENSOR REMOVAL AND RE-FITMENT ON VEHICLE 1033
8.6 EXHAUST FAN REMOVAL AND RE-FITMENT ON VEHICLE 1035
8.7 DIAGNOSTIC TROUBLE CODES FOR ELECTRONIC POWER ASSISTED STEERING 1038
8.8 BRAKE SWITCH FAILURE CASES AND RECOVERY ON VEHICLE 1039
8.9 DIAGNOSTIC TROUBLE CODES FOR ENGINE MANAGEMENT SYSTEM 1040
9. BODY 721
9.1 GENERAL INFORMATION 727
9.1.1 TECHNICAL SPECIFICATIONS 727
9.1.2 TIGHTENING TORQUE 728
9.2 ON VEHICLE REPAIRS 732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 732
9.2.2 FRONT BUMPER 733
9.2.3 FENDER (SIDE BONNET) 734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 735
9.2.5 FRONT DOOR 739
9.2.6 REAR DOOR 750
9.2.7 REAR SHELF 759
9.2.8 TAILGATE 759
9.2.9 REAR BUMPER 760
9.2.10 DASHBOARD 762
9.2.11 CENTER CONSOLE 765
9.2.12 SEATS & BELTS 766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 776
9.2.14 SUN VISOR 776
9.2.15 TRIMS 777
9.2.16 FLOOR CARPET 778
9.2.17 WINDSHIELD 781
9.3 PAINT CARE 783
9.4 BODY REPAIR DATA 786
9.5 TROUBLESHOOTING AND DIAGNOSIS 791
10. HVAC 793
10.1 GENERAL INFORMATION 799
10.1.1 TECHNICAL SPECIFICATIONS 799
10.1.2 TIGHTENING TORQUES 800
10.1.3 GENERAL PRECAUTIONS 802
10.1.4 SYSTEM LAYOUTS 804
10.1.5 COMPONENT DESCRIPTION 808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 825
10.2.3 FLUSHING OF AC SYSTEM 830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 832
10.2.5 A/C SYSTEM PERFORMANCE TEST 834
10.2.6 LEAK TEST SYSTEM 834
10.3 ON VEHICLE REPAIRS 835
10.3.1 CONTROL PANEL ASSEMBLY 836
10.3.2 AC COMPRESSOR 1068
10.3.2.1 AC COMPRESSOR LOCATION ON VEHICLE 1071
10.3.2.2 TECHNICAL SPECIFICATIONS 1072
10.3.2.3 TIGHTENING TORQUES 1073
10.3.2.4 PRECAUTIONS 1074
10.3.2.5 EXPLODED VIEW AND PART LIST 1077
10.3.2.6 AC COMPRESSOR REMOVAL AND RE-FITMENT ON VEHICLE 1078
10.3.3 HVAC UNIT 848
10.3.4 BLOWER UNIT 852
10.3.5 BLOWER RESISTER 852
10.3.6 FILTER 853
10.3.7 EVAPORATOR AND EXPANSION VALVE 854
10.3.8 HEATER ASSEMBLY 856
10.3.9 KINEMATICS 857
10.3.10 PRESSURE SWITCH 857
10.3.11 CONDENSER ASSEMBLY 858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 862
10.3.14 REFRIGERANT LINES 863
10.3.15 HEATER LINES 865
NANO CNG 1084
1. GENERAL 1090
1.1. INTRODUCTION TO CNG SYSTEM 1094
1.2. BENEFITS OF CNG 1094
1.3. FEATURES OF CNG BI-FUEL SYSTEM 1094
1.4. GENERAL INSTRUCTION / PRECAUTIONSWHILE WORKING ON CNG VEHICLE 1095
1.5. IN CASE OF LEAKAGE 1097
1.6. TECHNICAL SPECIFICATIONS 1099
1.7. TIGHTENING TORQUE 1103
1.8. SPECIAL TOOLS 1108
1.9. LIST OF APPROVED CNG CYLINDER TESTING STATION 1109
1.10. SERVICE SCHEDULE 1110
1.11. LUBRICANTS AND COOLANTS 1114
2. PRECAUTIONS 35
2.1 GENERAL SAFETY PRECAUTIONS 41
2.2 GENERAL SERVICE PRECAUTIONS 45
3. ENGINE 1116
3.1. TECHNICAL SPECIFICATION 1120
3.2. REPAIR DATA 1121
A. BELT TENSION VALUES 1121
3.3. ENGINE CONTRUCTIONAL DETAIL 1122
A. ENGINE 1122
B. INTAKE MANIFOLD 1122
3.4. GENERAL SYSTEM OVERVIEW OF Bi-FUEL ENGINE MANAGEMENT SYSTEM 1123
3.5. REMOVAL AND REFITMENT OF ENGINEACCESS WINDOW AND ENGINE COVER 1126
3.6. GAS INJECTOR 1129
3.7. GAS RAIL 1131
3.8. PRESSURE AND TEMPERATURE (P&T)SENSOR 1133
3.9. DIAGNOSTIC USER MANUAL 1135
4. DRIVETRAIN 315
4.1 CLUTCH 321
4.1.1 GENERAL INFORMATION 323
4.1.1.1 TECHNICAL SPECIFICATIONS 323
4.1.1.2 CONSTRUCTION 326
4.1.1.3 PRECAUTIONS 328
4.1.1.4 TIGHTENING TORQUES 329
4.1.1.5 SPECIAL TOOLS 330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 331
4.1.1.7 TROUBLE SHOOTING 334
4.1.1.8 MAINTENANCE AND REPAIR 335
A. PRELIMINARY INSPECTION 335
B. CLUTCH SLIPPAGE TEST 335
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST 335
D. CLUTCH PEDAL PLAY ADJUSTMENT 335
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT 336
4.1.2 OVERHAUL 337
EXPLODED VIEWS 337
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 340
B. CLUTCH ACTUATION MECHANISM OVERHAUL 341
C. CLUTCH CABLE REPLACEMENT 344
4.2 TRANSAXLE 1156
4.2.1 GENERAL INFORMATION 1162
A. TECHNICAL SPECIFICATIONS 1162
B. PRECAUTIONS 1163
C. TIGHTENING TORQUES 1164
D. SPECIAL TOOLS 1167
E. GENERAL SYMPTOMS AND DIAGNOSIS 1171
F. TRANSAXLE OIL REPLACEMENT 1172
4.2.2. OVERHAULING (EXPLODED VIEWS) 1173
A. TRANSAXLE HOUSING 1173
B. INPUT SHAFT AND LAY SHAFT 1174
C. SHIFTER SHAFT AND SHIFTER SLEEVE 1175
D. DIFFERENTIAL 1176
E. TOP COVER ASSEMBLY 1177
F. SHIFTER LINKAGE 1178
4.2.3. COMPONENT IDENTIFICATION 1180
A. SHIFTER SHAFTS 1180
B. SHIFTER FORKS (DOGS) 1180
C. SHIFTER SLEEVE 1181
4.2.4. REMOVAL OF TRANSAXLE FROM VEHICLE 1182
4.2.5. TRANSAXLE DISMANTLING 1185
4.2.6. INPUT SHAFT ASSEMBLY 1189
4.2.7. LAYSHAFT ASSEMBLY 1194
4.2.8. SHIFTER SHAFT AND SHIFTER FORK 1200
4.2.9. REVERSE GEAR SHIFTER BRACKET - ASSEMBLY 1201
4.2.10. DIFFERENTIAL ASSEMBLY 1203
4.2.11. REAR HALF HOUSING TOP COVER ASSEMBLY 1207
4.2.12. REAR HALF HOUSING ASSEMBLY 1214
4.2.13. FRONT HALF HOUSING 1216
4.2.14. TRANSAXLE ASSEMBLY 1218
A. SHIM SELECTION 1218
B. ASSEMBLING THE TRANSAXLE 1219
4.2.15. GEAR SHIFTER LINKAGE 1224
A. GEAR SHIFTER CABLE REPLACEMENT 1224
B. GEAR SHIFTER ADJUSTMENT 1226
4.3 DRIVESHAFT 411
4.3.1 GENERAL INFORMATION 413
4.3.1.1 TIGHTENING TORQUE 413
4.3.1.2 SPECIAL TOOL 414
4.3.1.3 CONSTRUCTIONAL DETAILS 415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 415
4.3.1.5 COMPONENT DESCRIPTION 416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 417
4.3.2 ON VEHICLE REPAIRS 418
4.3.2.1 PRECAUTIONS 418
4.3.2.2 REMOVAL FROM VEHICLE 420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 423
5. SUSPENSION SYSTEM 429
5.1 GENERAL INFORMATION 435
5.1.1 TECHNICAL SPECIFICATIONS 435
5.1.2 TIGHTENING TORQUES 436
5.1.3 SPECIAL TOOLS 439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 446
5.2 ON VEHICLE REPAIRS 449
5.2.1 FRONT SUSPENSION COMPONENTS 449
5.2.1.1 STRUT 449
5.2.1.2 ANTI-ROLL BAR 455
5.2.1.3 LOWER ARM 456
5.2.1.4 WHEEL BEARING 458
5.2.2 REAR SUSPENSION COMPONENTS 461
5.2.2.1 SHOCK ABSORBER 462
5.2.2.2 COIL SPRING 463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 464
5.2.2.4 SEMI TRAILING ARM 465
5.2.3 WHEEL HUB AND WHEEL BEARING 468
5.3 WHEELS AND TYRES 473
5.3.1 GENERAL INFORMATION 473
5.3.1.1 TECHNICAL SPECIFICATIONS 473
5.3.1.2 TIGHTENING TORQUE 474
5.3.1.3 EXPLODED VIEW 475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 476
5.3.2 ON VEHICLE REPAIRS 477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 479
5.3.2.3 WHEEL BALANCING 480
5.3.2.4 WHEEL RUNOUT 481
5.3.2.5 TYRE REPLACEMENT 482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 483
5.3.2.8 TYRE DIAGNOSIS 484
6. BRAKE SYSTEM 493
6.1 GENERAL INFORMATION 499
6.1.2 TECHNICAL SPECIFICATIONS 499
6.1.3 TIGHTENING TORQUES 500
6.1.4 SPECIAL TOOLS 504
6.1.5 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 507
6.2.1 FRONT DRUM BRAKES 507
6.2.2 REAR DRUM BRAKES 508
6.2.3 AUTO INCREMENTAL BRAKE 509
6.2.4 TANDEM MASTER CYLINDER (TMC) 510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 511
6.2.6 WHEEL CYLINDER 514
6.2.7 PARKING BRAKES 515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 523
6.4 ON VEHICLE REPAIRS 530
6.4.1 FRONT BRAKE COMPONENTS 531
6.4.2 FRONT BRAKE DRUM 532
6.4.3 FRONT BRAKE SHOES 534
6.4.4 FRONT BRAKE BACK PLATE 539
6.4.5 REAR BRAKE COMPONENTS 540
6.4.6 REAR BRAKE DRUM 541
6.4.7 REAR BRAKE SHOES 542
6.4.8 REAR BRAKE BACK PLATE 544
6.4.8 TMC 546
6.4.9 WHEEL CYLINDER 555
6.4.10 PARKING BRAKES 561
6.4.11 VACUUM BRAKE BOOSTER 564
6.4.12 BRAKE HOSES/PIPES SCHEMATIC 565
6.4.13 VACUUM LINES 567
7. STEERING 569
7.1 GENERAL INFORMATION 575
7.1.1 TECHNICAL SPECIFICATIONS 575
7.1.2 TIGHTENING TORQUES 576
7.1.3 SPECIAL TOOLS 578
7.1.4 EXPLODED VIEWS 579
7.1.5 SCHEMATIC OF STEERING SYSTEM 581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 583
7.3 ON VEHICLE REPAIRS 584
7.3.1 STEERING WHEEL 586
7.3.2 STEERING COLUMN ASSEMBLY 587
7.3.3 STEERING UPPER COLUMN 589
7.3.4 INTERMEDIATE SHAFT 589
7.3.5 STEERING RACK AND PINION ASSEMBLY 590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 592
7.3.7 WHEEL ALIGNMENT 601
7.3.8 TROUBLESHOOTING AND DIAGNOSIS 603
8. ELECTRICAL 1262
8.1 TECHNICAL SPECIFICATION 1266
8.2. LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE 1267
8.3. INSTRUMENT CLUSTER 1268
8.4. FUEL GAUGE 1269
8.5. REMOVAL AND REFITTMENT OF BATTERY 1270
8.6. STARTER MOTOR 1271
A. EXPLODED VIEW 1271
B. ON VEHICLE REMOVAL AND REFITTMENT OF STARTER MOTOR 1271
C. STARTER MOTOR OVER HAULING 1272
DTC CODES 1278
9. BODY 721
9.1 GENERAL INFORMATION 727
9.1.1 TECHNICAL SPECIFICATIONS 727
9.1.2 TIGHTENING TORQUE 728
9.2 ON VEHICLE REPAIRS 732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 732
9.2.2 FRONT BUMPER 733
9.2.3 FENDER (SIDE BONNET) 734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 735
9.2.5 FRONT DOOR 739
9.2.6 REAR DOOR 750
9.2.7 REAR SHELF 759
9.2.8 TAILGATE 759
9.2.9 REAR BUMPER 760
9.2.10 DASHBOARD 762
9.2.11 CENTER CONSOLE 765
9.2.12 SEATS & BELTS 766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 776
9.2.14 SUN VISOR 776
9.2.15 TRIMS 777
9.2.16 FLOOR CARPET 778
9.2.17 WINDSHIELD 781
9.3 PAINT CARE 783
9.4 BODY REPAIR DATA 786
9.5 TROUBLESHOOTING AND DIAGNOSIS 791
10. HVAC 793
10.1 GENERAL INFORMATION 799
10.1.1 TECHNICAL SPECIFICATIONS 799
10.1.2 TIGHTENING TORQUES 800
10.1.3 GENERAL PRECAUTIONS 802
10.1.4 SYSTEM LAYOUTS 804
10.1.5 COMPONENT DESCRIPTION 808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 825
10.2.3 FLUSHING OF AC SYSTEM 830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 832
10.2.5 A/C SYSTEM PERFORMANCE TEST 834
10.2.6 LEAK TEST SYSTEM 834
10.3 ON VEHICLE REPAIRS 835
10.3.1 CONTROL PANEL ASSEMBLY 836
10.3.2 A/C COMPRESSOR 837
10.3.3 HVAC UNIT 848
10.3.4 BLOWER UNIT 852
10.3.5 BLOWER RESISTER 852
10.3.6 FILTER 853
10.3.7 EVAPORATOR AND EXPANSION VALVE 854
10.3.8 HEATER ASSEMBLY 856
10.3.9 KINEMATICS 857
10.3.10 PRESSURE SWITCH 857
10.3.11 CONDENSER ASSEMBLY 858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 862
10.3.14 REFRIGERANT LINES 863
10.3.15 HEATER LINES 865
11. FUEL SYSTEM 1228
11.1 INTRODUCTION 1232
A. CNG LAYOUT (ON VEHICLE) 1233
11.2. CNG FUEL SYSTEM COMPONENTS 1234
A. CNG CYLINDER 1234
B. CYLINDER VALVE 1236
C. LOW PRESSURE CNG FILTER 1241
D. PRESSURE GAUGE 1244
E. PRESSURE REGULATOR 1245
F. HIGH PRESSURE (H.P) SENSOR 1250
G. CNG RECEPTACLE VALVE 1252
11.3. CNG TUBE FITTINGS / JOINTS TIGHTENING INSTRUCTIONS 1255
A. SWAGING PROCEDURE 1255
B. PROCEDURE FOR NPT THREAD ASSEMBLY 1257
11.4. CNG LEAK DETECTION TESTING 1259
11.5. TROUBLE SHOOTING 1260
NANO ePAS 1296
1. GENERAL 7
1.1 AN OVERVIEW - NANO 15
1.2 ABBREVIATIONS 16
1.3 LIFTING, JACKING, TOWING POINTS 19
1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS 22
1.5 AGGREGATE NUMBERING SYSTEM 23
1.6 TECHNICAL SPECIFICATIONS 26
1.7 VEHICLE DIMENSIONS 28
1.8 FUEL, LUBRICANTS & COOLANTS 29
1.9 SERVICE SCHEDULE 32
2. PRECAUTIONS 35
2.1 GENERAL SAFETY PRECAUTIONS 41
2.2 GENERAL SERVICE PRECAUTIONS 45
3. ENGINE 47
3.1 GENERAL INFORMATION 55
3.1.1 TECHNICAL SPECIFICATIONS 57
3.1.2 FEATURES OF 273 MPFI ENGINE 58
3.1.3 TIGHTENING TORQUE 59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 65
3.2 ON VEHICLE PROCEDURES 69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 71
3.2.2 ENGINE OIL REPLACEMENT 73
3.2.3 OIL FILTER REPLACEMENT 74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 75
3.2.5 FUEL FILTER REPLACEMENT 76
3.2.6 TAPPET SETTING 77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 86
3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE 89
3.3 ENGINE MECHANICAL 91
PRELIMINARY INSPECTION OF ENGINE 93
REMOVAL OF ENGINE FROM VEHICLE 95
3.3.1 CYLINDER HEAD 99
3.3.1.1 GENERAL DESCRIPTION 101
3.3.1.2 EXPLODED VIEW 102
3.3.1.3 CYLINDER HEAD OVERHAUL 104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 108
3.3.1.6 INSPECTION & REPAIR DATA 111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 118
3.3.2 ENGINE BLOCK 123
3.3.2.1 GENERAL DESCRIPTION 125
3.3.2.2 EXPLODED VIEW 126
3.3.2.3 ENGINE BLOCK OVERHAUL 128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 128
3.3.2.5 INSPECTION & REPAIR DATA 133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 156
3.3.2.8 ENGINE TESTING 158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 158
3.4 ACCELERATOR 159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 161
3.4.2 SYSTEM MAINTENANCE 163
3.5 COOLING SYSTEM 167
3.5.1 GENERAL DESCRIPTION 169
3.5.3 EXPLODED VIEWS 170
3.5.4 SPECIFICATIONS 172
3.5.5 SYSTEM COMPONENTS 173
3.5.6 SYSTEM MAINTENANCE 174
3.6 LUBRICATION SYSTEM 183
3.6.1 GENERAL DESCRIPTION 185
3.6.2 SYSTEM SCHEMATICS 185
3.6.3 SPECIFICATIONS 186
3.6.4 SYSTEM MAINTENANCE 187
3.7 FUEL SYSTEM 199
3.7.1 GENERAL DESCRIPTION 201
3.7.2 SYSTEM SCHEMATICS 201
3.7.3 EXPLODED VIEWS 202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 203
3.7.5 SYSTEM COMPONENTS 204
3.7.6 SYSTEM MAINTENANCE 208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 218
3.8 INTAKE SYSTEM 221
3.8.1 GENERAL DESCRIPTION 223
3.8.2 EXPLODED VIEWS 224
3.8.3 SYSTEM MAINTENANCE 225
3.9 EXHAUST SYSTEM 231
3.9.1 GENERAL DESCRIPTION 233
3.9.2 EXPLODED VIEWS 234
3.9.3 TIGHTENING TORQUE 235
3.9.4 SYSTEM COMPONENTS 236
3.9.5 SYSTEM MAINTENANCE 238
3.10 IGNITION SYSTEM 243
3.10.1 GENERAL DESCRIPTION 245
3.10.2 SYSTEM SCHEMATICS 245
3.10.3 SYSTEM MAINTENANCE 246
3.11 ENGINE MANAGEMENT SYSTEM 251
ABBREVIATIONS 251
AN OVERVIEW 254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 255
3.11.1.1 ECU BLOCK DIAGRAM 256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 257
3.11.1.3 ECU HANDLING AND CARE 258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 259
3.11.2 SENSORS 260
3.11.2.1 CRANK SHAFT POSITION SENSOR 260
3.11.2.2 COOLANT TEMPERATURE SENSOR 261
3.11.2.3 T-MAP SENSOR 263
3.11.2.4 KNOCK SENSOR 264
3.11.2.5 THROTTLE POSITION SENSOR 265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 268
3.11.2.7 VEHICLE SPEED SENSOR 269
3.11.3 ACTUATORS 271
3.11.3.1 CANISTER PURGE VALVE 271
3.11.3.2 FUEL INJECTOR 272
3.11.3.3 IGNITION COIL 274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 277
3.11.3.5 COMPONENT FITMENT DATA 279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 283
3.11.4.1 DTC LIST 283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 293
3.11.4.3 BLINK CODE 308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 310
3.11.5.1 REPAIRING STEPS 310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 311
3.11.5.3 SENSOR AND ACTUATOR TESTING 312
3.11.5.4 EMERGENCY SERVICE TIPS 314
4. DRIVETRAIN 315
4.1 CLUTCH 321
4.1.1 GENERAL INFORMATION 323
4.1.1.1 TECHNICAL SPECIFICATIONS 323
4.1.1.2 CONSTRUCTION 326
4.1.1.3 PRECAUTIONS 328
4.1.1.4 TIGHTENING TORQUES 329
4.1.1.5 SPECIAL TOOLS 330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 331
4.1.1.7 TROUBLE SHOOTING 334
4.1.1.8 MAINTENANCE AND REPAIR 335
A. PRELIMINARY INSPECTION 335
B. CLUTCH SLIPPAGE TEST 335
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST 335
D. CLUTCH PEDAL PLAY ADJUSTMENT 335
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT 336
4.1.2 OVERHAUL 337
EXPLODED VIEWS 337
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 340
B. CLUTCH ACTUATION MECHANISM OVERHAUL 341
C. CLUTCH CABLE REPLACEMENT 344
4.2 TRANSAXLE TA-59 347
4.2.1 GENERAL INFORMATION 349
4.2.1.1 TECHNICAL SPECIFICATION 349
4.2.1.2 CONSTRUCTION 349
4.2.1.3 PRECAUTIONS 350
4.2.1.4 TIGHTENING TORQUES 351
4.2.1.5 SPECIAL TOOLS 354
4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 358
4.2.1.7 TRANSAXLE OIL REPLACEMENT 359
4.2.2 OVERHAUL 360
4.2.2.1 EXPLODED VIEWS 360
4.2.2.2 COMPONENT IDENTIFICATION 367
4.2.2.3 PRECAUTIONS 369
4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE 369
4.2.2.5 TRANSAXLE DISMANTLING 372
4.2.2.6 INPUT SHAFT ASSEMBLY 376
4.2.2.7 LAY SHAFT ASSEMBLY 381
4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK 387
4.2.2.9 DIFFERENTIAL ASSEMBLY 390
4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY 394
4.2.2.11 REAR HALF HOUSING ASSEMBLY 400
4.2.2.12 FRONT HALF HOUSING 402
4.2.2.13 TRANSAXLE ASSEMBLY 404
A. SHIM SELECTION 404
B. ASSEMBLING THE TRANSAXLE 405
4.2.2.14 GEAR SHIFTER LINKAGE 409
A. GEAR SHIFTER CABLE REPLACEMENT 409
B. GEAR SHIFTER ADJUSTMENT 410
4.3 DRIVESHAFT 411
4.3.1 GENERAL INFORMATION 413
4.3.1.1 TIGHTENING TORQUE 413
4.3.1.2 SPECIAL TOOL 414
4.3.1.3 CONSTRUCTIONAL DETAILS 415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 415
4.3.1.5 COMPONENT DESCRIPTION 416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 417
4.3.2 ON VEHICLE REPAIRS 418
4.3.2.1 PRECAUTIONS 418
4.3.2.2 REMOVAL FROM VEHICLE 420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 423
5. SUSPENSION SYSTEM 429
5.1 GENERAL INFORMATION 435
5.1.1 TECHNICAL SPECIFICATIONS 435
5.1.2 TIGHTENING TORQUES 436
5.1.3 SPECIAL TOOLS 439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 446
5.2 ON VEHICLE REPAIRS 449
5.2.1 FRONT SUSPENSION COMPONENTS 449
5.2.1.1 STRUT 449
5.2.1.2 ANTI-ROLL BAR 455
5.2.1.3 LOWER ARM 456
5.2.1.4 WHEEL BEARING 458
5.2.2 REAR SUSPENSION COMPONENTS 461
5.2.2.1 SHOCK ABSORBER 462
5.2.2.2 COIL SPRING 463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 464
5.2.2.4 SEMI TRAILING ARM 465
5.2.3 WHEEL HUB AND WHEEL BEARING 468
5.3 WHEELS AND TYRES 473
5.3.1 GENERAL INFORMATION 473
5.3.1.1 TECHNICAL SPECIFICATIONS 473
5.3.1.2 TIGHTENING TORQUE 474
5.3.1.3 EXPLODED VIEW 475
5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 476
5.3.2 ON VEHICLE REPAIRS 477
5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) 478
5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) 479
5.3.2.3 WHEEL BALANCING 480
5.3.2.4 WHEEL RUNOUT 481
5.3.2.5 TYRE REPLACEMENT 482
5.3.2.6 WHEEL ASSEMBLY REPLACEMENT 483
5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE 483
5.3.2.8 TYRE DIAGNOSIS 484
6. BRAKE SYSTEM 493
6.1 GENERAL INFORMATION 499
6.1.1 TECHNICAL SPECIFICATIONS 499
6.1.2 TIGHTENING TORQUES 500
6.1.3 SPECIAL TOOLS 504
6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM 505
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 507
6.2.1 FRONT DRUM BRAKES 507
6.2.2 REAR DRUM BRAKES 508
6.2.3 AUTO INCREMENTAL BRAKE 509
6.2.4 TANDEM MASTER CYLINDER (TMC) 510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 511
6.2.6 WHEEL CYLINDER 514
6.2.7 PARKING BRAKES 515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 523
6.4 ON VEHICLE REPAIRS 530
6.4.1 FRONT BRAKE COMPONENTS 531
6.4.2 FRONT BRAKE DRUM 532
6.4.3 FRONT BRAKE SHOES 534
6.4.4 FRONT BRAKE BACK PLATE 539
6.4.5 REAR BRAKE COMPONENTS 540
6.4.6 REAR BRAKE DRUM 541
6.4.7 REAR BRAKE SHOES 542
6.4.8 REAR BRAKE BACK PLATE 544
6.4.9 TMC 546
6.4.10 WHEEL CYLINDER 555
6.4.11 PARKING BRAKES 561
6.4.12 VACUUM BRAKE BOOSTER 564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 565
6.4.14 VACUUM LINES 567
7. STEERING 1302
7.1 GENERAL INFORMATION 1307
7.1.1 SPECIFICATIONS 1307
7.1.2 SYSTEM LAYOUT 1307
7.1.3 GENERAL DESCRIPTION 1308
7.1.4 TIGHTENING TORQUES 1309
7.1.5 SPECIAL TOOLS 1311
7.2. MAINTENANCE, INSPECTION AND TEST 1312
7.2.1 PRELIMINARY INSPECTION 1312
7.2.2 REGULAR MAINTENANCE 1313
7.2.3 ON VEHICLE REPAIRS 1315
7.2.3.1 STEERING WHEEL REMOVAL 1315
7.2.3.2 STEERING COLUMN REMOVAL 1316
7.2.3.3 INTERMEDIATE SHAFT REMOVAL 1317
7.2.3.4 ECU REMOVAL 1318
7.2.3.5 RACK & PINION ASSEMBLY REMOVAL 1319
7.3. OVERHAULING 1321
7.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 1321
7.3.2 PRECAUTIONS 1322
7.3.3 DISMANTLING, INSPECTION AND ASSEMBLY 1322
7.3.3.1 DISASSEMBLY OF RACK & PINON 1322
7.3.3.2 INSPECTION OF DISMANTLED PARTS 1323
7.3.3.3 ASSEMBLY OF RACK & PINON 1324
7.3.3.4 OBJ ON-VEHICLE REMOVAL 1325
7.3.3.5 DO’S & DON’TS 1326
7.3.3.6 WHEEL ALIGNMENT 1326
7.3.4 TROUBLESHOOTING AND DIAGNOSIS 1328
8. ELECTRICAL 1334
8.1. TECHNICAL SPECIFICATION 1340
8.2. INSTRUMENT CLUSTER 1342
8.2.1. ART WORK 1342
8.2.2. TELL TALES 1342
8.2.3. SPECIFICATION 1343
8.2.4. CONNECTION DETAILS 1343
8.2.5. CONNECTOR DETAILS 1343
8.2.6. PINOUT DETAILS 1343
8.2.7 FREQUENTLY ASKED QUESTIONSDistance to Empty (DTE) 1344
8.2.8 SEASON ODOMETER WRITING /UPDATING PROCEDURE 1346
8.3. EPAS ECU 1347
8.3.1. SPECIFICATION 1347
8.3.2. LOCATION 1347
8.3.3. CONNECTION DETAILS 1348
8.3.4. PINOUT DETAILS 1348
8.4. FUSEBOX & RELAY DETAILS 1349
8.4.1 LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE 1349
8.4.2. BATTERY MOUNTED FUSE BOX DETAILS (FOR NANO CNG AND MY13) 1349
8.4.3. CABIN FUSE BOX DETAILS(NANO MY13 EPAS) 1350
8.4.4. RELAY BOX DETAILS (FOR NANO CNG AND MY13) 1352
8.4.5. DIAGNOSTIC CONNECTOR LOCATION 1352
8.4.6 ECU AND STEERING COLUMN PAIRING PROCESS 1353
8.5 DIAGNOSTIC USER MANUAL 1354
8.6 DIAGNOSTIC TROUBLE CODES - EPAS 1364
8.7 DIAGNOSTIC TROUBLE CODES – EMS ECU 1371
9. BODY 721
9.1 GENERAL INFORMATION 727
9.1.1 TECHNICAL SPECIFICATIONS 727
9.1.2 TIGHTENING TORQUE 728
9.2 ON VEHICLE REPAIRS 732
9.2.1 EXPLODED VIEW - BUMPERS & HOOD 732
9.2.2 FRONT BUMPER 733
9.2.3 FENDER (SIDE BONNET) 734
9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER 735
9.2.5 FRONT DOOR 739
9.2.6 REAR DOOR 750
9.2.7 REAR SHELF 759
9.2.8 TAILGATE 759
9.2.9 REAR BUMPER 760
9.2.10 DASHBOARD 762
9.2.11 CENTER CONSOLE 765
9.2.12 SEATS & BELTS 766
9.2.13 OUTER REAR VIEW MIRROR (ORVM) 776
9.2.14 SUN VISOR 776
9.2.15 TRIMS 777
9.2.16 FLOOR CARPET 778
9.2.17 WINDSHIELD 781
9.3 PAINT CARE 783
9.4 BODY REPAIR DATA 786
9.5 TROUBLESHOOTING AND DIAGNOSIS 791
10. HVAC 793
10.1 GENERAL INFORMATION 799
10.1.1 TECHNICAL SPECIFICATIONS 799
10.1.2 TIGHTENING TORQUES 800
10.1.3 GENERAL PRECAUTIONS 802
10.1.4 SYSTEM LAYOUTS 804
10.1.5 COMPONENT DESCRIPTION 808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 825
10.2.3 FLUSHING OF AC SYSTEM 830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 832
10.2.5 A/C SYSTEM PERFORMANCE TEST 834
10.2.6 LEAK TEST SYSTEM 834
10.3 ON VEHICLE REPAIRS 835
10.3.1 CONTROL PANEL ASSEMBLY 836
10.3.2 A/C COMPRESSOR 837
10.3.3 HVAC UNIT 848
10.3.4 BLOWER UNIT 852
10.3.5 BLOWER RESISTER 852
10.3.6 FILTER 853
10.3.7 EVAPORATOR AND EXPANSION VALVE 854
10.3.8 HEATER ASSEMBLY 856
10.3.9 KINEMATICS 857
10.3.10 PRESSURE SWITCH 857
10.3.11 CONDENSER ASSEMBLY 858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 862
10.3.14 REFRIGERANT LINES 863
10.3.15 HEATER LINES 865
NANO OTG 1383
1. GENERAL 1387
1.1 TECHNICAL SPECIFICATION 1391
1.2 FUEL, LUBRICANTS AND COOLANTS 1393
1.3 SERVICE SCHEDULE 1394
2. PRECAUTIONS 35
2.1 GENERAL SAFETY PRECAUTIONS 41
2.2 GENERAL SERVICE PRECAUTIONS 45
3. ENGINE 47
3.1 GENERAL INFORMATION 55
3.1.1 TECHNICAL SPECIFICATIONS 57
3.1.2 FEATURES OF 273 MPFI ENGINE 58
3.1.3 TIGHTENING TORQUE 59
3.1.4 SPECIAL TOOLS & EQUIPMENTS 61
3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS 65
3.2 ON VEHICLE PROCEDURES 69
3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES 71
3.2.2 ENGINE OIL REPLACEMENT 73
3.2.3 OIL FILTER REPLACEMENT 74
3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT 75
3.2.5 FUEL FILTER REPLACEMENT 76
3.2.6 TAPPET SETTING 77
3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 78
3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 79
3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE 81
3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE 86
3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE 89
3.3 ENGINE MECHANICAL 91
PRELIMINARY INSPECTION OF ENGINE 93
REMOVAL OF ENGINE FROM VEHICLE 95
3.3.1 CYLINDER HEAD 99
3.3.1.1 GENERAL DESCRIPTION 101
3.3.1.2 EXPLODED VIEW 102
3.3.1.3 CYLINDER HEAD OVERHAUL 104
3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 104
3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES 108
3.3.1.6 INSPECTION & REPAIR DATA 111
3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 118
3.3.2 ENGINE BLOCK 123
3.3.2.1 GENERAL DESCRIPTION 125
3.3.2.2 EXPLODED VIEW 126
3.3.2.3 ENGINE BLOCK OVERHAUL 128
3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES 128
3.3.2.5 INSPECTION & REPAIR DATA 133
3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 143
3.3.2.7 REFITMENT OF ENGINE ACCESSORIES 156
3.3.2.8 ENGINE TESTING 158
3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE 158
3.4 ACCELERATOR 159
3.4.1 EXPLODED VIEWS & CABLE ROUTING 161
3.4.2 SYSTEM MAINTENANCE 163
3.5 COOLING SYSTEM 167
3.5.1 GENERAL DESCRIPTION 169
3.5.2 SYSTEM SCHEMATICS 169
3.5.3 EXPLODED VIEWS 170
3.5.4 SPECIFICATIONS 172
3.5.5 SYSTEM COMPONENTS 173
3.5.6 SYSTEM MAINTENANCE 174
3.6 LUBRICATION SYSTEM 183
3.6.1 GENERAL DESCRIPTION 185
3.6.2 SYSTEM SCHEMATICS 185
3.6.3 SPECIFICATIONS 186
3.6.4 SYSTEM MAINTENANCE 187
3.7 FUEL SYSTEM 199
3.7.1 GENERAL DESCRIPTION 201
3.7.2 SYSTEM SCHEMATICS 201
3.7.3 EXPLODED VIEWS 202
3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE 203
3.7.5 SYSTEM COMPONENTS 204
3.7.6 SYSTEM MAINTENANCE 208
3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM 218
3.8 INTAKE SYSTEM 221
3.8.1 GENERAL DESCRIPTION 223
3.8.2 EXPLODED VIEWS 224
3.8.3 SYSTEM MAINTENANCE 225
3.9 EXHAUST SYSTEM 231
3.9.1 GENERAL DESCRIPTION 233
3.9.2 EXPLODED VIEWS 234
3.9.3 TIGHTENING TORQUE 235
3.9.4 SYSTEM COMPONENTS 236
3.9.5 SYSTEM MAINTENANCE 238
3.10 IGNITION SYSTEM 243
3.10.1 GENERAL DESCRIPTION 245
3.10.2 SYSTEM SCHEMATICS 245
3.10.3 SYSTEM MAINTENANCE 246
3.11 ENGINE MANAGEMENT SYSTEM 251
ABBREVIATIONS 253
AN OVERVIEW 254
3.11.1 ECU (ELECTRONIC CONTROL UNIT) 255
3.11.1.1 ECU BLOCK DIAGRAM 256
3.11.1.2 ECU PIN ASSIGNMENT DETAILS 257
3.11.1.3 ECU HANDLING AND CARE 258
3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE 259
3.11.2 SENSORS 260
3.11.2.1 CRANK SHAFT POSITION SENSOR 260
3.11.2.2 COOLANT TEMPERATURE SENSOR 261
3.11.2.3 TMAP SENSOR 263
3.11.2.4 KNOCK SENSOR 264
3.11.2.5 THROTTLE POSITION SENSOR 265
3.11.2.6 LAMBDA (OXYGEN) SENSOR 268
3.11.2.7 VEHICLE SPEED SENSOR 269
3.11.3 ACTUATORS 271
3.11.3.1 CANISTER PURGE VALVE 271
3.11.3.2 FUEL INJECTOR 272
3.11.3.3 IGNITION COIL 274
3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) 277
3.11.3.5 COMPONENT FITMENT DATA 279
3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) 283
3.11.4.1 DTC LIST 283
3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER 293
3.11.4.3 BLINK CODE 308
3.11.5 TROUBLE SHOOTING AND DIAGNOSIS 310
3.11.5.1 REPAIRING STEPS 310
3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART 311
3.11.5.3 SENSOR AND ACTUATOR TESTING 312
3.11.5.4 EMERGENCY SERVICE TIPS 314
4. DRIVETRAIN 315
4.1 CLUTCH 321
4.1.1 GENERAL INFORMATION 323
4.1.1.1 TECHNICAL SPECIFICATIONS 323
4.1.1.2 CONSTRUCTION 326
4.1.1.3 PRECAUTIONS 328
4.1.1.4 TIGHTENING TORQUES 329
4.1.1.5 SPECIAL TOOLS 330
4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 331
4.1.1.7 TROUBLE SHOOTING 334
4.1.1.8 MAINTENANCE AND REPAIR 335
A. PRELIMINARY INSPECTION 335
B. CLUTCH SLIPPAGE TEST 335
C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST 335
D. CLUTCH PEDAL PLAY ADJUSTMENT 335
E. CLUTCH PEDAL FREE PLAY ADJUSTMENT 336
4.1.2 OVERHAUL 337
EXPLODED VIEWS 337
A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER 340
B. CLUTCH ACTUATION MECHANISM OVERHAUL 341
C. CLUTCH CABLE REPLACEMENT 344
4.2 TRANSAXLE TA-59 347
4.2.1 GENERAL INFORMATION 349
4.2.1.1 TECHNICAL SPECIFICATION 349
4.2.1.2 CONSTRUCTION 349
4.2.1.3 PRECAUTIONS 350
4.2.1.4 TIGHTENING TORQUES 351
4.2.1.5 SPECIAL TOOLS 354
4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS 358
4.2.1.7 TRANSAXLE OIL REPLACEMENT 359
4.2.2 OVERHAUL 360
4.2.2.1 EXPLODED VIEWS 360
4.2.2.2 COMPONENT IDENTIFICATION 367
4.2.2.3 PRECAUTIONS 369
4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE 369
4.2.2.5 TRANSAXLE DISMANTLING 372
4.2.2.6 INPUT SHAFT ASSEMBLY 376
4.2.2.7 LAY SHAFT ASSEMBLY 381
4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK 387
4.2.2.9 DIFFERENTIAL ASSEMBLY 390
4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY 394
4.2.2.11 REAR HALF HOUSING ASSEMBLY 400
4.2.2.12 FRONT HALF HOUSING 402
4.2.2.13 TRANSAXLE ASSEMBLY 404
A. SHIM SELECTION 404
B. ASSEMBLING THE TRANSAXLE 405
4.2.2.14 GEAR SHIFTER LINKAGE 409
A. GEAR SHIFTER CABLE REPLACEMENT 409
B. GEAR SHIFTER ADJUSTMENT 410
4.3 DRIVESHAFT 411
4.3.1 GENERAL INFORMATION 413
4.3.1.1 TIGHTENING TORQUE 413
4.3.1.2 SPECIAL TOOL 414
4.3.1.3 CONSTRUCTIONAL DETAILS 415
4.3.1.4 EXPLODED VIEW - DRIVESHAFT 415
4.3.1.5 COMPONENT DESCRIPTION 416
4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS 417
4.3.2 ON VEHICLE REPAIRS 418
4.3.2.1 PRECAUTIONS 418
4.3.2.2 REMOVAL FROM VEHICLE 420
4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY 423
5. SUSPENSION SYSTEM 429
5.1 GENERAL INFORMATION 435
5.1.1 TECHNICAL SPECIFICATIONS 435
5.1.2 TIGHTENING TORQUES 436
5.1.3 SPECIAL TOOLS 439
5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM 441
5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM 442
5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM 443
5.1.7 TROUBLESHOOTING AND DIAGNOSIS 446
5.2 ON VEHICLE REPAIRS 449
5.2.1 FRONT SUSPENSION COMPONENTS 449
5.2.1.1 STRUT 449
5.2.1.2 ANTI-ROLL BAR 455
5.2.1.3 LOWER ARM 456
5.2.1.4 WHEEL BEARING 458
5.2.2 REAR SUSPENSION COMPONENTS 461
5.2.2.1 SHOCK ABSORBER 462
5.2.2.2 COIL SPRING 463
5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT 464
5.2.2.4 SEMI TRAILING ARM 465
5.2.3 WHEEL HUB AND WHEEL BEARING 468
5.3 WHEELS AND TYRES 473
5.3.1 GENERAL INFORMATION 473
TECHNICAL SPECIFICATIONS 473
TIGHTENING TORQUE 474
EXPLODED VIEW 475
MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY 476
5.3.2 ON VEHICLE REPAIRS 477
WHEEL REMOVAL FROM VEHICLE (ON HOIST) 478
WHEEL REMOVAL FROM VEHICLE (WITH JACK) 479
WHEEL BALANCING 480
WHEEL RUNOUT 481
TYRE REPLACEMENT 482
WHEEL ASSEMBLY REPLACEMENT 483
REPAIRING TUBELESS TYRE PUNCTURE 483
TYRE DIAGNOSIS 484
6. BRAKE SYSTEM 493
6.1 GENERAL INFORMATION 499
6.1.1 TECHNICAL SPECIFICATIONS 499
6.1.2 TIGHTENING TORQUES 500
6.1.3 SPECIAL TOOLS 504
6.1.4 BRAKE CIRCUIT 1427
6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM 507
6.2.1 FRONT DRUM BRAKES 507
6.2.2 REAR DRUM BRAKES 508
6.2.3 AUTO INCREMENTAL BRAKE 509
6.2.4 TANDEM MASTER CYLINDER (TMC) 510
6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY 511
6.2.6 WHEEL CYLINDER 514
6.2.7 PARKING BRAKES 515
6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION 516
6.3.1 BLEEDING OF HYDRAULIC SYSTEM 521
6.3.2 TROUBLESHOOTING AND DIAGNOSIS 523
6.4 ON VEHICLE REPAIRS 530
6.4.1 FRONT BRAKE COMPONENTS 531
6.4.2 FRONT BRAKE DRUM 532
6.4.3 FRONT BRAKE SHOES 534
6.4.4 FRONT BRAKE BACK PLATE 539
6.4.5 REAR BRAKE COMPONENTS 540
6.4.6 REAR BRAKE DRUM 541
6.4.7 REAR BRAKE SHOES 542
6.4.8 REAR BRAKE BACK PLATE 544
6.4.9 TMC 546
6.4.10 WHEEL CYLINDER 555
6.4.11 PARKING BRAKES 561
6.4.12 VACUUM BRAKE BOOSTER 564
6.4.13 BRAKE HOSES/PIPES SCHEMATIC 565
6.4.14 VACUUM LINES 567
7. STEERING 569
7.1 GENERAL INFORMATION 575
7.1.1 TECHNICAL SPECIFICATIONS 575
7.1.2 TIGHTENING TORQUES 576
7.1.3 SPECIAL TOOLS 578
7.1.4 EXPLODED VIEWS 579
7.1.5 SCHEMATIC OF STEERING SYSTEM 581
7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM 583
7.3 ON VEHICLE REPAIRS 584
7.3.1 STEERING WHEEL 586
7.3.2 STEERING COLUMN ASSEMBLY 587
7.3.3 STEERING UPPER COLUMN 589
7.3.4 INTERMEDIATE SHAFT 589
7.3.5 STEERING RACK AND PINION ASSEMBLY 590
7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 592
7.3.7 WHEEL ALIGNMENT 601
7.3.8 TROUBLESHOOTING AND DIAGNOSIS 603
8. ELECTRICAL 607
8.1 TECHNICAL SPECIFICATION 613
8.2 GENERAL PRECAUTIONS 614
8.3 BATTERY 617
8.4 ALTERNATOR 620
8.5 STARTER MOTOR 641
8.6 LIGHTING SYSTEM 659
8.7 HORN 675
8.8 WIPER SYSTEM 677
8.9 FLASHER 686
8.10 FOG LAMP CONTROLLER 687
8.11 BRAKE LAMP CHECK 689
8.12 POWER SOCKET 689
8.13 CIGARETTE LIGHTER (IF EQUIPPED) 690
8.14 CENTRAL DOOR LOCKING 691
8.15 POWER WINDOW SYSTEM 694
8.16 INSTRUMENT CLUSTER 697
8.17 ELECTRICAL SWITCHES 700
8.18 ACCESSORY CONNECTORS 710
8.19 FUSE BOX/RELAY LOCATION & DETAILS 715
8.20 ELECTRIC WIRING AND FITMENT SCHEMATICS 716
8.20.1 HARNESS & CONNECTOR DESCRIPTION 716
8.20.2 UNDERSTANDING THE CIRCUIT SCHEMATIC 718
8.20.3 CONNECTOR CODE/PIN NO./CONNECTOR LAYOUT 719
8.20.4 ELECTRICAL SYMBOLS 720
9. BODY 1397
9.1 TIGHTENING TORQUES 1401
9.2 FRONT BUMPER REMOVAL AND REFITMENT 1402
9.3 REAR BUMPER REMOVAL AND REFITMENT 1403
9.4 TAILGATE REMOVAL AND REFITMENT 1404
9.5 TAIL LAMP ASSEMBLY REMOVAL ANDREFITMENT 1407
9.6 FRONT FOG LAMP REMOVAL AND REFITMENT 1408
9.7 LIGHT STALK REMOVAL AND REFITMENT 1409
9.8 COMBINATION SWITCH REMOVAL AND REFITMENT 1411
10. HVAC 793
10.1 GENERAL INFORMATION 799
10.1.1 TECHNICAL SPECIFICATIONS 799
10.1.2 TIGHTENING TORQUES 800
10.1.3 GENERAL PRECAUTIONS 802
10.1.4 SYSTEM LAYOUTS 804
10.1.5 COMPONENT DESCRIPTION 808
10.2 MAINTENANCE OF AC/HVAC SYSTEM 811
10.2.1 TROUBLESHOOTING AND DIAGNOSIS 812
10.2.2 PRESSURE TEST USING MANIFOLD GAUGES 825
10.2.3 FLUSHING OF AC SYSTEM 830
10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 832
10.2.5 A/C SYSTEM PERFORMANCE TEST 834
10.2.6 LEAK TEST SYSTEM 834
10.3 ON VEHICLE REPAIRS 835
10.3.1 CONTROL PANEL ASSEMBLY 836
10.3.2 A/C COMPRESSOR 837
10.3.3 HVAC UNIT 848
10.3.4 BLOWER UNIT 852
10.3.5 BLOWER RESISTER 852
10.3.6 FILTER 853
10.3.7 EVAPORATOR AND EXPANSION VALVE 854
10.3.8 HEATER ASSEMBLY 856
10.3.9 KINEMATICS 857
10.3.10 PRESSURE SWITCH 857
10.3.11 CONDENSER ASSEMBLY 858
10.3.12 DRIER CARTRIDGE/R.D. BOTTLE 860
10.3.13 CONDENSER FAN AND CONDENSER MOTOR 862
10.3.14 REFRIGERANT LINES 863
10.3.15 HEATER LINES 865
11. FUEL SYSTEM 1415
11.1 INTRODUCTION 1419
11.2 PRECAUTIONS 1419
11.3 SPECIFICATIONS 1419
11.4 TIGHTENING TORQUE 1420
11.5 FUEL TANK UNIT REMOVAL AND REFITMENT 1421
11.6 FUEL TANK REMOVAL AND REFITMENT 1422

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