Table of Contents 1 1080

TIGOR

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. PETROL ENGINE 30
2.1. GENERAL INFORMATION 36
A. ENGINE INTRODUCTION 36
B. ELECTRONIC FUEL INJECTION CONTROL 37
C. TECHNICAL SPECIFICATION 38
D. SPECIAL TOOLS 39
E. ASSEMBLY CLEARANCES 42
F. SEALANTS 42
G. LEAKAGE RATES 42
H. RECOMMENDED LUBRICANTS & COOLANTS 42
I. SERVICE SCHEDULE 43
2.2. TROUBLESHOOTING 44
2.3. CONSTRUCTIONAL AND SERVICE DETAILS 51
A. ENGINE LIFTING 51
B. INTAKE MANIFOLD 52
C.CYLINDER HEAD AND COVER 54
D. CYLINDER HEAD-A 56
E. CYLINDER HEAD-B 58
F. CYLINDER BLOCK 60
G. OIL SUMP 62
H. MOVING PARTS 64
I. ENGINE TIMING 67
J. EXHAUST MANIFOLD 69
K. FUEL INJECTION EQUIPMENT 71
L. LUBRICATION PUMP AND COMPONENTS 73
M. AIR INTAKE SYSTEM 75
N. SPECIAL INSTALLATION 77
O. ENGINE SUSPENSION 80
2.4. ENGINE TESTS AND MAINTENANCE 83
A. PRELIMINARY INSPECTION 83
B. ENGINE TESTS 84
I. ENGINE COMPRESSION TEST 84
II. ENGINE OIL CONSUMPTION TEST 85
III. ENGINE OIL PRESSURE TEST 86
C. REGULAR MAINTENANCE 87
I. ENGINE OIL AND FILTER CHANGE 87
II. ENGINE COOLANT REPLACEMENT 88
III. AIR FILTER ELEMENT REPLACEMENT 89
IV. SPARK PLUG REPLACEMENT 90
V. FUEL FILTER REPLACEMENT 93
VI. AIR CONDITIONER COMPRESSOR BELT REPLACEMENT 94
2.5. REPAIR AND INSPECTION DETAILS 95
A. ACCESSORY DRIVING BELT 95
B. TIMING CHAIN 95
C. CYLINDER HEAD 95
D. VALVES 96
E. CYLINDER HEAD VALVE SEATS 98
F. ROCKER ARM AND SHAFTS 99
G. HYDRAULIC LASH ADJUSTER 99
H. CAMSHAFT 99
I. PISTON AND PISTON RINGS 101
J. CONNECTING RODS 102
K. CRANKSHAFT 104
L. CRANK CASE 106
M. FUEL TANK 107
N. CANISTER PURGE VALVE 107
O. CANISTER 108
2.6. ENGINE SYSTEM 109
A. AIR INTAKE SYSTEM 109
B. BLOW BY SYSTEM 111
C. LUBRICATION SYSTEM 112
D. EXHAUST SYSTEM 116
E. COOLING SYSTEM 119
F. FUEL SYSTEM 122
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE 125
A. ENGINE REMOVAL AND INSTALLATION 125
B. AIR FILTER ASSY 130
C. INJECTION SYSTEM 131
D. SPARK PLUG 132
E. EXHAUST SYSTEM 132
F. FUEL SYSTEM 135
G. COOLING SYSTEM 141
H. REMOVAL OF ACCESSORIES 144
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 145
A. ENGINE DIS-ASSEMBLY 145
I. REMOVAL OF INTAKE MANIFOLD 145
II. REMOVAL OF EXHAUST MANIFOLD 146
III. REMOVAL OF OIL SUMP 148
IV. REMOVAL OF SENSORS 148
V. REMOVAL OF ACCESSORIES 149
VI. REMOVAL OF TIMING CHAIN 152
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT 154
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 155
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 157
B. ENGINE ASSEMBLY 161
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES 161
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 165
III. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 167
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 169
V. ASSEMBLY OF TIMING CHAIN 170
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT 174
VII. FITMENT OF ENGINE SENSORS AND PERIPHERALS 175
VIII. FITMENT OF OIL SUMP 176
IX. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 177
X. ASSEMBLY OF INTAKE MANIFOLD 179
2.9. ENGINE MANAGEMENT SYSTEM 181
A. ABBREVIATIONS 181
B. AN OVERVIEW 182
C. ELECTRONIC CONTROL UNIT 183
D. SENSORS 188
I. T-MAP SENSOR 189
II. LAMBDA SENSOR 190
III. CAMSHAFT POSITION SENSOR 192
IV. KNOCK SENSOR 193
V. CRANKSHAFT POSITION SENSOR 194
VI. COOLANT TEMPERATURE SENSOR 195
E. ACTUATORS 197
I. IGNITION COIL 198
II. PURGE CONTROL VALVE 199
III. SOLENOID VALVE (OCV) 200
IV. FUEL INJECTOR 201
V. ELECTRONIC THROTTLE BODY 202
F. SWITCH 204
I. OIL PRESSURE SWITCH 204
II. THROTTLE PEDAL SENSOR 205
III. CLUTCH SWITCH 206
IV. BRAKE SWITCH 207
V. VEHICLE SPEED SENSOR 208
VI. WHEEL SPEED SENSOR 209
3. DIESEL ENGINE 210
3.1. GENERAL INFORMATION 215
A. ENGINE INTRODUCTION 215
B. TECHNICAL SPECIFICATION 216
C. SPECIAL TOOLS 217
D.ASSEMBLY CLEARANCES 221
E. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES 222
F. SERVICE SCHEDULE 223
3.2. TROUBLESHOOTING 224
3.3. CONSTRUCTIONAL AND SERVICE DETAILS 232
A. ENGINE MOUNTING SYSTEM 232
B. CYLINDER HEAD AND COVER 234
C. LUBRICATION SYSTEM 236
D. ENGINE 238
E. OIL SUMP 240
F. CYLINDER HEAD 242
G. SPECIAL INSTALLATION 244
H. EXHAUST SYSTEM 246
I. INTAKE SYSTEM 248
J. ENGINE SUSPENSION 250
K. MOVING PARTS 252
L. ENGINE TIMING 254
M. FUEL INJECTION EQUIPMENT 256
3.4. ENGINE TESTS AND MAINTENANCE 258
A. PRELIMINARY INSPECTION 258
B. ENGINE TESTS 258
C. REGULAR MAINTENANCE 262
I. ENGINE OIL AND FILTER CHANGE 262
II.ENGINE COOLANT REPLACEMENT 263
III. AIR FILTER ELEMENT REPLACEMENT 264
IV. FUEL FILTER REPLACEMENT 265
V. DRAINING WATER FROM PRE-FILTER 266
VI. PRE-FILTER REPLACEMENT 266
VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT 267
3.5. REPAIR AND INSPECTION DETAILS 268
A. TIMING BELT 268
B. FUEL TANK 268
C. CYLINDER HEAD 269
D. VALVES 270
E. VALVE SEATS 271
F. CRANKCASE 272
G. VALVE SEAT INSERT 273
H. HYDRAULIC LASH ADJUSTER 273
I. VALVE GUIDES 274
J. CAMSHAFT 275
K. PISTON AND PISTON RINGS 276
L. CONNECTING ROD 277
M. CRANKSHAFT 279
3.6. ENGINE SYSTEM 281
A. AIR INTAKE SYSTEM 281
B. EXHAUST SYSTEM 283
C. COOLING SYSTEM 287
D. LUBRICATION SYSTEM 290
E. EXHAUST GAS RECIRCULATION SYSTEM 293
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM 295
G. VACUUM MANAGEMENT SYSTEM 296
H. FUEL SYSTEM 297
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE 303
A. ENGINE REMOVAL 303
B. ENGINE INSTALLATION 307
C. EXHAUST SYSTEM 308
D. COOLING SYSTEM 310
E. FUEL SYSTEM 312
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) 319
A. ENGINE DIS-ASSEMBLY 319
I ON OVERHAUL STAND 319
II. REMOVAL OF INTAKE MANIFOLD 322
III. REMOVAL OF EXHAUST MANIFOLD 324
IV. REMOVAL OF OIL SUMP 328
V. REMOVAL OF TIMING BELT 329
VI. REMOVAL OF CYLINDER HEAD 332
VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 333
VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 335
IX. PISTON CONNECTING ROD DIS-ASSEMBLY 337
B. ENGINE ASSEMBLY 343
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES 343
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 344
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES 345
IV.FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK 346
V. FITMENT OFTIMING BELT 347
VI. FITMENT OF OIL SUMP 350
VII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS 352
VIII. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS 356
IX. ON ENGINE SUPPORT STAND 358
3.9. ENGINE MANAGEMENT SYSTEM 362
A. ABBREVIATIONS 362
B. AN OVERVIEW 363
C. ELECTRONIC CONTROL UNIT (ECU) 364
D. EMS SENSORS 368
I. CRANK POSITION SENSOR 368
II. VEHICLE SPEED SENSOR 369
III. WHEEL SPEED SENSOR 370
IV. CAMSHAFT POSITION SENSOR 371
V. AIR MASS FLOW SENSOR 372
VI. INLET METERING VALVE 373
VII. VENTURI 373
VIII. RAIL PRESSURE SENSOR 373
IX. THROTTLE PEDAL SENSOR 374
X. WATER IN FUEL SENSOR 375
XI. CLUTCH SWITCH 375
XII. OIL PRESSURE SWITCH 376
XIII. BRAKE SWITCH 378
XIV. COOLANT TEMPERATURE SENSOR 379
XV. GLOW PLUG 380
XVI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) 381
4. DRIVETRAIN 382
4.1. PRECAUTION 386
4.2. SPECIFCICATIONS & TIGHTENING TORQUES 387
A. CLUTCH 387
B. TRANSAXLE 392
C. TIGHTENING TORQUES 393
4.3. SPECIAL TOOLS 394
A. CLUTCH 394
B. TRANSAXLE 394
4.4. DIAGNOSIS 399
A. CLUTCH 399
B. TRANSAXLE 402
4.5. MAINTENANCE, ADJUSTMENT & TEST 403
A. PRELIMINARY INSPECTION OF CLUTCH 403
B. DRIVESHAFT 404
4.6. CLUTCH 406
A. THEORY OF DIAPHRAGM SPRING CLUTCH 406
B. CONSTRUCTIONAL DETAILS 407
C. FACTOR AFFECTING CLUTCH WEAR 409
D. CLUTCH CABLE – REMOVAL AND INSPECTION 410
E. REMOVAL OF CLUTCH FROM THE CAR 411
F. INSTALLATION OF CLUTCH ON THE CAR 411
G. PROCEDURE FOR CLUTCH ADJUSTMENT 412
4.7. TRANSAXLE 413
A. GENERAL DISCRIPTION 413
B. CUT SECTION OF TRANSAXLE TA 65 STAR 415
C. CUT SECTION OF TOP COVER ASSEMBLY 416
D. EXPLODED VIEW OF TRANSAXLE 417
E. EXPLODED VIEWS OF DIFFERENTIAL 419
F. EXPLODED VIEW OF SHIFTER FORK 421
G. EXPLODED VIEWS OF GEAR SHIFT LINKAGE ASSSEMBLY 423
H. EXPLODED VIEWS OF LAY SHAFT AND INPUT SHAFT 424
I. REMOVAL OF TRANSAXLE FROM THE VEHICLE 427
J. TRANSAXLE TA65 STAR (ON BENCH) DISASSSEMBLY 429
K. INPUT SHAFT SUB- ASSEMBLY 435
L. INPUT SHAFT ASSEMBLY 435
M. DISASSEMBLY OF LAY SHAFT 436
N. IDENTIFICATION OF COMPONENTS 438
O. SUBASSEMBLIE 441
P. LAY SHAFT ASSEMBLY 443
Q. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL 446
R. ASSEMBLY OF TRANSAXLE 448
S. ASSEMBLY OF TOP COVER 451
T. INSTALLATION OF TRANSAXLE ON CAR 455
U. REMOVAL OF GEARSHIFT HOUSING, GEAR SHIFTER AND SELECTOR CABLE 456
4.8. DRIVE SHAFT 458
A. DRIVE SHAFT PARTS 458
B. DISASSEMBLY AND ASSEMBLY PROCEDURE DRIVESHAFT TRIPOT JOINT 459
C. DISASSEMBLY AND ASSEMBLY CV JOINT ASSEMBLY (OUTER) 462
5. SUSPENSION 466
5.1. TECHNICAL SPECIFICATION AND TIGHTENING TORQUE 470
5.1.1. SPECIFCICATIONS 470
5.1.2. TIGHTENING TORQUES 471
5.2. SPECIAL TOOLS 472
5.3. DIAGNOSIS 478
5.4. PRECAUTION 479
5.5. SUSPENSION SYSTEM 480
5.6. EXPLODED VIEWS FRONT SUSPENSION SYSTEM 483
5.6.1. ASSEMBLY FRONT STRUT EXPLODED VIEW 483
5.6.2. LOWER ARM LINK EXPLODED VIEW 484
5.6.3. ANTI ROLL BAR MOUNTING EXPLODED VIEW 485
5.6.4. FRONT AXLE ASSEMBLY EXPLODED VIEW 486
5.7. ON VEHICLE REPAIRS FRONT SUSPENSION 487
5.7.1. REMOVAL AND INSTALLATION OF STRUT ASSEMBLY 487
5.7.2. DISASSEMBLY AND ASSEMBLY OF FRONT STRUT 488
5.7.3. REMOVAL AND INSTALLATION OF WHEEL HUB 491
5.7.4. REMOVAL AND INSTALLATION OF ANTI ROLL BAR 494
5.7.5. REMOVAL AND INSTALLATION OF LOWER ARM ASSEMBLY 496
5.7.6. REMOVAL AND INSTALLATION OF LOWER ARM BALL JOINT 497
5.7.7. REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES 499
5.7.8. PROCEDURE FOR CHECKING BALL JOINT PLAY ON LOWER ARM 500
5.8. EXPLODED VIEWS REAR SUSPENSION SYSTEM 501
5.8.1. REAR SHOCK ABSORBER EXPLODED VIEW 501
5.8.2. REAR HUB ASSEMBLY EXPLODED VIEW 502
5.8.3. PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW 503
5.9. ON VEHICLE REPAIRS REAR SUSPENSION 504
5.9.1. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER FROM VEHICLE 504
5.9.2. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER 504
5.9.3. REMOVAL AND INSTALLATION OF TORSION BEAM 507
5.9.4. TWIST BEAM BUSH REMOVAL 510
5.10. WHEELS AND TYRES 512
A. TYRE INSPECTION 512
B. PRLACEMENT OF TYRE 512
C. TYRE INSPECTION 512
5.10.1. HOW TO MEASURE WHEEL RUNOUT 512
5.10.2. INFLATION OF TYRES 513
5.10.3. TYRE ROTATION 514
5.10.4. WHEEL REMOVAL 514
5.10.5. TYRE MOUNTING AND DEMOUNTING 514
5.10.6. WHEEL ALIGNMENT 515
5.10.7. BALANCING WHEELS 515
5.10.8. TYRE CARE 515
6.BRAKE 516
6.1. PRECAUTIONS 520
6.2. TECHNICAL SPECIFICATIONS 521
6.3. TIGHTENING TORQUES 523
6.4. DIAGNOSIS 524
6.5. NESSECITY OF ABS WITH EBD 527
6.6. BRAKE HYDRAULIC LINES 528
6.7. VACUUM BRAKE BOOSTER 530
6.8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 531
6.9. ABS COMPONENTS 535
6.9.1. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 535
6.9.2. HYDRAULIC CONTROL UNIT 537
6.9.3. WHEEL SPEED SENSOR (MONITORS WHEEL SPEED) 538
6.9.4. ABS SYSTEM FAILURE WARNING LIGHT 539
6.10. MAINTENANCE, ADJUSTMENTS & TEST 540
6.10.1. FRONT BRAKE MAINTENANCE 540
6.10.2. REAR BRAKE MAINTENANCE 542
6.10.3. BRAKE TROUBLE SHOOTING 547
6.10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO 548
6.11. BRAKE PEDAL ASSEMBLY 550
6.12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 551
6.13. REPAIRS 552
6.13.1. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT 553
6.13.2. REMOVAL OF FRONT BRAKE DISC 559
6.13.3. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY 560
6.13.4. REAR BRAKE ASSEMBLY 562
6.13.5. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY 564
6.13.6. REMOVAL OF PARKING BRAKE LEVER 570
6.13.7. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE 571
6.13.8A PARKING BRAKE CABLE ADJUSTMENT 572
6.13.8B PARKING BRAKE CABLE ADJUSTMENT 572
6.13.9. REMOVAL AND REFITMENT OF ABS ECU / HCU 573
6.13.10. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR 574
6.13.11. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR 575
6.14. TROUBLE SHOOTING & DIAGNOSIS 577
6.15. ABS ECU CONNECTOR 579
7A. STEERING (BOSCH) 581
7.1. GENERAL INFORMATION 584
7.1.1. SPECIFICATIONS 584
7.1.2. SYSTEM LAYOUT 584
7.1.3. GENERAL DISCRIPTION 585
7.1.4. TIGHTENING TORQUES 586
7.1.5. SPECIAL TOOLS 588
7.2. MAINTENANCE, INSPECTION AND TEST 589
7.2.1. PRELIMINARY INSPECTION 589
7.2.2. REGULAR MAINTENANCE 590
7.2.3. ON VEHICLE REPAIRS 591
7.2.3.1. STEERING WHEEL REMOVAL 591
7.2.3.2. STEERING COLUMN REMOVAL 592
7.2.3.3. INTERMEDIATE SHAFT REMOVAL 594
7.2.3.4. ECU REMOVAL 594
7.2.3.5. RACK & PINION ASSEMBLY REMOVAL 596
7.3. OVERHAULING 598
7.3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY 598
7.3.2. PRECAUTIONS 599
7.3.3. DISMANTLING, INSPECTION & ASSEMBLY 599
7.3.3.1. DISASSEMBLY OF RACK & PINOIN 599
7.3.3.2. INSPECTION OF DISMANTLED PARTS 600
7.3.3.3. ASSEMBLY OF RACK & PINOIN 600
7.3.3.4. OBJ ON VEHICLE REMOVAL 601
7.3.3.5. DO'S & DON’T'S 601
7.3.3.6. WHEEL ALIGNMENT 602
7.4. TROUBLESHOOTING AND DIAGNOSIS 605
7.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS 609
7.6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD 611
7B. STEERING (MANDO) 617
1 GENERAL INFORMATION 623
1.1 SPECIFICATIONS 623
1.2 SYSTEM LAYOUT 623
1.3 GENERAL DESCRIPTION 624
1.4 TIGHTENING TORQUES 625
2. MAINTENANCE, INSPECTION AND TEST 628
2.1 PRELIMINARY INSPECTION 628
2.2 REGULAR MAINTENANCE 629
2.3 ON VEHICLE REPAIRS 630
2.3.1 STEERING WHEEL REMOVAL 630
2.3.2 STEERING COLUMN REMOVAL 632
2.3.3 INTERMEDIATE SHAFT REMOVAL 634
2.3.4 ECU REMOVAL 634
2.3.5 MOTOR REMOVAL 635
2.3.6 RACK & PINION ASSEMBLY REMOVAL 636
3. OVERHAULING 638
3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 638
3.2 PRECAUTIONS 639
3.3 DISMANTLING, INSPECTION AND ASSEMBLY 639
3.3.1 DISASSEMBLY OF RACK & PINON 639
3.3.2 INSPECTION OF DISMANTLED PARTS 640
3.3.3 ASSEMBLY OF RACK & PINON 640
3.3.4 OBJ ON-VEHICLE REMOVAL NOTE 641
3.3.5 DO’S & DON’TSDON’TS 641
3.3.6 WHEEL ALIGNMENT 645
4. TROUBLESHOOTING AND DIAGNOSIS 647
5. STEERING ANGLE CALIBRATION PROCESS 651
6. Electric Power Assisted Steering (EPAS) ECU replacement and software update procedure in fieldGeneral 658
7. CIRCUIT SCHEMATICS OF MANDO EPAS 662
8.ELECTRICAL 663
8.1. TECHNICAL SPECIFICATION 668
8.2. GENERAL PRECAUTIONS 670
8.3. FUSE BOX / RELAY LOCATIONS 674
8.4. BATTERY 675
8.5. ALTERNATOR 677
8.6. STARTER MOTOR 680
8.7. LIGHTING SYSTEM 687
8.7.1. BULB SPECIFICATIONS 687
8.7.2. FASTENERS TORQUE VALUE TABLE 688
8.7.3. GENERAL SYMPTOMS AND DIAGNOSTICS 688
8.7.4. HEAD LAMP 692
8.7.5. SIDE REPEATER LAMP 699
8.7.6. ROOF LAMP 700
8.7.7. HIGH MOUNTED STOP LAMP 701
8.7.8. TAIL LAMP 702
8.7.9. FRONT FOG LAMP 706
8.7.10. REGISTRATION PLATE LAMP 707
8.8. HORN 708
8.9. WIPER & WASHER SYSTEM 710
8.9.1. FRONT AND REARWIPER ANDWAHSER SYSTEM LAYOUT 711
8.9.2. FRONT AND REARWASH/WIPE SWITCH FUNCTIONALITY 712
8.9.3. WIPER ANDWIPER CARE 716
8.10. POWER SOCKETS 718
8.11. GLOWPLUG CONTROL UNIT 719
8.12. FUEL GAUGE AND FUEL LEVEL METER 721
8.13. COMBI-SWITCH 723
8.14. STEERING LOCK CUM IGNITION SWITCH 729
8.15. FASCIA SWITCHES 731
8.16. HAZARD SWITCH 735
8.17. MIRROR SWITCH 736
8.18. INFOTAINMENT SYSTEM 737
8.18.1. USB/AUX PORT 738
8.18.2. USB / AUX PORT 741
8.18.3. SPEAKERS 742
8.18.4. TWEETER 743
8.18.5. ANTENNA 745
8.18.6. MICROPHONE 745
8.18.7. DTC FOR INFOTAINMENT SYSTEM 747
8.19. WINDOW WINDING MODULE 748
8.20. POWER WINDOW SWITCHES 751
8.21. STEERING WHEEL SWITCHES 756
8.22. IGNITION E-KEY 759
8.23. INSTRUMENT CLUSTER 761
8.23.1. BASIC FUNCTIONALMATRIX 763
8.23.2.TELL TALESMATRIX 764
8.23.3. DRIVER INFORMATION SYSTEM 770
8.23.4. DTC FOR INSTRUMENT CLUSTER 774
8.23.5. CONNECTOR DETAILS 775
8.23.6. FUEL GAUGE DETAILS 776
8.23.7. TEMPERATURE BAR GRAPH DETAILS 777
8.23.8. CHIME TABLE 778
8.23.9. DISPLAY SCREEN FLOWAND SETTINGS 778
8.24 IMMOBILIZER SYSTEM 784
8.24.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 789
8.24.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU 790
8.24.3. DTC FOR IMMOBILIZER 792
8.24.4. IGNITION KEYLEARNINGPROCEDURE 794
8.25. BODY CONTROLMODULE (BCM) 797
8.25.1. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 803
8.25.2. BCM FUNCTIONS 815
8.25.3. DTC FOR BCM 853
8.26. CLUTCH PEDAL SENSOR 860
8.27. FUSE AND RELAY BOX DETAILS 863
8.27.1. BATTERY MOUNTED FUSE BOX (BDU) 866
8.27.2. ENGINE FUSE AND RELAY BOX 867
8.27.3. CABIN FUSE AND RELAY BOX 872
8.27.4. CIRCUIT SCHMATICS 875
8.27.5. DTC 875
8.28. REVERSE PARK ASSIST SYSTEM 876
8.28.1. PARK ASSIST 876
8.28.2. PARK ASSIST FUNCTIONALITY OVERVIEW 876
8.28.3. PARK ASSIST ACTIVATION PROCEDURE 876
8.28.4. PARK ASSIST DEACTIVATION PROCEDURE 877
8.28.5. PARK ASSIST AUDIO SETTING 877
8.28.6. PARK ASSIST VOLUME 877
8.28.7. MIXWITH AUDIO 877
8.28.8. PARK ASSIST TONE 878
8.28.9. PARK ASSIST DELAY TIMER 878
8.28.10. PARK ASSIST HMI INDICATIONS 878
8.28.11. PARK ASSIST LIMITATIONS 879
8.28.12. PARK ASSIST SYSTEM MAINTENANCE 879
8.28.13. PARK ASSIST SYSTEM ARCHITECTURE 880
8.28.14. REAR VIEW CAMERA 881
8.28.15. ECU TO SENSOR ELECTRICAL INTERFACE 882
8.28.16. ECU MOUNTING 882
8.28.17. PHYSICAL IMAGE 884
8.28.18. SENSOR FITMENT TO THE BUMPER 884
9. BODY 887
9.1 GENERAL INFORMATION 891
9.1.1. LAYOUT 891
9.1.2. TIGHTENING TORQUES 892
9.1.3. SPECIAL TOOLS 898
9.2 ON VEHICLE REPAIRS 899
9.2.1. BONNET 899
9.2.2. FLOOR CONSOLE 901
9.2.3. DASHBOARD SKIN REMOVAL PROCEDURE 904
9.2.4. CROSS CAR BEAM WITH COCKPIT ASSEMBLY REMOVAL 907
9.2.5. GLOVE BOX 911
9.2.6. SIDE AIR VENTS 912
9.2.7. FRONT BUMPER 913
9.2.8. REAR BUMPER 914
9.2.9. FRONT DOOR 915
9.2.10. FRONT DOOR TRIMS 916
9.2.11. DOOR INNER LOCK HANDLE 917
9.2.12. FRONT OUTER DOOR LOCK 918
9.2.13. FRONT DOOR LATCH 919
9.2.14. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 921
9.2.15. REAR DOOR 922
9.2.16. REAR DOOR TRIM 923
9.2.17. REAR OUTER DOOR LOCK 925
9.2.18. DOOR LATCH REAR 926
9.2.19. TRUNK LID 927
9.2.20. TRUNK LID TRIM 930
9.2.21. ORVM 931
9.2.22. INNER REAR VIEW MIRROR 932
9.2.23. FRONT ROW SEAT 932
9.2.24. REAR ROW SEAT 933
9.2.25. REAR ROW SEAT ARMREST 934
9.2.26. FRONT SEAT BELTS 935
9.2.27. REAR SEAT BELT 937
9.2.28. “A” PILLAR TRIM 939
9.2.29. FRONT SCUFF PLATE 940
9.2.30. “B" PILLAR TRIMS 941
9.2.31. “C” PILLAR TRIM 942
9.2.32. GRAB HANDLES 943
9.2.33. SUNVISOR 943
9.2.34. ROOF LINER 944
9.2.35. PLENUM COVER 945
9.2.36. GEAR LEVER BOOT 946
9.2.37. BONNET INSULATION 946
9.2.38. GLASS 947
9.2.39. REAR QUARTER GLASS 948
9.2.40. FUEL FILLER ASSEMBLY 949
9.2.41. FRONT WHEEL ARCH LINER 951
9.2.42. REAR WHEEL ARCH LINER 952
9.2.43. FRONT FENDER 953
9.2.44. FRONT WIPER 954
9.2.45. REAR DOOR CHEATER 955
10. HVAC 957
10.1. GENERAL INFORMATION 960
10.1.1. SPECIFICATIONS 960
10.1.2. TIGHTENING TORQUES 962
10.1.3. PRECAUTIONS 970
10.1.4. HVAC SYSTEM LAYOUT & WORKING 972
10.1.5. COMPONENTS OF HVAC 976
10.1.5.1. CONTROL PANEL 976
10.1.5.2. HVAC UNIT 979
10.1.5.3. COMPRESSOR 982
10.1.5.4. CONDENSOR & RECEIVER DRIER 983
10.1.5.5. THERMISTOR / THERMO SENSOR 984
10.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR 987
10.1.5.7. AIR INLET ACTUATOR 988
10.1.6. TROUBLESHOOTING 989
10.2. MAINTAINANCE 1003
10.2.1. PRELIMINARY INSPECTION 1003
10.2.2. REGULAR MAINTENANCE 1005
10.3. ON VEHICLE REPAIR 1010
10.3.1. CONTROL PANEL ASSEMBLY 1010
10.3.2. COMPRESSOR 1015
10.3.3. BLOWER 1015
10.3.4. BLOWER RESISTER 1016
10.3.5. FILTER 1016
10.3.6. TXV 1017
10.3.7. PRESSURE SENSOR / SWITCH 1017
10.3.8. HVAC UNIT 1018
10.3.9. CONDENSOR SEALING DUCT 1019
10.3.10. CONDENSOR 1019
10.3.11. REFRIGERANT HOSES 1021
10.3.12. DO's & DON’T's 1023
10.4. OVERHAULING HVAC UNIT 1024
11.FATC 1031
11.1.1. TECHNICAL SPECIFICATIONS 1034
11.1.2. TIGHTENING TORQUES 1036
A. FOR PETROL VARIENT 1036
B. FOR DIESEL VARIENT 1039
11.1.3. FATC LAYOUT 1043
11.1.4. FATC CONTROL PANEL 1045
11.1.5. CONTROL PANEL CONNECTOR DETAILS 1049
11.1.6. FATC SENSOR 1051
A. SOLAR LOAD SENSOR 1051
B. OAT SENSOR 1052
C. THERMISTOR OR THERMO SENSOR 1054
D. AIR INLET ACTUATOR 1055
E. LINEAR POWER MODULE 1056
12.SRS 1058
12.1. WORKING OF RESTRAINTS 1061
A. RESTRAINTSWITHOUT AIRBAGS 1061
B. RESTRAINTSWITH AIRBAGS 1061
12.2. SYSTEM LAYOUT 1062
12.2.1 RESTRAINT WITHOUT AIRBAG 1062
12.2.2 RESTRAINT WITH AIRBAG 1062
12.3. SAFETY PRECAUTIONS 1063
12.4. DISPOSAL OF FAULTY AIR BAG UNIT 1065
12.5. SRS POST ACCIDENT PROCEDURE 1066
12.6. TIGHTENING TORQUES 1067
12.7. COMPONENTS 1068
12.7.1 RESTRAINT WITHOUT AIRBAGS 1068
A. SEAT BELT 1068
B. EMERGENCY LOCKING RETRACTOR (ELR) 1068
C. MICROSWITCH / SEAT BELT REMINDERWARNING LAMP 1068
12.7.2 RESTRAINT WITH AIRBAGS 1068
12.7.2.1.ECU 1068
12.7.2.2. SENSORS 1071
12.7.2.3. AIR BAGS 1073
12.7.2.4. RPLL BELTS 1075
12.7.2.5. CLOCK SPRING 1077

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