|
1.2L REVOTRON NGNA ENGINE
|
6 |
|
1. GENERAL INFORMATION
|
12 |
|
A. ENGINE INTRODUCTION
|
12 |
|
B. ELECTRONIC FUEL INJECTION CONTROL
|
13 |
|
C. TECHNICAL SPECIFICATION
|
14 |
|
D. SPECIAL TOOLS
|
15 |
|
E. ASSEMBLY CLEARANCES
|
18 |
|
F. SEALANTS
|
18 |
|
G. LEAKAGE RATES
|
18 |
|
2. TROUBLESHOOTING
|
19 |
|
3. CONSTRUCTIONAL AND SERVICE DETAILS
|
25 |
|
A. ENGINE LIFTING
|
25 |
|
B. INTAKE MANIFOLD
|
26 |
|
C. CYLINDER HEAD AND COVER
|
28 |
|
D. CYLINDER HEAD-A
|
30 |
|
E. CYLINDER HEAD-B
|
32 |
|
F. CYLINDER BLOCK
|
33 |
|
G. OIL SUMP
|
35 |
|
H. MOVING PARTS
|
36 |
|
I. ENGINE TIMING
|
38 |
|
J. EXHAUST MANIFOLD
|
40 |
|
K. FUEL INJECTION EQUIPMENT
|
41 |
|
L. LUBRICATION PUMP AND COMPONENTS
|
42 |
|
M. AIR INTAKE SYSTEM
|
44 |
|
N. SPECIAL INSTALLATION
|
46 |
|
O. ENGINE SUSPENSION
|
49 |
|
4. ENGINE TESTS AND MAINTENANCE
|
51 |
|
A. PRELIMINARY INSPECTION
|
51 |
|
B. ENGINE TESTS
|
52 |
|
I. ENGINE COMPRESSION TEST
|
52 |
|
II. ENGINE OIL CONSUMPTION TEST
|
53 |
|
III. ENGINE OIL PRESSURE TEST
|
54 |
|
C. REGULAR MAINTENANCE
|
55 |
|
I. ENGINE OIL AND FILTER CHANGE
|
55 |
|
II. ENGINE COOLANT REPLACEMENT
|
56 |
|
III. AIR FILTER ELEMENT REPLACEMENT
|
60 |
|
IV. SPARK PLUG REPLACEMENT
|
61 |
|
V. FUEL FILTER REPLACEMENT
|
63 |
|
VI. AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT
|
64 |
|
5. REPAIR AND INSPECTION DETAILS
|
65 |
|
A. ACCESSORY DRIVING BELT
|
65 |
|
B. TIMING CHAIN
|
65 |
|
C. CYLINDER HEAD
|
65 |
|
D. VALVES
|
66 |
|
E. CYLINDER HEAD VALVE SEATS
|
67 |
|
F. ROCKER ARM AND SHAFTS
|
67 |
|
G. HYDRAULIC LASH ADJUSTER
|
68 |
|
H. CAMSHAFT
|
68 |
|
I. PISTON AND PISTON RINGS
|
69 |
|
J. CONNECTING RODS
|
70 |
|
K. CRANKSHAFT
|
71 |
|
L. CRANK CASE
|
72 |
|
M. FUEL TANK
|
73 |
|
N. CANISTER PURGE VALVE
|
73 |
|
O. CANISTER
|
74 |
|
6. ENGINE SYSTEM
|
75 |
|
A. AIR INTAKE SYSTEM
|
75 |
|
B. BLOW BY SYSTEM
|
77 |
|
C. LUBRICATION SYSTEM
|
78 |
|
D. EXHAUST SYSTEM
|
82 |
|
E. COOLING SYSTEM
|
84 |
|
F. FUEL SYSTEM
|
87 |
|
7. ENGINE ON VEHICLE SERVICE PROCEDURE
|
90 |
|
A. FUSE BOX SHIFTING PROCEDURE
|
90 |
|
B. ENGINE REMOVAL AND INSTALLATION
|
91 |
|
C. AIR FILTER ASSY
|
97 |
|
D. FUEL RAIL AND INJECTOR
|
98 |
|
E. SPARK PLUG
|
99 |
|
F. EXHAUST SYSTEM
|
100 |
|
G. FUEL SYSTEM
|
103 |
|
H. COOLING SYSTEM
|
108 |
|
I. COMPRESSOR AND ALTERNATOR BELT REMOVAL
|
112 |
|
J. TIMING BELT REMOVAL
|
113 |
|
K. WATER PUMP
|
117 |
|
L. SOLENOID
|
118 |
|
M. ELECTRONIC THROTTLE BODY
|
118 |
|
N. STARTER MOTOR
|
119 |
|
O. ALTERNATOR
|
119 |
|
P. COMPRESSOR
|
120 |
|
8. ENGINE OVEHAULING (ON OVERHAUL STAND)
|
121 |
|
A. ENGINE DIS-ASSEMBLY
|
121 |
|
I. REMOVAL OF INTAKE MANIFOLD
|
121 |
|
II. REMOVAL OF EXHAUST MANIFOLD
|
122 |
|
III. REMOVAL OF OIL SUMP
|
124 |
|
IV. REMOVAL OF SENSORS
|
124 |
|
V. REMOVAL OF ACCESSORIES
|
125 |
|
VI. REMOVAL OF TIMING CHAIN
|
128 |
|
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT
|
130 |
|
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES
|
131 |
|
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES
|
132 |
|
B. ENGINE ASSEMBLY
|
136 |
|
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES
|
136 |
|
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES
|
140 |
|
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES
|
142 |
|
IV. ASSEMBLY OF CYLINDER HEAD
|
143 |
|
V. ASSEMBLY OF ENGINE TIMING CHAIN
|
145 |
|
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT
|
148 |
|
VII. ASSEMBLY OF SENSORS AND PERIPHERALS
|
150 |
|
VIII. ASSEMBLY OF OIL SUMP
|
151 |
|
IX. ASSEMBLY OF EXHAUST MANIFOLD
|
151 |
|
X. ASSEMBLY OF INTAKE MANIFOLD S
|
153 |
|
9. ENGINE MANAGEMENT SYSTEM
|
155 |
|
A. ABBREVIATIONS
|
155 |
|
B. AN OVERVIEW
|
156 |
|
C. ELECTRONIC CONTROL UNIT
|
157 |
|
D. SENSORS
|
162 |
|
I. T-MAP SENSOR
|
163 |
|
II. LAMBDA SENSOR
|
164 |
|
III. CAMSHAFT POSITION SENSOR
|
166 |
|
IV. KNOCK SENSOR
|
167 |
|
V. CRANKSHAFT POSITION SENSOR
|
168 |
|
VI. COOLANT TEMPERATURE SENSOR
|
169 |
|
E. ACTUATORS
|
171 |
|
I. IGNITION COIL
|
172 |
|
II. PURGE CONTROL VALVE
|
173 |
|
III. SOLENOID VALVE (OCV)
|
174 |
|
IV. FUEL INJECTOR
|
175 |
|
V. ELECTRONIC THROTTLE BODY
|
176 |
|
F. SWITCH
|
178 |
|
I. OIL PRESSURE SWITCH
|
178 |
|
II. THROTTLE PEDAL SENSOR
|
179 |
|
III. CLUTCH SWITCH
|
180 |
|
IV. BRAKE SWITCH
|
181 |
|
V. VEHICLE SPEED SENSOR
|
182 |
|
VI. WHEEL SPEED SENSOR
|
183 |
|
1.2L REVOTRON NGTC ENGINE
|
184 |
|
1. GENERAL INFORMATION
|
189 |
|
A ENGINE INTRODUCTION
|
189 |
|
B ELECTRONIC FUEL INJECTION CONTROL
|
190 |
|
C TECHNICAL SPECIFICATION
|
191 |
|
D SPECIAL TOOLS
|
192 |
|
E ASSEMBLY CLEARANCES
|
195 |
|
F SEALANTS
|
195 |
|
G LEAKAGE RATES
|
195 |
|
F RECOMMENDED LUBRICANTS & COOLANTS
|
195 |
|
G SERVICE SCHEDULE
|
195 |
|
2. TROUBLESHOOTING
|
196 |
|
3. CONSTRUCTIONAL AND SERVICE DETAILS
|
204 |
|
A ENGINE LIFTING HOOKS
|
204 |
|
B INTAKE MANIFOLD
|
205 |
|
C CYLINDER HEAD COVER
|
206 |
|
D CYLINDER HEAD-A
|
208 |
|
E CYLINDER HEAD-B
|
210 |
|
F CYLINDER BLOCK
|
212 |
|
G LUBRICATION PUMP & COMPONENTS
|
214 |
|
H PISTON, CRANKSHAFT & COMPONENTS
|
217 |
|
I ENGINE TIMING
|
220 |
|
J TURBOCHARGER, CATCON & COMPONENTS
|
222 |
|
K FUEL INJECTION EQUIPMENT
|
224 |
|
L AIR INTAKE SYSTEM
|
226 |
|
M WATER PUMP, THERMOSTAT AND COMPONENTS
|
228 |
|
N STARTER MOTOR AND ALTERNATOR
|
230 |
|
O COMPRESSOR, AUTO TENSIONER AND BELT
|
231 |
|
P ENGINE SUSPENSION
|
232 |
|
Q INTERCOOLER AND HOSES
|
234 |
|
4. ENGINE TESTS AND MAINTENANCE
|
236 |
|
A PRELIMINARY INSPECTION
|
236 |
|
B ENGINE TESTS
|
237 |
|
I ENGINE COMPRESSION TEST
|
237 |
|
II ENGINE OIL CONSUMPTION TEST
|
238 |
|
III ENGINE OIL PRESSURE TEST
|
239 |
|
C REGULAR MAINTENANCE
|
240 |
|
I ENGINE OIL AND FILTER CHANGE
|
240 |
|
II ENGINE COOLANT REPLACEMENT
|
242 |
|
III AIR FILTER ELEMENT REPLACEMENT
|
246 |
|
IV SPARK PLUG REPLACEMENT
|
247 |
|
V AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT
|
249 |
|
5. REPAIR AND INSPECTION DETAILS
|
251 |
|
A ACCESSORY DRIVING BELT
|
251 |
|
B TIMING CHAIN
|
251 |
|
C CYLINDER HEAD
|
251 |
|
D VALVES
|
252 |
|
E CYLINDER HEAD VALVE SEATS
|
254 |
|
F ROLLER FINGER FOLLOWER
|
255 |
|
G HYDRAULIC LASH ADJUSTER
|
255 |
|
H CAMSHAFT
|
256 |
|
I PISTON AND PISTON RINGS
|
257 |
|
J CONNECTING RODS
|
258 |
|
K CRANKSHAFT
|
260 |
|
L CRANK CASE
|
262 |
|
M FUEL TANK
|
263 |
|
N CANISTER PURGE VALVE
|
263 |
|
O CANISTER
|
264 |
|
6. ENGINE SYSTEM
|
265 |
|
A AIR INTAKE SYSTEM
|
265 |
|
B BLOW BY SYSTEM
|
268 |
|
C LUBRICATION SYSTEM
|
269 |
|
D EXHAUST SYSTEM
|
273 |
|
E COOLING SYSTEM
|
277 |
|
F FUEL SYSTEM
|
280 |
|
7. ON VEHICLE SERVICE PROCEDURE
|
283 |
|
A ENGINE REMOVAL AND INSTALLATION
|
283 |
|
B AIR FILTER ASSY
|
289 |
|
C FUEL RAIL AND INJECTOR
|
290 |
|
D SPARK PLUG
|
291 |
|
E EXHAUST SYSTEM
|
291 |
|
F FUEL SYSTEM
|
295 |
|
G COOLING SYSTEM
|
300 |
|
H COMPRESSOR AND ALTERNATOR BELT REMOVAL
|
305 |
|
I TIMING BELT REMOVAL
|
306 |
|
J WATER PUMP
|
310 |
|
K SOLENOID
|
311 |
|
L ELECTRONIC THROTTLE BODY
|
311 |
|
M STARTER MOTOR
|
312 |
|
N ALTERNATOR
|
312 |
|
O COMPRESSOR
|
313 |
|
8. ENGINE OVEHAULING (ON OVERHAUL STAND)
|
314 |
|
A ENGINE DIS-ASSEMBLY
|
314 |
|
I REMOVAL OF INTAKE MANIFOLD
|
314 |
|
II REMOVAL OF CLOSED COUPLED CATCON AND TURBOCHARGER
|
316 |
|
III REMOVAL OF OIL SUMP
|
318 |
|
IV REMOVAL OF SENSORS
|
319 |
|
V REMOVAL OF ACCESSORIES
|
320 |
|
VI REMOVAL OF TIMING CHAIN
|
322 |
|
VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT
|
325 |
|
VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES
|
327 |
|
IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES
|
329 |
|
B ENGINE ASSEMBLY
|
333 |
|
I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES
|
333 |
|
II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES
|
337 |
|
III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES.
|
339 |
|
IV ASSEMBLY OF CYLINDER HEAD
|
341 |
|
V ASSEMBLY OF ENGINE TIMING CHAIN
|
343 |
|
VI ASSEMBLY OF CYLINDER HEAD COVER AND PERIPHERALS
|
346 |
|
VII ASSEMBLY OF SENSORS
|
349 |
|
VIII ASSEMBLY OF OIL SUMP
|
350 |
|
IX ASSEMBLY OF CLOSED COUPLED CATCON AND TURBOCHARGER
|
351 |
|
X ASSEMBLY OF INTAKE MANIFOLD
|
353 |
|
9. ENGINE MANAGEMENT SYSTEM
|
355 |
|
A ABBREVIATIONS
|
355 |
|
B AN OVERVIEW
|
356 |
|
C ELECTRONIC CONTROL UNIT
|
357 |
|
D SENSORS
|
364 |
|
I T-MAP SENSOR
|
365 |
|
II LAMBDA SENSOR
|
366 |
|
III CAMSHAFT POSITION SENSOR
|
368 |
|
IV KNOCK SENSOR
|
369 |
|
V CRANKSHAFT POSITION SENSOR
|
371 |
|
VI COOLANT TEMPERATURE SENSOR
|
372 |
|
E ACTUATORS
|
374 |
|
I IGNITION COIL
|
375 |
|
II PURGE CONTROL VALVE
|
376 |
|
III SOLENOID VALVE (OCV)
|
377 |
|
IV FUEL INJECTOR
|
378 |
|
V ELECTRONIC THROTTLE BODY
|
379 |
|
F SWITCH
|
381 |
|
I OIL PRESSURE SWITCH
|
381 |
|
II THROTTLE PEDAL SENSOR
|
382 |
|
III CLUTCH SWITCH
|
383 |
|
IV BRAKE SWITCH
|
384 |
|
V WHEEL SPEED SENSOR
|
385 |
|
VI ELECTRONIC VACCUM REGULATING VALVE (EVRV)
|
386 |
|
VII START STOP SWITCH
|
387 |
|
VIII AC PRESSURE SENSOR
|
388 |
|
1.5L REVOTORQ ENGINE
|
389 |
|
CONTENTS
|
390 |
|
1. GENERAL INFORMATION
|
394 |
|
A. ENGINE INTRODUCTION
|
394 |
|
B. TECHNICAL SPECIFICATION
|
395 |
|
C. SPECIAL TOOLS
|
396 |
|
D. ASSEMBLY CLEARANCES
|
400 |
|
2. TROUBLESHOOTING
|
401 |
|
3. CONSTRUCTIONAL AND SERVICE DETAILS
|
405 |
|
A. Engine Lifting Hook
|
405 |
|
B. Intake Manifold and Fuel Injection System
|
406 |
|
C. Lubrication system
|
408 |
|
D. Air Filter, Snorkel, Blow By Pipe
|
411 |
|
E. Starter Motor, Compressor and Alternator
|
413 |
|
F. Timing Belt, Auto Tensioner, Water pump
|
415 |
|
G. Exhaust manifold, CATCON, Turbocharger
|
417 |
|
H. Cylinder head and Components
|
420 |
|
I. Piston, Crankshaft and Components
|
423 |
|
J. Engine Suspension
|
425 |
|
K. EGR Valve, Thermostat and Components
|
427 |
|
L. Crankcase and Components
|
430 |
|
4. ENGINE TESTS AND MAINTENANCE
|
432 |
|
A. PRELIMINARY INSPECTION
|
432 |
|
B. ENGINE TESTS
|
432 |
|
C. REGULAR MAINTENANCE
|
437 |
|
5. REPAIR AND INSPECTION DETAILS
|
446 |
|
A. TIMING BELT
|
446 |
|
B. FUEL TANK
|
446 |
|
C. CYLINDER HEAD
|
447 |
|
D. VALVES
|
447 |
|
E. VALVE SEATS
|
449 |
|
F. CRANKCASE
|
450 |
|
G. VALVE SEAT INSERT
|
451 |
|
H. HYDRAULIC LASH ADJUSTER
|
451 |
|
I. VALVE GUIDES
|
452 |
|
J. CAMSHAFT
|
453 |
|
K. PISTON AND PISTON RINGS
|
454 |
|
L. CONNECTING ROD
|
455 |
|
M. CRANK SHAFT
|
457 |
|
6. ENGINE SYSTEMS
|
459 |
|
A. AIR INTAKE SYSTEM
|
459 |
|
B. EXHAUST SYSTEM
|
462 |
|
C. COOLING SYSTEM
|
466 |
|
D. LUBRICATION SYSTEM
|
469 |
|
E. EXHAUST GAS RECIRCULATION SYSTEM (EGR)
|
473 |
|
F. BLOW-BY VENTILATION SYSTEM
|
475 |
|
G. VACUUM MANAGEMENT SYSTEM
|
476 |
|
H. FUEL SYSTEM
|
477 |
|
7. ENGINE ON VEHICLE SERVICEPROCEDUR
|
483 |
|
A. FUSE BOX SHIFTING PROCEDURE:
|
483 |
|
B. ENGINE REMOVAL
|
484 |
|
C. ENGINE INSTALLATION
|
490 |
|
D. EXHAUST SYSTEM
|
491 |
|
E. COOLING SYSTEM
|
494 |
|
F. FUEL SYSTEM
|
499 |
|
G. TURBOCHARGER REMOVAL ANDREFITMENT
|
506 |
|
H. TIMING BELT REMOVAL AND REFITMENT
|
508 |
|
I. STARTER MOTOR REMOVAL ANDREFITMENT
|
509 |
|
J. ALTERNATOR MOTOR REMOVAL ANDREFITMENT
|
510 |
|
K. COMPRESSOR MOTOR REMOVAL ANDREFITMENT
|
511 |
|
L. HIGH PRESSURE PUMP REMOVAL ANDREFITMENT
|
512 |
|
8. ENGINE OVERHAULING
|
515 |
|
A. ENGINE DIS-ASSEMBLY
|
515 |
|
i. ON OVERHAUL STAND
|
515 |
|
ii. REMOVAL OF EGR VALVE & OIL FILTER
|
519 |
|
iii. REMOVAL OF INTAKE MANIFOLD
|
520 |
|
iv. REMOVAL OF EXHAUST MANIFOLD
|
522 |
|
v. REMOVAL OF EVRV AND THERMOSTAT
|
523 |
|
vi. REMOVAL OF OIL SUMP
|
524 |
|
vii. REMOVAL OF TIMING BELT
|
525 |
|
viii. REMOVAL OF CYLINDER HEAD
|
530 |
|
ix. REMOVAL OF CYLINDER HEAD SUBASSEMBLIES
|
531 |
|
x. REMOVAL OF CYLINDER BLOCK SUBASSEMBLI
|
534 |
|
xi. PISTON CONNECTING RODDISASSEMBLY
|
536 |
|
B. ENGINE ASSEMBLY
|
542 |
|
i. FITMENT OF CYLINDER HEAD SUBASSEMBLIES
|
542 |
|
ii. FITMENT OF PISTON AND CONNECTINGROD SUB-ASSEMBLIES
|
543 |
|
iii. FITMENT OF CYLINDER BLOCK SUBASSEMBLIE
|
544 |
|
iv. FITMENT OF CYLINDER HEAD ONCYLINDER BLOCK
|
546 |
|
v. FITMENT OF TIMING BELT
|
548 |
|
vi. FITMENT OF ENGINE SUPPORT
|
552 |
|
vii. FITMENT OF OIL SUMP
|
553 |
|
viii. FITMENT OF EXHAUST MANIFOLD ANDOTHER COMPONENTS
|
554 |
|
ix. FITMENT OF INTAKE MANIFOLD
|
558 |
|
x. FITMENT OF PERIPHERALS
|
560 |
|
9. ENGINE MANAGEMENT SYSTEM
|
563 |
|
A. ABBREVIATIONS
|
563 |
|
B. AN OVERVIEW
|
563 |
|
C. ELECTRONIC CONTROL UNIT (ECU)
|
564 |
|
D. EMS SENSORS
|
569 |
|
CLUTCH DIESEL
|
584 |
|
1.1. GENERAL INFORMATION
|
587 |
|
A. CLUCTH MASTER CYLINDER
|
588 |
|
B. CONCENTRIC SLAVE CYLINDER (CSC)
|
588 |
|
C. PEAK TORQUE LIMITER
|
588 |
|
D. HYDRAULIC ADAPTER
|
588 |
|
E. SINGLE MASS FLYWHEEL
|
589 |
|
F. CONVENTIONAL CLUTCH
|
589 |
|
1.2. TECHNICAL SPECIFICATIONS
|
590 |
|
A. CLUTCH DISC ASSEMBLY
|
590 |
|
B. CONVENTIONAL CLUTCH
|
591 |
|
C. SINGLE MASS FLYWHEEL (FOR DIESEL VERSION)
|
592 |
|
1.3. TIGHTENING TORQUES
|
593 |
|
1.4. SPECIAL TOOLS
|
594 |
|
1.5. MAINTENANCE, INSPECTION ANDTESTS
|
595 |
|
1.5.1. PRELIMINARY INSPECTION
|
595 |
|
1.5.2. REGULAR MAINTENANCE
|
596 |
|
A. CLUTCH SWITCH ADJUSTMENT
|
596 |
|
B. CLUTCH BLEEDING PROCEDURE
|
596 |
|
C. CLUTCH FLUID DRAINING PROCEDURE
|
597 |
|
1.6. GENERAL SYMPTOMS DIAGNOSIS
|
598 |
|
1.7. EXPLODE VIEWS
|
600 |
|
A. CLUTCH PEDAL ASSEMBLY
|
600 |
|
B. CONVENTIONAL CLUTCH ASSEMBLY
|
601 |
|
C. CLUTCH HYDRAULIC SYSTEM COMPONENTS
|
602 |
|
1.8. ON VEHICLE PROCEDURES
|
603 |
|
A. FUSE BOX SHIFTING PROCEDURE
|
603 |
|
B. CLUTCH PEDAL REMOVAL
|
604 |
|
C. CONTROL BRACKET ASSEMBLYREMOVAL
|
605 |
|
D. CONVENTIONAL CLUTCH ASSEMBLYREMOVAL
|
606 |
|
E. CLUTCH MASTER CYLINDER REMOVAL
|
607 |
|
F. FLYWHEEL REMOVAL
|
609 |
|
CLUTCH PETROL
|
610 |
|
1. GENERAL INFORMATION
|
613 |
|
2. TECHNICAL SPECIFICATIONS
|
614 |
|
A. CLUTCH DISC
|
614 |
|
B. CLUTCH PLATE
|
616 |
|
C. FLYWHEEL
|
618 |
|
3. TIGHTENING TORQUE
|
620 |
|
4. SPECIAL TOOLS
|
621 |
|
5
. DIAGNOSIS OF CLUTCH
|
622 |
|
6. MAINTENANCE, TESTS AND FACTOR AFFECTING
|
625 |
|
A. INSPECTION OF COMPONENTS
|
625 |
|
B. TEST
|
625 |
|
C. FACTORS AFFECTING CLUTCH
|
625 |
|
7. CONSTRUCTIONAL DETAILS
|
626 |
|
8. ON VECHILE PROCEDURE
|
628 |
|
A. FUSE BOX SHIFTING PROCEDURE
|
628 |
|
B. CLUTCH CABLE REMOVAL ANDINSPECTION
|
629 |
|
C. REMOVAL OF CLUTCH
|
630 |
|
D. FLYWHEEL
|
631 |
|
E. CLUTCH ADJUSTMENT PROCEDURE
|
632 |
|
TRANSAXLE (TA65 Star)
|
659 |
|
1. TECHNICAL SPECIFICATIONS
|
663 |
|
2. PRECAUTIONS
|
663 |
|
3. GENERAL DESCRIPTION
|
664 |
|
4. TIGHTENING TORQUES
|
665 |
|
5. SPECIAL TOOLS LIST
|
666 |
|
6. DIAGNOSIS
|
670 |
|
7. CONSTRUCTIONAL DETAILS
|
671 |
|
8. CUT SECTION OF TRANSAXLE TA 65 STAR
|
672 |
|
9. CUT SECTION OF TOP COVER ASSEMBLY
|
673 |
|
10. EXPLODED VIEWS OF TRANSAXLE
|
674 |
|
A. TRANSAXLE HOUSING
|
674 |
|
B. TOP COVER ASSEMBLY
|
675 |
|
C. DIFFERENTIAL
|
676 |
|
D. SHIFTER FORK
|
677 |
|
E. GEAR SHIFT LINKAGE ASSEMBLY
|
678 |
|
F. LAY SHAFT AND INPUT SHAFT
|
679 |
|
11. FUSE BOX SHIFTING PROCEDURE
|
681 |
|
12. REMOVAL OF TRANSAXLE FROMVEHICLE
|
682 |
|
13. ON VEHICLE ASSEMBLY OFTRANSAXLE
|
685 |
|
14. TRANSAXLE TA65 STAR (ON BENCH)DISASSEMBLY
|
687 |
|
15. INPUT SHAFT DEEP GROOVEBEARING REMOVAL
|
692 |
|
16. INPUT SHAFT DEEP GROOVEBEARING ASSEMBLY
|
692 |
|
17. DISASSEMBLY OF LAY SHAFT
|
693 |
|
18. IDNETIFICATION OF COMPONENTS
|
695 |
|
A. ENGAGING GEARS
|
695 |
|
B. SHIFTER SHAFT SUB ASSEMBLY
|
696 |
|
C. SHIFTER FORKS
|
696 |
|
D. SHIFTER SHAFTS
|
697 |
|
F. SYNCHROCONE
|
697 |
|
G. SUB ASSEMBLIES
|
697 |
|
19. LAY SHAFT ASSEMBLY
|
699 |
|
20. DIFFERENTIAL ASSEMBLY:
|
702 |
|
1. DISASSEMBLY
|
702 |
|
2. ASSEMBLY
|
703 |
|
21. TRANSAXLE ASSEMBLY
|
704 |
|
22. DISASSEMBLY OF TOP COVER
|
709 |
|
23. ASSEMBLY TOP COVER
|
710 |
|
24. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX
|
712 |
|
25. REMOVAL OF GEAR SHIFTER ANDSELECTOR CABLE
|
713 |
|
26. GEAR SHIFTER CABLE ASSEMBLY
|
714 |
|
TRANSAXLE (TA5260)
|
715 |
|
1. TECHNICAL SPECIFICATIONS
|
719 |
|
2. PRECAUTIONS
|
719 |
|
3. GENERAL INFORMATION TA5260
|
720 |
|
4. TIGHTENING TORQUES
|
721 |
|
5. SPECIAL TOOL LIST
|
725 |
|
6. DIAGNOSIS OF TRANSAXLE
|
731 |
|
7. CUT SECTION OF TRANSAXLE TA 5260
|
732 |
|
8. CUT SECTION OF TOP COVER ASSEMBLY
|
734 |
|
9. EXPLODED VIEWS OF TRANSAXLE
|
735 |
|
10. FUSE BOX SHIFTING PROCEDURE
|
742 |
|
11. REMOVAL OF TRANSAXLE FROMVEHICLE
|
743 |
|
12. DISASSEMBLY OF TRANSAXLE (ONBENCH)
|
746 |
|
A. DISASSEMBLY OF INPUT SHAFT
|
752 |
|
B. ASSEMBLY OF INPUT SHAFT
|
754 |
|
C. REMOVAL OF DEEP GROOVE BALLBEARING FROM LAY SHAFT
|
755 |
|
D. ASSEMBLY OF DEEP GROOVE BALLBEARING ON LAY SHAFT
|
756 |
|
E. DISASSEMBLY OF LAY SHAFT
|
756 |
|
F. ASSEMBLY OF LAY SHAFT
|
758 |
|
G. DISASSEMBLY OF DIFFERENTIAL
|
759 |
|
H. ASSEMBLY OF DIFFERENTIAL
|
761 |
|
I. DISASSEMBLY OF TOP COVER
|
762 |
|
J. IDNETIFICATION OF COMPONENTS
|
763 |
|
I. SHIFTER SHAFTS
|
763 |
|
II. ENGAGING GEARS
|
763 |
|
III. SHIFTER SHAFT SUB ASSEMBLY
|
764 |
|
13. ASSEMBLIES OF TRANSAXLE ONBENCH
|
765 |
|
14. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX
|
770 |
|
15. REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE
|
771 |
|
16. ASSEMBLY OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE
|
772 |
|
17. NEUTRAL SETTING PROCEDURE
|
774 |
|
DRIVE SHAFT PETROL
|
775 |
|
1. INTRODUCTION
|
779 |
|
2. DRIVESHAFT
|
780 |
|
3. DRIVE SHAFT PARTS
|
781 |
|
4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE
|
781 |
|
5. TESTING FOR NOISE
|
782 |
|
6. TIGHTENING TORQUES
|
783 |
|
7. SPECIAL TOOLS
|
783 |
|
8. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE)
|
784 |
|
9. ON VEHICLE ASSEMBLY OF DRIVESHAFT (LH & RH SIDE)
|
785 |
|
10. DISASSEMBLY PROCEDURE FOR DRIVESHAFT
|
786 |
|
11. ASSEMBLY PROCEDURE FORDRIVESHAFT
|
787 |
|
12. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT
|
788 |
|
13. DISASSEMBLY PROCEDURE FOR(TRIPOT JOINT)
|
789 |
|
14. DISASSEMBLY AND ASSEMBLY OF CVJOINT ASSEMBLY (OUTER)
|
792 |
|
15. DO’S AND DON’T’S FOR DRIVE SHAFT
|
796 |
|
DRIVE SHAFT DIESEL
|
797 |
|
1. INTRODUCTION
|
801 |
|
2. DRIVESHAFT
|
802 |
|
3. DRIVE SHAFT PARTS
|
803 |
|
4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE
|
803 |
|
5. TESTING FOR NOISE
|
804 |
|
6. TIGHTENING TORQUES
|
805 |
|
7. SPECIAL TOOLS
|
806 |
|
8. LH SIDE DRIVE SHAFT REMOVAL
|
807 |
|
9. LH SIDE DRIVE SHAFT ASSEMBLY
|
808 |
|
10. RH SIDE DRIVE SHAFT REMOVAL
|
810 |
|
11. RH SIDE DRIVE SHAFT ASSEMBLY
|
811 |
|
12. DISASSEMBLY PROCEDURE FOR DRIVESHAFT
|
813 |
|
13. ASSEMBLY PROCEDURE FORDRIVESHAFT
|
814 |
|
14. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT
|
816 |
|
15. DO’S AND DON’T’S FOR DRIVE SHAFT
|
817 |
|
SUSPENSION
|
818 |
|
1. GENERAL INFORMATION
|
820 |
|
1.1. FRONT SUSPENSION
|
820 |
|
1.2. REAR SUSPENSION
|
821 |
|
1.3. SHOCK ABSORBER
|
823 |
|
2. TECHNICAL SPECIFICATIONS
|
824 |
|
3. TIGHTENING TORQUES
|
825 |
|
4. SPECIAL TOOLS
|
830 |
|
5. DIAGNOSIS
|
835 |
|
6. PRECAUTIONS
|
836 |
|
7. EXPLODED VIEWS FRONT SUSPENSION
|
837 |
|
A) ASSEMBLY FRONT STRUT EXPLODED VIEW
|
837 |
|
B) ANTI ROLL BAR MOUNTING EXPLODED VIEW
|
838 |
|
C) LOWER LINK EXPLODED VIEW
|
839 |
|
8. EXPLODED VIEWS REAR SUSPENSION
|
841 |
|
A) REAR SHOCK ABSORBER AND SPRING EXPLODED VIEW
|
841 |
|
B) REAR HUB ASSEMBLY EXPLODED VIEW
|
842 |
|
C) REAR TWIST BEAM AND PIVOT BUSH EXPLODED VIEW
|
843 |
|
9. ON VEHICLE AND ON BENCH REMOVALAND ASSEMBLY PROCEDURE
|
844 |
|
9.1 ON VEHICLE FRONT STRUT REMOVALAND ASSEMBLY
|
844 |
|
9.2 ON BENCH FRONT STRUT REMOVAL ANDASSEMBLY
|
845 |
|
9.3 ON VEHICLE WHEEL HUB REMOVAL ANDASSEMBLY
|
846 |
|
9.4 ON BENCH SUB ASSEMBLY OF KNUCKLEAND WHEEL HUB
|
849 |
|
9.5 REMOVAL AND ASSEMBLY OFSUBFRAME ASSEMBLY
|
850 |
|
9.6 ON VEHICLE REMOVAL AND ASSEMBLYOF ANTI ROLL BAR
|
851 |
|
9.7 REMOVAL AND ASSEMBLY OF LOWERARM BALL JOINT
|
851 |
|
9.8 ON BENCH LOWER ARM PIVOT BUSHREMOVAL AND ASSEMBLY
|
853 |
|
9.9 ON VEHICLE SUBFRAME ASSEMBLY
|
854 |
|
9.10 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING REMOVAL ANDASSEMBLY
|
855 |
|
9.11 ON BENCH DISASSEMBLY ANDASSEMBLY OF REAR SHOCK ABSORBER
|
856 |
|
9.12 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING ASSEMBLY
|
857 |
|
9.13 ON VEHICLE TORSION BEAM REMOVALAND ASSEMBLY
|
858 |
|
10 SUSPENSION PRE-LOADING CONDITION
|
861 |
|
STEERING (EPAS)-BOSCH
|
863 |
|
1. GENERAL INFORMATION
|
867 |
|
2. SYSTEM LAYOUT
|
867 |
|
3. BLOCK DIAGRAM OF EPAS SYSTEM
|
868 |
|
4. TIGHTENING TORQUES
|
869 |
|
5. SPECIAL TOOLS
|
871 |
|
6. MAINTENANCE, INSPECTION AND TEST
|
873 |
|
6.1 PRELIMINARY INSPECTION
|
873 |
|
6.2. REGULAR MAINTENANCE
|
874 |
|
7. ON VEHICLE REPAIRS
|
876 |
|
7.1. STEERING WHEEL REMOVAL
|
876 |
|
7.2 STEERING COLUMN REMOVAL
|
877 |
|
7.3 INTERMEDIATE SHAFT REMOVAL
|
878 |
|
7.4. RACK & PINION ASSEMBLY REMOVAL
|
879 |
|
8. OVERHAULING
|
881 |
|
8.1. DISASSEMBLY OF RACK & PINON
|
882 |
|
8.2. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE
|
884 |
|
8.3. OBJ ON-VEHICLE REMOVAL
|
885 |
|
8.4. WHEEL ALIGNMENT
|
886 |
|
8.5. CAMBER ADJUSTMENT
|
887 |
|
9. TROUBLESHOOTING AND DIAGNOSIS
|
888 |
|
10. STEERING ANGLE CALIBRATION
|
892 |
|
11. TUNING DATA SELECTION
|
895 |
|
STEERING (EPAS)-MANDO
|
897 |
|
1. GENERAL INFORMATION
|
899 |
|
2. SYSTEM LAYOUT
|
899 |
|
3. BLOCK DIAGRAM OF EPAS SYSTEM
|
900 |
|
4.
TIGHTENING TORQUES
|
901 |
|
5. SPECIAL TOOLS
|
904 |
|
6. MAINTENANCE, INSPECTION AND TEST
|
905 |
|
6.1. PRELIMINARY INSPECTION
|
905 |
|
6.2. REGULAR MAINTENANCE
|
906 |
|
7. ON VEHICLE REPAIRS
|
908 |
|
7.1. STEERING WHEEL REMOVAL
|
908 |
|
7.2. STEERING COLUMN REMOVAL
|
909 |
|
7.3. INTERMEDIATE SHAFT REMOVAL
|
911 |
|
7.4. ECU REMOVAL
|
912 |
|
7.5. MOTOR REMOVAL
|
913 |
|
7.6. RACK & PINION ASSEMBLY REMOVAL
|
914 |
|
8. OVERHAULING
|
916 |
|
8.1. EXPLODED VIEWS OF STEERING RACK & PINION ASSEMBLY
|
916 |
|
8.2. DISASSEMBLY OF RACK & PINOIN
|
917 |
|
8.3. INSPECTION OF DISMANTLED PARTS
|
918 |
|
8.4. ASSEMBLY OF RACK & PINOIN
|
918 |
|
8.5. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE
|
919 |
|
8.6. OBJ ON VEHICLE REMOVAL
|
920 |
|
8.7. DO'S & DON’T'S
|
920 |
|
8.8. WHEEL ALIGNMENT
|
923 |
|
8.9. CAMBER ADJUSTMENT
|
924 |
|
9. TROUBLESHOOTING AND DIAGNOSIS
|
925 |
|
10 STEERING ANGLE CALIBRATION
|
929 |
|
11 FLOW CHART FOR STEERING ANGLE CALIBRATION
|
933 |
|
12 TUNING DATA SELECTION
|
936 |
|
13 EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD
|
937 |
|
BRAKES
|
941 |
|
1. TECHNICAL SPECIFICATIONS
|
947 |
|
2. TIGHTENING TORQUES
|
948 |
|
3. SPECIAL TOOL
|
949 |
|
4. PRECAUTIONS
|
949 |
|
5. DIAGNOSIS
|
950 |
|
6. NESSECITY OF ABS WITH EBD
|
953 |
|
7. BRAKE HYDRAULIC LINES
|
954 |
|
8. VACUUM BRAKE BOOSTER
|
955 |
|
9. WORKING OF ANTI-LOCK BRAKING (ABS) SYSTEM
|
956 |
|
10. ABS COMPONENTS
|
960 |
|
10.1. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU)
|
961 |
|
10.2. HYDRAULIC CONTROL UNIT
|
962 |
|
10.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED)
|
962 |
|
10.4. ABS SYSTEM FAILURE WARNING LIGHT
|
963 |
|
11. MAINTENANCE, ADJUSTMENTS & TEST
|
964 |
|
11.1. FRONT BRAKE MAINTENANCE
|
964 |
|
11.2. REAR BRAKE MAINTENANCE
|
966 |
|
11.3 BRAKE TROUBLE SHOOTING
|
972 |
|
11.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO
|
973 |
|
12. BRAKE PEDAL ASSEMBLY
|
975 |
|
13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE
|
976 |
|
14. REPAIRS
|
977 |
|
14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT
|
978 |
|
14
.2. REMOVAL OF FRONT BRAKE DISC
|
985 |
|
14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY
|
986 |
|
14.4. REAR BRAKE ASSEMBLY
|
988 |
|
14.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY
|
989 |
|
14.6.
REMOVAL AND INSTALLATION OF PARKING BRAKE LEVER (LOW VERSION)
|
995 |
|
14.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE (LOW VERSION)
|
996 |
|
14.8 PARKING BRAKE CABLE ADJUSTMENTPROCEDURE (FOR HIGH & LOW END
|
997 |
|
14.9 REMOVAL OF PARKING BRAKE LEVER (HIGH VERSION)
|
998 |
|
14.10 REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE (HIGH VERSION)
|
999 |
|
14.11. REMOVAL AND REFITMENT OF ABSECU / HCU
|
1000 |
|
14.12. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR
|
1001 |
|
14.13. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR
|
1002 |
|
15. TROUBLE SHOOTING & DIAGNOSIS
|
1004 |
|
16. ABS ECU CONNECTOR (K2)
|
1006 |
|
BODY
|
1008 |
|
1 TECHNICAL SPECIFICATION
|
1013 |
|
1.1 LAYOUT
|
1013 |
|
1.2 TIGHTENING TORQUES
|
1014 |
|
1.3 SPECIAL TOOL
|
1016 |
|
2 ON VEHICLE REPAIRS
|
1017 |
|
2.1 BONNET
|
1017 |
|
2.2 ARM REST
|
1019 |
|
2.3 FLOOR CONSOLE
|
1020 |
|
2.4 DASHBOARD SKIN
|
1022 |
|
2.5 COCKPIT REMOVAL ( COMPLETE ASSY)
|
1026 |
|
2.6 GLOVE BOX
|
1030 |
|
2.7 SIDE AIR VENTS
|
1031 |
|
2.8 FRONT BUMPER
|
1032 |
|
2.9 REAR BUMPER
|
1033 |
|
2.10 FRONT DOOR
|
1034 |
|
2.11 FRONT DOOR TRIMS
|
1035 |
|
2.12 DOOR INNER LOCK HANDLE
|
1036 |
|
2.13 FRONT OUTER DOOR HANDLE
|
1037 |
|
2.14 FRONT DOOR LATCH
|
1037 |
|
2.15 FRONT DOOR GLASS AND WINDOWWINDING MECHANISM
|
1038 |
|
2.16 REAR DOOR
|
1039 |
|
2.17 REAR DOOR TRIM
|
1040 |
|
2.18 REAR OUTER DOOR HANDLE
|
1042 |
|
2.19 DOOR LATCH REAR
|
1043 |
|
2.20 TAIL GATE
|
1044 |
|
2.21 INNER REAR VIEW MIRROR
|
1046 |
|
2.22 ORVM
|
1046 |
|
2.23 FRONT ROW SEAT
|
1047 |
|
2.24 REAR ROW SEAT
|
1048 |
|
2.25. FRONT SEAT BELT
|
1049 |
|
2.26 REAR SEAT BELT
|
1051 |
|
2.27 “A” PILLAR TRIM
|
1051 |
|
2.28 FRONT SCUFF PLATE
|
1052 |
|
2.29 “B” PILLAR TRIMS
|
1052 |
|
2.30 “C” PILLAR TRIMS
|
1053 |
|
2.31. GRAB HANDLE
|
1053 |
|
2.32 SUNVISOR
|
1054 |
|
2.33 ROOF LINEAR
|
1054 |
|
2.34 PLENUM COVER
|
1055 |
|
2.35 GEAR LEVER BOOT
|
1055 |
|
2.36 BONNET INSULATION
|
1055 |
|
2.37 GLASS
|
1056 |
|
2.38 FUEL FILLER ASSEMBLY
|
1057 |
|
2.39 FRONT WHEEL ARCH LINER
|
1058 |
|
2.40 REAR WHEEL ARCH LINER
|
1059 |
|
2.41 FRONT FENDER
|
1060 |
|
2.42 REAR WIPER MOTOR
|
1061 |
|
2.43 FRONT WIPER
|
1061 |
|
ELECTRICAL
|
1063 |
|
1. TECHNICAL SPECIFICATION
|
1067 |
|
2. GENERAL PRECAUTIONS
|
1069 |
|
3. FUSE BOX / RELAY LOCATIONS (Applicable for RHD variants)
|
1073 |
|
4. BATTERY
|
1074 |
|
5. ALTERNATOR
|
1076 |
|
5.1. CHECKS ON ENGINE
|
1076 |
|
5.2. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALTERNATOR & BATTERY
|
1077 |
|
6. STARTER MOTOR
|
1080 |
|
7. LIGHTING SYSTEM
|
1088 |
|
7.1. BULB SPECIFICATIONS
|
1088 |
|
7.2. FASTENERS TORQUE VALUE TABLE
|
1089 |
|
7.3. GENERAL SYMPTOMS AND DIAGNOSTICS
|
1089 |
|
7.4. HEADLAMP
|
1092 |
|
7.5. SIDE REPEATER LAMP (LH/RH)
|
1097 |
|
7.6. ROOF LAMP
|
1097 |
|
7.7. HIGH MOUNTED STOP LAMP
|
1098 |
|
7.8. TAIL LAMP
|
1099 |
|
7.9. FRONT FOG LAMP
|
1102 |
|
7.10. REGISTRATION PLATE LAMP
|
1103 |
|
8. HORN
|
1104 |
|
9. WIPER & WASHER SYSTEM
|
1105 |
|
9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT
|
1105 |
|
9.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY
|
1106 |
|
9.3. WIPER AND WIPER CARE
|
1109 |
|
10. POWER SOCKETS
|
1111 |
|
11. GLOWPLUG CONTROL UNIT
|
1111 |
|
12. FUEL GAUGE AND FUEL LEVEL METER
|
1113 |
|
13. INSPECTION OF FUEL GAUGE
|
1113 |
|
14 COMBI-SWITCH
|
1114 |
|
14.1 COMBI SWITCH CONNECTION DETAILS
|
1115 |
|
14.2 REMOVAL & REFITMENT OF COMBISWITCH
|
1117 |
|
14.3 COMBI STALK REPLACEMENTPROCEDURE
|
1118 |
|
15. FASCIA SWITCHES (IF APPLICABLE
|
1120 |
|
16. STEERING CUM IGNITION SWITCH (IF APPLICABLE)
|
1122 |
|
17. HAZARD SWITCH
|
1123 |
|
19. MIRROR SWITCH (IF APPLICABLE)
|
1125 |
|
20. SILVER BOX
|
1127 |
|
20.1 SILVER BOX (XZ-HIGH VERSION)
|
1127 |
|
20.2. SILVER BOX (XM-MID VERSION)
|
1129 |
|
21. INFOTAINMENT SYSTEM
|
1131 |
|
21.1 INFOTAINMENT SYSTEM (XZ – HIGH)
|
1131 |
|
21.2. INFOTAINMENT SYSTEM (XM – MID)
|
1133 |
|
21.3 USB PORT
|
1135 |
|
21.4 SPEAKERS
|
1136 |
|
21.5 ANTENNA (IF APPLICABLE)
|
1137 |
|
21.6. MICROPHONE (XZ-HIGH)
|
1138 |
|
21.7. MICROPHONE (XM - MID
|
1139 |
|
21.8. TWEETERS
|
1139 |
|
21.9. DTC FOR INFOTAINMENT SYSTEM
|
1141 |
|
22. WINDOW WINDING MODULE
|
1142 |
|
23. POWER WINDOW SWITCHES & INHIBITSWITCH
|
1145 |
|
24. STEERING WHEEL SWITCHES
|
1150 |
|
25. IGNITION E-KEY (IF APPLICABLE)
|
1152 |
|
26. INSTRUMENT CLUSTER
|
1155 |
|
26.1. BASIC FUNCTIONAL MATRIX
|
1160 |
|
26.2. MAIN CONNECTOR PIN-OUTS
|
1161 |
|
26.3. FUEL GAUGE DETAILS
|
1162 |
|
26.4. TEMPERATURE BAR GRAPH DETAILS
|
1163 |
|
26.5. CHIME TABLE
|
1164 |
|
27. IMMOBILIZER SYSTEM (IF APPLICABLE)
|
1165 |
|
27.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB
|
1169 |
|
27.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU
|
1170 |
|
27.3. IGNITION KEY LEARNINGPROCEDURE
|
1172 |
|
28. BODY CONTROL MODULE (BCM
|
1174 |
|
28.1 CONNECTION DETAILS (PINOUT DEATAILS)
|
1175 |
|
28.2 BCM SPECIFICATION
|
1179 |
|
28.3 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX
|
1180 |
|
28.4 BCM FEATURES (IF APPLICABLE)
|
1185 |
|
28.5 BCM FUNCTIONS
|
1187 |
|
28.6 BCM REPLACEMENT STRATEGY
|
1188 |
|
29. FUSE AND RELAY BOX DETAILS
|
1190 |
|
30. REVERSE PARK ASSIST SYSTEM
|
1198 |
|
31. PASSIVE ENTRY PASSIVE START(PEPS)
|
1212 |
|
32. RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE)
|
1221 |
|
33. TELEMATICS
|
1226 |
|
HVAC
|
1229 |
|
1. HVAC SYSTEM LAYOUT
|
1235 |
|
2. TECHNICAL SPECIFICATIONS
|
1236 |
|
3. TIGHTENING TORQUES
|
1239 |
|
4. PRECAUTIONS
|
1242 |
|
5. HVAC SYSTEM LAYOUT AND WORKING
|
1243 |
|
6. CONTROL PANEL
|
1245 |
|
7. HVAC UNIT COMPONENTS
|
1247 |
|
8. COMPRESSOR
|
1248 |
|
9. CONDENSER
|
1250 |
|
10. RECEIVER DRIER (R.D)
|
1250 |
|
11. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT)
|
1250 |
|
12. TRINARY PRESSURE SENSOR
|
1251 |
|
13. MODE & TEMPRATURE CONTROL ACTUATOR
|
1252 |
|
14. INSPECTION OF MODE AND TEMPERATURE ACTUATOR
|
1253 |
|
15. TROUBLESHOOTING
|
1255 |
|
16. MAINTENANCE
|
1265 |
|
A. PRELIMINARY INSPECTION
|
1265 |
|
B. REGULAR MAINTENANCE
|
1267 |
|
17. ON VEHICLE REPAIRS
|
1271 |
|
A. AC FILTER REMOVAL AND ASSEMBLY
|
1271 |
|
B. COMPRESSOR REMOVAL AND ASSEMBLY
|
1271 |
|
C. CONTROL PANEL REMOVAL AND ASSEMBLY
|
1272 |
|
D. BLOWER MOTOR REMOVAL AND ASSEMBLY
|
1273 |
|
E. FRONT HVAC UNIT REMOVAL AND ASSEMBLY
|
1274 |
|
F. CONDENSER REMOVAL AND ASSEMBLY
|
1275 |
|
18. DO’S AND DONT’S FOR A/C SYSTEM
|
1277 |
|
FATC
|
1279 |
|
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM
|
1285 |
|
2. FATC SYSTEM LAYOUT
|
1285 |
|
3. TECHNICAL SPECIFICATIONS
|
1286 |
|
4. TIGHTENING TORQUES
|
1290 |
|
5. PRECAUTIONS
|
1293 |
|
6. HMI CLIMATE CONTRL DISPLAY
|
1294 |
|
7. CONTROL PANEL
|
1296 |
|
8. CONTROL PANEL MODULE CONNECTOR DETAILS
|
1301 |
|
9. FATC UNIT
|
1303 |
|
A. BLOWER
|
1303 |
|
B. EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE)
|
1303 |
|
C. HEATER COIL
|
1303 |
|
10. FATC SENSOR & ACTUATOR
|
1304 |
|
A. EVAPORATER SENSOR
|
1304 |
|
B. TRINARY PRESSURE SENSOR
|
1305 |
|
C. INCAR SENSOR
|
1305 |
|
D. MODE ACTUATOR
|
1306 |
|
E. TEMPERATURE ACTUATOR
|
1306 |
|
F. FRESH AIR / RECIRCULATION ACTUATOR
|
1306 |
|
G. BLOWER CONTROL MODULE
|
1307 |
|
11. COMPRESSOR
|
1307 |
|
12. CONDENSER AND RECEIVER DRIER CONDENSER
|
1308 |
|
13. TROUBLESHOOTING
|
1309 |
|
14. MAINTENANCE
|
1320 |
|
A PRELIMINARY INSPECTION
|
1320 |
|
B. REGULAR MAINTENANCE
|
1322 |
|
15. ON VEHICLE REPAIR
|
1326 |
|
A. AC FILTER REMOVAL AND ASSEMBLY
|
1326 |
|
B. CONTROL PANEL REMOVAL AND ASSEMBLY
|
1326 |
|
C. BLOWER MOTOR REMOVAL AND ASSEMBLY
|
1327 |
|
D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY
|
1328 |
|
E. REAR VENT REMOVAL AND ASSEMBLY
|
1330 |
|
F. COMPRESSOR REMOVAL ANDASEMBLY
|
1331 |
|
G. CONDENSER REMOVAL AND ASSEMBLY
|
1331 |
|
16. DO’S AND DONT’S FOR A/C SYSTEM
|
1333 |
|
SUPPLEMENTARY RESTRAINT SYSTEM
(SRS)
|
1334 |
|
1.1. WORKING OF RESTRAINTS
|
1336 |
|
1.2. SYSTEM LAYOUT
|
1338 |
|
1.3. SAFETY PRECAUTIONS
|
1339 |
|
1.4. DISPOSAL OF FAULTY AIR BAG UNIT
|
1341 |
|
1.5. SRS POST ACCIDENT PROCEDURE
|
1342 |
|
1.6. TIGHTENING TORQUES
|
1343 |
|
1.7. COMPONENTS
|
1347 |
|
1.7.1. RESTRAINT WITHOUT AIRBAGS
|
1347 |
|
1.7.2. RESTRAINT WITH AIRBAGS
|
1347 |
|
1.7.2.1. ECU
|
1347 |
|
1.7.2.2. FRONT IMPACT SENSOR (FIS)
|
1351 |
|
1.7.2.3. AIR BAGS
|
1353 |
|
1.7.2.4. RPLL BELTS
|
1355 |
|
1.7.2.5. CLOCK SPRING
|
1358 |
|
WHEELS AND TYRES
|
1363 |
|
1.1 GENERAL INFORMATION
|
1365 |
|
A. SPECIFICATIONS
|
1365 |
|
B. CONSTRUCTION
|
1366 |
|
C. TIGHTENING TORQUES
|
1368 |
|
1.2 GENERAL SYMPTOMS DIAGNOSIS
|
1369 |
|
A. DIAGNOSIS CHART
|
1369 |
|
B. TYRE WEAR PATTERN
|
1371 |
|
C. WEAR CAUSES
|
1372 |
|
D. TYRE VIBRATION DIAGNOSIS
|
1373 |
|
1.3 MAINTENANCE, INSPECTION AND TESTS
|
1374 |
|
A. PRELIMINARY INSPECTION
|
1374 |
|
B. REGULAR MAINTENANCE
|
1375 |
|
I. INFLATION
|
1375 |
|
II. WHEEL BALANCING
|
1375 |
|
III. TYRE ROTATION
|
1376 |
|
IV. WHEEL RUN OUT
|
1377 |
|
V. DO'S AND DON’TS
|
1377 |
|
1.4 WHEEL AND TYRE REPLACEMENT
|
1378 |
|
A. PRECAUTIONS DURING TYREREPLACEMENT
|
1378 |
|
B. TYRE REPLACEMENT
|
1379 |
|
C. WHEEL ASSEMBLY REPLACEMENT
|
1379 |
|
D. WHEEL REMOVAL
|
1379 |