Table of Contents 1 1423

ALTROZ SERVICE MANUAL

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
HVAC (ETC) 1279
CONTENTS 1280
1 HVAC SYSTEM LAYOUT 1282
2 TECHNICAL SPECIFICATIONS 1283
3 TIGHTENING TORQUES 1287
4 PRECAUTIONS 1289
5 HVAC SYSTEM LAYOUT AND WORKING 1290
6 CONTROL PANEL 1292
7 WORKING / FUNCTION OF ETC 1293
8 CONNECTOR DETAILS 1295
9 HVAC UNIT COMPONENTS 1296
10 COMPRESSOR 1297
11 CONDENSOR 1298
12 RECEIVER DRIER (R.D) 1298
13 TRINARY PRESSURE SENSOR 1298
14 TROUBLESHOOTING 1299
15 MAINTAINANCE 1309
16 ON VEHICLE REPAIR 1315
17 DO’S AND DONT’S FOR A/C SYSTEM 1321
FATC 1322
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM 1328
2. FATC SYSTEM LAYOUT 1328
3. TECHNICAL SPECIFICATIONS 1329
4. TIGHTENING TORQUES 1333
5. PRECAUTIONS 1336
6. HMI CLIMATE CONTRL DISPLAY 1337
7. CONTROL PANEL 1339
8. CONTROL PANEL MODULE CONNECTOR DETAILS 1344
9. FATC UNIT 1346
A. BLOWER 1346
B. EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE) 1346
C. HEATER COIL 1346
10. FATC SENSOR & ACTUATOR 1347
A. EVAPORATER SENSOR 1347
B. TRINARY PRESSURE SENSOR 1348
C. INCAR SENSOR 1348
D. MODE ACTUATOR 1349
E. TEMPERATURE ACTUATOR 1349
F. FRESH AIR / RECIRCULATION ACTUATOR 1349
G. BLOWER CONTROL MODULE 1350
11. COMPRESSOR 1350
12. CONDENSER AND RECEIVER DRIER CONDENSER 1351
13. TROUBLESHOOTING 1352
14. MAINTENANCE 1363
A PRELIMINARY INSPECTION 1363
B. REGULAR MAINTENANCE 1365
15. ON VEHICLE REPAIR 1369
A. AC FILTER REMOVAL AND ASSEMBLY 1369
B. CONTROL PANEL REMOVAL AND ASSEMBLY 1369
C. BLOWER MOTOR REMOVAL AND ASSEMBLY 1370
D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY 1371
E. REAR VENT REMOVAL AND ASSEMBLY 1373
F. COMPRESSOR REMOVAL ANDASEMBLY 1374
G. CONDENSER REMOVAL AND ASSEMBLY 1374
16. DO’S AND DONT’S FOR A/C SYSTEM 1376
SUPPLEMENTARY RESTRAINT SYSTEM (SRS) 1377
1.1. WORKING OF RESTRAINTS 1379
1.2. SYSTEM LAYOUT 1381
1.3. SAFETY PRECAUTIONS 1382
1.4. DISPOSAL OF FAULTY AIR BAG UNIT 1384
1.5. SRS POST ACCIDENT PROCEDURE 1385
1.6. TIGHTENING TORQUES 1386
1.7. COMPONENTS 1390
1.7.1. RESTRAINT WITHOUT AIRBAGS 1390
1.7.2. RESTRAINT WITH AIRBAGS 1390
1.7.2.1. ECU 1390
1.7.2.2. FRONT IMPACT SENSOR (FIS) 1394
1.7.2.3. AIR BAGS 1396
1.7.2.4. RPLL BELTS 1398
1.7.2.5. CLOCK SPRING 1401
WHEELS AND TYRES 1404
1.1 GENERAL INFORMATION 1408
A. SPECIFICATIONS 1408
B. CONSTRUCTION 1409
C. TIGHTENING TORQUES 1411
1.2 GENERAL SYMPTOMS DIAGNOSIS 1412
A. DIAGNOSIS CHART 1412
B. TYRE WEAR PATTERN 1414
C. WEAR CAUSES 1415
D. TYRE VIBRATION DIAGNOSIS 1416
1.3 MAINTENANCE, INSPECTION AND TESTS 1417
A. PRELIMINARY INSPECTION 1417
B. REGULAR MAINTENANCE 1418
I. INFLATION 1418
II. WHEEL BALANCING 1418
III. TYRE ROTATION 1419
IV. WHEEL RUN OUT 1420
V. DO'S AND DON’TS 1420
1.4 WHEEL AND TYRE REPLACEMENT 1421
A. PRECAUTIONS DURING TYREREPLACEMENT 1421
B. TYRE REPLACEMENT 1422
C. WHEEL ASSEMBLY REPLACEMENT 1422
D. WHEEL REMOVAL 1422

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