TIAGO

1. GENERAL	6
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS	9
1.2. PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE	10
1.3. PRECAUTIONS OF COMMON RAIL SYSTEM (CR SYSTEM)	11
1.4. VEHICLE JACKING AND LIFTING POINTS	13
1.5. JACK, AND TOOL BAG LOCATION	14
1.6. NUMBERING SYSTEM	15
1.6.1. CHASSIS NUMBERING SYSTEM	15
1.6.2. AGGREGATE NUMBERING SYSTEM	17
1.7. CHASSIS TYPE AND SALES DESIGNATIONS	18
1.8. TECHNICAL SPECIFICATIONS (PETROL)	19
1.9. TECHNICAL SPECIFICATIONS (DIESEL)	22
1.10. VEHICLE DIMENSIONS	25
1.11. RECOMMENDED LUBRICANTS & COOLANTS	26
1.12. SERVICE AND MAINTENANCE	28
2. 1.2L REVOTRON ENGINE	32
2.1. GENERAL INFORMATION	38
A. ENGINE INTRODUCTION	38
B. ELECTRONIC FUEL INJECTION CONTROL	39
C. TECHNICAL SPECIFICATION	40
D. SPECIAL TOOLS	41
E. ASSEMBLY CLEARANCES	44
F. SEALANTS	44
G. LEAKAGE RATES	44
H. RECOMMENDED LUBRICANTS & COOLANTS	44
I. SERVICE SCHEDULE	45
2.2. TROUBLESHOOTING	46
2.3. CONSTRUCTIONAL AND SERVICE DETAILS	53
A. ENGINE LIFTING	53
B. INTAKE MANIFOLD	54
C. CYLINDER HEAD AND COVER	56
D. CYLINDER HEAD-A	58
E. CYLINDER HEAD-B	60
F. CYLINDER BLOCK	62
G. OIL SUMP	64
H. MOVING PARTS	66
I. ENGINE TIMING	68
J. EXHAUST MANIFOLD	70
K. FUEL INJECTION EQUIPMENT	72
L. LUBRICATION PUMP AND COMPONENTS	74
M. AIR INTAKE SYSTEM	76
N. SPECIAL INSTALLATION	78
O. ENGINE SUSPENSION	81
2.4. ENGINE TESTS AND MAINTENANCE	84
A. PRELIMINARY INSPECTION	84
B. ENGINE TESTS	85
I. ENGINE COMPRESSION TEST	85
II. ENGINE OIL CONSUMPTION TEST	86
III. ENGINE OIL PRESSURE TEST	87
C. REGULAR MAINTENANCE	88
I. ENGINE OIL AND FILTER CHANGE	88
II. ENGINE COOLANT REPLACEMENT	89
III. AIR FILTER ELEMENT REPLACEMENT	90
IV. SPARK PLUG REPLACEMENT	91
V. FUEL FILTER REPLACEMENT	94
VI. AIR CONDITIONER COMPRESSOR BELT REPLACEMENT	95
2.5. REPAIR AND INSPECTION DETAILS	96
A. ACCESSORY DRIVING BELT	96
B. TIMING CHAIN	96
C. CYLINDER HEAD	96
D. VALVES	97
E. CYLINDER HEAD VALVE SEATS	99
F. ROLLER FINGER FOLLOWER	100
G. HYDRAULIC LASH ADJUSTER	100
H. CAMSHAFT	100
I. PISTON AND PISTON RINGS	102
J. CONNECTING RODS	103
K. CRANKSHAFT	105
L. CRANK CASE	107
M. FUEL TANK	108
N. CANISTER PURGE VALVE	108
O. CANISTER	109
2.6. ENGINE SYSTEM	110
A. AIR INTAKE SYSTEM	110
B. BLOW BY SYSTEM	112
C. LUBRICATION SYSTEM	113
D. EXHAUST SYSTEM	117
E. COOLING SYSTEM	120
F. FUEL SYSTEM	123
2.7. ENGINE ON VEHICLE SERVICE PROCEDURE	126
A. ENGINE REMOVAL AND INSTALLATION	126
B. AIR FILTER ASSY	131
C. INJECTION SYSTEM	132
D. SPARK PLUG	133
E. EXHAUST SYSTEM	133
F. FUEL SYSTEM	136
G. COOLING SYSTEM	142
H. REMOVAL OF ACCESSORIES	145
2.8. ENGINE OVEHAULING (ON OVERHAUL STAND)	146
A. ENGINE DIS-ASSEMBLY	146
I. REMOVAL OF INTAKE MANIFOLD	146
II. REMOVAL OF EXHAUST MANIFOLD	147
III. REMOVAL OF OIL SUMP	149
IV. REMOVAL OF SENSORS	149
V. REMOVAL OF ACCESSORIES	150
VI. REMOVAL OF TIMING CHAIN	153
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	160
I. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES	160
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES	162
III. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES	164
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK	165
V. ASSEMBLY OF TIMING CHAIN	167
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT	170
VII. FITMENT OF ENGINE SENSORS AND PERIPHERALS	172
VIII. FITMENT OF OIL SUMP	173
IX. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS	173
X. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS	175
2.9. ENGINE MANAGEMENT SYSTEM	178
A. ABBREVIATIONS	178
B. AN OVERVIEW	179
C. ELECTRONIC CONTROL UNIT	180
D. SENSORS	185
I. T-MAP SENSOR	186
II. LAMBDA SENSOR	187
III. CAMSHAFT POSITION SENSOR	189
IV. KNOCK SENSOR	190
V. CRANKSHAFT POSITION SENSOR	191
VI. COOLANT TEMPERATURE SENSOR	192
E. ACTUATORS	194
I. IGNITION COIL	195
II. PURGE CONTROL VALVE	196
III. SOLENOID VALVE (OCV)	197
IV. FUEL INJECTOR	198
V. ELECTRONIC THROTTLE BODY	199
F. SWITCH	201
I. OIL PRESSURE SWITCH	201
II. THROTTLE PEDAL SENSOR	202
III. CLUTCH SWITCH	203
IV. BRAKE SWITCH	204
V. VEHICLE SPEED SENSOR	205
WHEEL SPEED SENSOR	206
3. 1.05L REVOTORQ ENGINE	207
3.1. GENERAL INFORMATION	212
A. ENGINE INTRODUCTION	212
B. TECHNICAL SPECIFICATION	213
C. SPECIAL TOOLS	214
D. ASSEMBLY CLEARANCES	218
E. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES	219
F. SERVICE SCHEDULE	220
3.2. TROUBLESHOOTING	221
3.3. CONSTRUCTIONAL AND SERVICE DETAILS	229
A. ENGINE MOUNTING SYSTEM	229
B. CYLINDER HEAD AND COVER	231
C. LUBRICATION SYSTEM	233
D. ENGINE	235
E. OIL SUMP	237
F. CYLINDER HEAD	239
G. SPECIAL INSTALLATION	241
H. EXHAUST SYSTEM	243
I. INTAKE SYSTEM	245
J. ENGINE SUSPENSION	247
K. MOVING PARTS	249
L. ENGINE TIMING	251
M. FUEL INJECTION EQUIPMENT	253
3.4. ENGINE TESTS AND MAINTENANCE	255
A. PRELIMINARY INSPECTION	255
B. ENGINE TESTS	255
C. REGULAR MAINTENANCE	259
I. ENGINE OIL AND FILTER CHANGE	259
II. ENGINE COOLANT REPLACEMENT	260
III. AIR FILTER ELEMENT REPLACEMENT	261
IV. FUEL FILTER REPLACEMENT	262
V. DRAINING WATER FROM PRE-FILTER	263
VI. PRE-FILTER REPLACEMENT	263
VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT	264
3.5. REPAIR AND INSPECTION DETAILS	265
A. TIMING BELT	265
B. FUEL TANK	265
C. CYLINDER HEAD	266
D. VALVES	267
E. VALVE SEATS	268
F. CRANKCASE	269
G. VALVE SEAT INSERT	270
H. HYDRAULIC LASH ADJUSTER	270
I. VALVE GUIDES	271
J. CAMSHAFT	272
K. PISTON AND PISTON RINGS	273
L. CONNECTING ROD	274
M. CRANKSHAFT	276
3.6. ENGINE SYSTEM	278
A. AIR INTAKE SYSTEM	278
B. EXHAUST SYSTEM	280
C. COOLING SYSTEM	284
D. LUBRICATION SYSTEM	287
E. EXHAUST GAS RECIRCULATION SYSTEM	290
F. BLOW BY/ CRANKCASE VENTILATION SYSTEM	292
G. VACUUM MANAGEMENT SYSTEM	293
H. FUEL SYSTEM	294
3.7. ENGINE ON VEHICLE SERVICE PROCEDURE	300
A. ENGINE REMOVAL	300
B. ENGINE INSTALLATION	304
C. EXHAUST SYSTEM	305
D. COOLING SYSTEM	307
E. FUEL SYSTEM	309
3.8. ENGINE OVEHAULING (ON OVERHAUL STAND)	316
A. ENGINE DIS-ASSEMBLY	316
I. ON OVERHAUL STAND	316
II. REMOVAL OF INTAKE MANIFOLD	319
III. REMOVAL OF EXHAUST MANIFOLD	321
IV. REMOVAL OF OIL SUMP	325
V. REMOVAL OF TIMING BELT	326
VI. REMOVAL OF CYLINDER HEAD	329
VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES	330
VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES	332
IX. PISTON CONNECTING ROD DIS-ASSEMBLY	334
B. ENGINE ASSEMBLY	340
I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES	340
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES	341
III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES	342
IV. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK	343
V. FITMENT OFTIMING BELT	344
VI. FITMENT OF OIL SUMP	347
VII. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS	349
VIII. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS	353
IX. ON ENGINE SUPPORT STAND	355
3.9. ENGINE MANAGEMENT SYSTEM	359
A. ABBREVIATIONS	359
B. AN OVERVIEW	360
C. ELECTRONIC CONTROL UNIT (ECU)	361
D. EMS SENSORS	365
I. CRANK POSITION SENSOR	365
II. VEHICLE SPEED SENSOR	366
III. WHEEL SPEED SENSOR	367
IV. CAMSHAFT POSITION SENSOR	368
V. AIR MASS FLOW SENSOR	369
VI. INLET METERING VALVE	370
VII. VENTURI	370
VIII. RAIL PRESSURE SENSOR	370
IX. THROTTLE PEDAL SENSOR	371
X. WATER IN FUEL SENSOR	372
XI. CLUTCH SWITCH	372
XII. OIL PRESSURE SWITCH	373
XIII. BRAKE SWITCH	375
XIV. COOLANT TEMPERATURE SENSOR	376
XV. GLOW PLUG	377
XVI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV)	378
4. DRIVETRAIN-TA65 STAR	379
4.1 PRECAUTION	383
4.2 SPECIFCICATIONS & TIGHTENING TORQUES	384
A. CLUTCH	384
B. TRANSAXLE	389
C. TIGHTENING TORQUES	390
4.3 SPECIAL TOOLS	391
A. CLUTCH	391
B. TRANSAXLE	391
4.4 DIAGNOSIS	396
A. CLUTCH	396
B. TRANSAXLE	399
4.5 MAINTENANCE, ADJUSTMENT & TEST	400
A. PRELIMINARY INSPECTION OF CLUTCH	400
B. DRIVESHAFT	401
4.6 CLUTCH	403
A. THEORY OF DIAPHRAGM SPRING CLUTCH	403
B. CONSTRUCTIONAL DETAILS	404
C. FACTOR AFFECTING CLUTCH WEAR	406
D. CLUTCH CABLE - REMOVAL AND INSPECTION	407
E. REMOVAL OF CLUTCH FROM THE CAR	408
F. INSTALLATION OF CLUTCH ON THE CAR	408
H. PROCEDURE FOR CLUTCH ADJUSTMENT	409
4.7 TRANSAXLE	410
A. GENERAL DISCRIPTION	410
B. CUT SECTION OF TRANSAXLE TA 65 STAR	412
C. CUT SECTION OF TOP COVER ASSEMBLY	413
D. EXPLODED VIEW OF TRANSAXLE	414
E. EXPLODED VIEWS OF DIFFERENTIAL	416
F. EXPLODED VIEW OF SHIFTER FORK	418
G. EXPLODED VIEWS OF GEAR SHIFT LINKAGE ASSSEMBLY	420
H. EXPLODED VIEWS OF LAY SHAFT AND INPUT SHAFT	421
I. REMOVAL OF CLUTCH FROM THE CAR	424
J. TRANSAXLE TA65 STAR (ON BENCH) DISASSSEMBLY	426
K. INPUT SHAFT SUB- ASSEMBLY	432
L. INPUT SHAFT ASSEMBLY	432
M. DISASSEMBLY OF LAY SHAFT	433
N. IDENTIFICATION OF COMPONENTS	435
O. SUBASSEMBLIE	438
P. LAY SHAFT ASSEMBLY	440
Q. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL	443
R. ASSEMBLY OF TRANSAXLE	445
S. ASSEMBLY OF TOP COVER	448
T. INSTALLATION OF TRANSAXLE ON CAR	452
U. REMOVAL OF GEARSHIFT HOUSING, GEAR SHIFTER AND SELECTOR CABLE	453
4.8 DRIVE SHAFT	455
A. DRIVE SHAFT PARTS	455
B. DISASSEMBLY AND ASSEMBLY PROCEDURE DRIVESHAFT TRIPOT JOINT	456
C. DISASSEMBLY AND ASSEMBLY CV JOINT ASSEMBLY (OUTER)	459
5. SUSPENSION	463
5.1 TECHNICAL SPECIFICATION AND TIGHTENING TORQUE	467
5.1.1 SPECIFCICATIONS	467
5.1.2 TIGHTENING TORQUES	468
5.2 SPECIAL TOOLS	470
5.3 DIAGNOSIS	476
5.4 PRECAUTION	477
5.5 SUSPENSION SYSTEM	478
5.6 EXPLODED VIEWS FRONT SUSPENSION SYSTEM	482
5.6.1. ASSEMBLY FRONT STRUT EXPLODED VIEW	482
5.6.2. LOWER ARM LINK EXPLODED VIEW	483
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. REPLACEMENT OF WHEELS	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. BALANCING WHEELS	515
5.10.7. TYRE CARE	515
6. BRAKES	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 ARKING BRAKE LEVER PRIMARY CABLE GREASING	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 (ELECTRICAL POWER ASSIST SYSTEM-EPAS) (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	604
7.5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS	608
7.6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	611
7B. STEERING (ELECTRICAL POWER ASSIST SYSTEM-EPAS) (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
1.5 SPECIAL TOOLS	627
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	641
3.3.5 DO’S & DON’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 FIELD	658
7. CIRCUIT SCHEMATICS OF MANDO EPAS	662-663
8. ELECTRICAL	664
8.1 TECHNICAL SPECIFICATION	669
8.2 GENERAL PRECAUTIONS	671
8.3 FUSE BOX / RELAY LOCATIONS	675
8.4 BATTERY	676
8.5 ALTERNATOR	678
8.6 STARTER MOTOR	681
8.7 LIGHTING SYSTEM	688
8.7.1 BULB SPECIFICATIONS	688
8.7.2 FASTENERS TORQUE VALUE TABLE	689
8.7.3 GENERAL SYMPTOMS AND DIAGNOSTICS	689
8.7.4 HEAD LAMP	693
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	705
8.7.10 REGISTRATION PLATE LAMP	706
8.8 HORN	707
8.9 WIPER & WASHER SYSTEM	709
8.9.1 FRONT AND REARWIPER ANDWAHSER SYSTEM LAYOUT	710
8.9.2 FRONT AND REARWASH/WIPE SWITCH FUNCTIONALITY	711
8.9.3 WIPER ANDWIPER CARE	715
8.10 POWER SOCKETS	717
8.11 GLOW PLUG CONTROL UNIT	718
8.12 FUEL GAUGE AND FUEL LEVEL METER	720
8.13 COMBI-SWITCH	722
8.14 STEERING LOCK CUM IGNITION SWITCH	727
8.15 FASCIA SWITCHES	730
8.16 HAZARD SWITCH	734
8.17 MIRROR SWITCH	735
8.18 INFOTAINMENT SYSTEM	736
8.18.1 USB/AUX PORT	739
8.18.2 SPEAKERS	740
8.18.3 TWEETER	742
8.18.4 ANTENNA	743
8.18.5 MICROPHONE	744
8.18. DTC FOR INFOTAINMENT SYSTEM	745
8.19 WINDOW WINDING MODULE	746
8.20 POWER WINDOW SWITCHES	749
8.21 STEERING WHEEL SWITCHES	754
8.22 IGNITION E-KEY	757
8.23 INSTRUMENT CLUSTER	760
8.23.1 BASIC FUNCTIONALMATRIX	762
8.23.2 TELL TALESMATRIX	763
8.23.3 DRIVER INFORMATION SYSTEM	769
8.23.4 DTC FOR INSTRUMENT CLUSTER	774
8.23.5 CONNECTOR DETAILS	777
8.23.6 FUEL GAUGE DETAILS	779
8.23.7 TEMPERATURE BAR GRAPH DETAILS	780
8.23.8 CHIME TABLE	781
8.23.9 DISPLAY SCREEN FLOWAND SETTINGS	781
8.24 IMMOBILIZER SYSTEM	785
8.24.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB	790
8.24.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU	791
8.24.3 DTC FOR IMMOBILIZER	793
8.24.4 IGNITION KEYLEARNINGPROCEDURE	795
8.25 BODY CONTROL MODULE (BCM)	798
8.25.1 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX	804
8.25.2 BCM FUNCTIONS	816
8.25.3 DTC FOR BCM	854
8.26 CLUTCH PEDAL SENSOR	861
8.27 FUSE AND RELAY BOX DETAILS	864
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
8.28 REVERSE PARK ASSIST SYSTEM	877
8.28.1 PARK ASSIST	877
8.28.2 PARK ASSIST FUNCTIONALITY OVERVIEW	877
8.28.3 PARK ASSIST ACTIVATION PROCEDURE	877
8.28.4 PARK ASSIST DEACTIVATION PROCEDURE	878
8.28.5 PARK ASSIST AUDIO SETTING	878
8.28.6 PARK ASSIST VOLUME	878
8.28.7 MIXWITH AUDIO	878
8.28.8 PARK ASSIST TONE	879
8.28.9 PARK ASSIST DELAY TIMER	879
8.28.10 PARK ASSIST HMI INDICATIONS	879
8.28.11 PARK ASSIST LIMITATIONS	880
8.28.12 PARK ASSIST SYSTEM MAINTENANCE	880
8.28.13 PARK ASSIST SYSTEM ARCHITECTURE	881
8.28.14 ECU TO SENSOR ELECTRICAL INTERFACE	882
8.28.15 ECU MOUNTING	882
8.28.16 PHYSICAL IMAGES	884
8.28.17 SENSOR FITMENT TO THE BUMPER	885
9. BODY	887
9.1 GENERAL INFORMATION	891
9.1.1 LAYOUT	891
9.1.2 TIGHTENING TORQUES	892
9.1.3 SPECIAL TOOLS	895
9.2 ON VEHICLE REPAIRS	896
9.2.1 BONNET	896
9.2.2 FLOOR CONSOLE	898
9.2.3 DASHBOARD	900
9.2.4 GLOVE BOX	909
9.2.5 SIDE AIR VENTS	910
9.2.6 FRONT BUMPER	910
9.2.7 REAR BUMPER	911
9.2.8 FRONT DOOR	913
9.2.9 FRONT DOOR TRIMS	914
9.2.10 DOOR INNER LOCK HANDLE	915
9.2.11 FRONT OUTER DOOR LOCK	916
9.2.12 FRONT DOOR LATCH	917
9.2.13 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM	919
9.2.14 REAR DOOR	920
9.2.15 REAR DOOR TRIM	921
9.2.16 REAR OUTER DOOR LOCK	923
9.2.17 DOOR LATCH REAR	924
9.2.18 TAIL GATE	925
9.2.19 TAIL GATE LATCH CABLE	928
9.2.20 TAILGATE TRIM	929
9.2.21 ORVM	930
9.2.22 INNER REAR VIEW MIRROR	931
9.2.23 FRONT ROW SEAT	931
9.2.24 REAR ROW SEAT	932
9.2.25 FRONT SEAT BELTS	935
9.2.26 REAR SEAT BELT	937
9.2.27 “A” PILLAR TRIM	938
9.2.28 FRONT SCUFF PLATE	940
9.2.29 “B" PILLAR TRIMS	940
9.2.30 “C” PILLAR TRIM	941
9.2.31 GRAB HANDLES	942
9.2.32 SUNVISOR	943
9.2.33 ROOF LINER	943
9.2.34 PLENUM COVER	944
9.2.35 GEAR LEVER BOOT	945
9.2.36 BONNET INSULATION	945
9.2.37 GLASS	946
9.2.38 FUEL FILLER ASSEMBLY	947
9.2.39 FRONT WHEEL ARCH LINER	949
9.2.40 REAR WHEEL ARCH LINER	950
9.2.41 FRONT FENDER	951
9.2.42 REAR WIPER MOTOR	953
9.2.43 FRONT WIPER	954
10. HVAC	955
10.1 GENERAL INFORMATION	958
10.1.1. SPECIFICATIONS	958
10.1.2. TIGHTENING TORQUES	960
10.1.3. PRECAUTIONS	968
10.1.4. HVAC SYSTEM LAYOUT & WORKING	970
10.1.5. COMPONENTS OF HVAC	972
10.1.5.1. CONTROL PANEL	972
10.1.5.2. HVAC UNIT	975
10.1.5.3. COMPRESSOR	978
10.1.5.4. CONDENSOR & RECEIVER DRIER	979
10.1.5.5. THERMISTOR / THERMO SENSOR	980
10.1.5.6. TRINARY PRESSURE SWITCH/ SENSOR	982
10.1.5.7. AIR INLET ACTUATOR	983
10.1.6. TROUBLESHOOTING	984
10.2 MAINTAINANCE	998
10.2.1. PRELIMINARY INSPECTION	998
10.2.2. REGULAR MAINTENANCE	1000
10.3 ON VEHICLE REPAIR	1004
10.3.1. CONTROL PANEL ASSEMBLY	1004
10.3.2. COMPRESSOR	1009
10.3.3. BLOWER	1009
10.3.4. BLOWER RESISTER	1010
10.3.5. FILTER	1010
10.3.6. TXV	1011
10.3.7. PRESSURE SENSOR / SWITCH	1011
10.3.8. HVAC UNIT	1012
10.3.9. CONDENSOR SEALING DUCT	1012
10.3.10. CONDENSOR	1013
10.3.11. REFRIGERANT HOSES	1014
10.3.12. DO'S & DON’TS	1016
10.4 OVERHAULING HVAC UNIT	1017
11. SUPPLEMENTARY RESTRAINT SYSTEM (SRS)	1024
11.1.1 TIGHTENING TORQUES	1027
11.1.2 WORKING OF RESTRAINTS	1029
A. RESTRAINTSWITHOUT AIRBAGS	1029
B. RESTRAINTSWITH AIRBAGS	1029
11.1.3 SYSTEM LAYOUT	1030
11.1.3.1 RESTRAINTWITHOUT AIRBAG	1030
11.1.3.2 RESTRAINTWITH AIRBAG	1030
11.1.4 SAFETY PRECAUTIONS	1031
11.1.5 DISPOSAL OF FAULTY AIR BAG UNIT	1033
11.1.6 COMPONENTS	1034
11.1.6.1 RESTRAINT WITHOUT AIRBAGS	1034
A. SEAT BELT	1034
B. EMERGENCY LOCKING RETRACTOR (ELR)	1034
C. MICROSWITCH / SEAT BELT REMINDERWARNING LAMP	1034
11.1.6.2 RESTRAINT WITH AIRBAGS	1035
A. ECU	1035
B. SENSORS	1039
C. AIR BAGS	1040
D. RPLL BELTS	1043
E. CLOCK SPRING	1045
11.1.7. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT	1048

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