| 1. GENERAL |
8 |
| 1.1 GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS |
10 |
| 1.2 PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE |
12 |
| 1.3 PRECAUTIONS OF COMMON RAILSYSTEM (CR SYSTEM) |
13 |
| 1.4 LIFTING, JACKING, TOWING POINTSUSING THE TWO POST LIFT |
15 |
| 1.5 JACK AND TOOL BAG LOCATION IN VEHICLE |
16 |
| 1.6 NUMBERING SYSTEM |
17 |
| 1.6.1 CHASSIS NUMBERING SYSTEM |
17 |
| 1.6.2 AGGREGATE NUMBERING SYSTEM |
18 |
| 1.7 LOCATION OF CHASSIS AND AGGREGATE NUMBERS |
21 |
| 1.8 CHASSIS TYPE AND SALES DESIGNATIONS |
22 |
| 1.9 TECHNICAL SPECIFICATION FOR BOLT |
23 |
| 1.10. TECHNICAL SPECIFICATION FOR ZEST |
26 |
| 1.11 A VEHICLE DIMENSIONS |
29 |
| 1.11 B VEHICLE DIMENSIONS |
30 |
| 1.12 RECOMMENDED LUBRICANTS & COOLANTS |
31 |
| FOR BOLT AND ZEST (QUADRAJET) |
31 |
| FOR BOLT AND ZEST (REVOTRON) |
32 |
| FUEL, LUBRICANTS AND COOLANTS |
33 |
| 1.13 SERVICE AND MAINTENANCE (BOLT / ZEST) |
34 |
| 2. ENGINE (REVOTRON 1.2T) |
38 |
| 2.1 GENERAL INFORMATION |
48 |
| A. ENGINE INTRODUCTION |
48 |
| B. Electronic Fuel Injection Control |
49 |
| C. TECHNICAL SPECIFICATION |
50 |
| D. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
51 |
| E. SERVICE SCHEDULE |
52 |
| F. TIGHTENING TORQUE SPECIFICATIONS |
53 |
| G. SPECIAL TOOLS |
56 |
| 2.2 TROUBLESHOOTING |
58 |
| 2.3 CONSTRUCTIONAL AND SERVICE DETAILS |
66 |
| A. Intake Manifold |
66 |
| B. Cylinder Head and Cover |
67 |
| C. Cylinder Head |
69 |
| D. Cylinder Block |
71 |
| E. Moving Parts |
73 |
| F. Engine Timing |
75 |
| G. Exhaust Manifold |
77 |
| H. Fuel Injection Equipment |
79 |
| I. Lubrication Pump and Components |
81 |
| J. Engine Suspension |
83 |
| K. Air Intake System |
85 |
| L. Special Installation |
88 |
| 2.4 ENGINE TESTS AND MAINTENANCE |
90 |
| A. PRELIMINARY INSPECTION |
90 |
| B. Engine Tests |
92 |
| i. Engine Compression Test |
92 |
| ii. Engine Oil Consumption Test |
93 |
| iii. Engine Oil Pressure Test |
94 |
| C. REGULAR MAINTENANCE |
95 |
| i. Engine Oil and Filter Change |
95 |
| ii. Engine Coolant Replacement |
96 |
| iii. Air Filter Element Replacement |
98 |
| iv. Spark Plug Replacement |
99 |
| v. Fuel Filter Replacement |
101 |
| vi. Air Conditioner Compressor BeltReplacement |
102 |
| vii. Alternator Belt Replacement |
103 |
| 2.5 REPAIR AND INSPECTION DETAILS |
106 |
| A. Timing Belt |
106 |
| B. Cylinder Head |
106 |
| C. Valves |
107 |
| D. Cylinder Head Valve Seats |
109 |
| E. Rocker Arms and Shafts |
109 |
| F. Cylinder Head Valve Guides |
110 |
| G. Camshaft |
111 |
| H. Piston and Piston Rings |
112 |
| I. Connecting Rods |
113 |
| J. Crankshaft |
115 |
| K. Fuel Tank |
117 |
| 2.6 ENGINE SYSTEM |
120 |
| A. AIR INTAKE SYSTEM |
120 |
| B. BLOW BY SYSTEM |
123 |
| C. LUBRICATION SYSTEM |
124 |
| D. EXHAUST SYSTEM |
127 |
| E. COOLING SYSTEM |
129 |
| 2.7 ENGINE ON VEHICLE SERVICE PROCEDURE |
134 |
| A. Engine Removal |
134 |
| B. Engine Installation |
137 |
|
2.8 ENGINE OVERHAULING: (ON OVERHAUL STAND) |
140 |
| A. Engine Dis-assembly |
140 |
| i. Removal of Intake Manifold |
140 |
| ii. Removal of Exhaust Manifold |
143 |
| iii. Removal of Oil Sump |
147 |
| iv. Removal of Sensors |
147 |
| v. Removal of Timing Belt |
148 |
| vi. Removal of Cylinder Head |
151 |
| vii. Removal of Cylinder Head Sub-Assemblies |
152 |
| viii. Removal of Cylinder Block Sub-Assemblies |
154 |
| B. Engine Assembly |
158 |
| i. Fitment of Cylinder Head Sub-Assemblies |
158 |
| ii. Fitment of Piston and Connecting rod Sub-Assemblies |
160 |
| iii. Fitment of Cylinder Block Sub-Assemblies |
161 |
| iv. Fitment of Cylinder Head on CylinderBlock |
164 |
| v. Fitment of Oil Sump |
170 |
| vi. Fitment of Engine Sensors andPeripherals |
171 |
| vii. Fitment of Exhaust Manifold andPeripherals |
174 |
| viii. Fitment of Intake Manifold and
Peripherals |
176 |
| 2.9 ENGINE MANAGEMENT SYSTEM |
180 |
| A. ABBREVIATIONS |
182 |
| B. AN OVERVIEW |
183 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
184 |
| D. SENSORS |
190 |
|
i. Manifold Air Pressure Sensor andTemperature Sensor |
191 |
| ii. Lambda Sensor |
193 |
| iii. Camshaft Position Sensor |
195 |
| iv. Knock Sensor |
196 |
| v. Crankshaft Position Sensor |
197 |
| vi. Coolant Temperature Sensor |
199 |
| vii. Boost Pressure Sensor |
200 |
| E. ACTUATORS |
203 |
| i. Ignition Coil |
204 |
| ii. WG PWM actuator |
205 |
| iii. Dump Valve |
207 |
| iv. Purge Control Valve |
208 |
| v. Fuel Injectors |
210 |
| vi. Electronic Throttle Body |
211 |
| F. SWITCH |
213 |
| i. Oil Pressure Switch |
213 |
| DIAGNOSIS TROUBLESHOOTING CODES |
216 |
| LIST OF DIAGNOSTIC TROUBLESHOOTING CODES |
218 |
| 3A.
ENGINE (QUADRAJET 75PS) |
224 |
| 3A.1.1.GENERAL INFORMATION |
229 |
| 3A.1.1.1 TECHNICALSPECIFICATIONS |
229 |
| 3A.1.1.2 TIGHTENING TORQUES |
230 |
| 3A.1.1.3 SPECIAL TOOLS |
232 |
| 3A.1.1.4 MAINTENANCE , INSPECTION ANDTESTS |
237 |
| A. ENGINE OIL REPLACEMENT |
237 |
| B. ENGINE OIL FILTER CARTRIDGEREPLACEMENT. |
238 |
| C. AIR FILTER INSPECTION AND CLEANING |
239 |
| D. AIR FILTER ASSY – REMOVAL |
240 |
| E. FUEL FILTER – REPLACE |
240 |
| 3A.1.2 ENGINE – MECHANICAL |
242 |
| 3A.1.2.1 REMOVAL OF ENGINE FROMVEHICLE |
242 |
| CYLINDER HEAD ASSEMBLY |
246 |
| 3A.1.2.2.1 EXPLODED VIEW |
246 |
| 3A.1.2.2.2 REMOVAL OF CYLINDER HEADASSEMBLY AND OIL SUMP |
246 |
| 3A.1.2.2.3 CYLINDER HEAD – OVERHAUL |
254 |
| 3A.1.2.2.4 VALVE AND VALVE SPRING |
257 |
| A. EXPLODED VIEW |
257 |
| B. REMOVAL AND OVERHAUL |
258 |
| C. INSTALLATION |
260 |
| 3A.1.2.2.5 CYLINDER HEAD BLOCK |
261 |
| A. HEAD GASKET CORRECTION BASED ONCYLINDER HEAD BLOCK PLANARITY. |
261 |
| B. CAMSHAFT HOUSING INSPECTION ANDMEASUREMENT |
262 |
| C. CYLIDER HEAD BLOCK ASSEMBLY -REFITTING |
262 |
| 3A.1.2.2.6 SELECTION OF CYLINDER HEADGASKET |
264 |
| 3A.1.2.2.7 INSTALLATION OF CYLINDER HEADASSEMBLY AND OIL SUMP |
265 |
| 3A.1.2.3 ENGINE BLOCK |
388 |
| 3A.1.2.3.1 DISMANTLING |
388 |
| 3A.1.2.3.2 PISTON - REMOVAL & FITMENT |
392 |
| 3A.1.2.3.3 ENGINE OIL PUMP - REMOVALAND FITMENT |
392 |
| 3A.1.2.3.4 ENGINE BLOCK -MEASUREMENT, INSPECTION & GRADEDETERMINATION |
395 |
| 3A.1.2.3.5 ENGINE BLOCK – ASSEMBLY |
401 |
| 3A.1.3. ENGINE COOLING |
404 |
| A. SYSTEM DESCRIPTION |
404 |
| B. COMPONENTS |
405 |
| 3A.1.4. LUBRICATING SYSTEM |
406 |
| A. COMPONENTS |
406 |
| B. CONSTRUCTION AND WORKING |
406 |
| 3A.1.5 FUEL SUPPLY SYSTEM |
288 |
| 3A.1.5.1 INTRODUCTION |
288 |
| 3A.1.5.2 COMPONENTS |
289 |
| 3A.1.5.2.1 VACUUM PUMP |
289 |
| 3A.1.5.2.2 INJECTORS |
289 |
| A. IMA CLASSIFICATION |
290 |
| 3A.1.5.2.3 SINGLE FUEL MANIFOLD PIPE |
291 |
| 3A.1.5.2.4 FUEL FEED SYSTEM |
292 |
| A. FUEL TANK |
294 |
| B. INTANK FUEL PUMP |
298 |
| C. FUEL LEVEL SENSOR |
299 |
| E. FUEL LEVEL WARNING LIGHT |
306 |
| F. FUEL FILTER |
306 |
| G. FUEL FILLER CAP |
307 |
| H. FUEL HOSES & LINES |
307 |
| I. ASSEMBLY FILLER NECK COMPLETE |
308 |
| 3A.1.6 INTAKE SYSTEM |
309 |
| WORKING |
309 |
| 3.1.7 EXHAUST SYSTEM |
310 |
| A. DESCRIPTION |
310 |
| B. COMPONENTS |
310 |
| C. EXHAUST GAS RECIRCULATION (EGR). |
311 |
| D. E.G.R. SOLENOID VALVE |
312 |
| E. EXHAUST PIPE REMOVAL |
313 |
| 3A.1.8 ENGINE MANAGEMENT SYSTEM |
314 |
| 3A.1.8.1 SYSTEM OVERVIEW |
314 |
| 3A.1.8.2 FUNCTIONAL DESCRIPTION |
314 |
| 3A.1.8.3 SENSORS AND CONTROL UNIT |
315 |
| 3A.1.8.4 DIESEL FUEL INJECTION SYSTEM |
321 |
| 3.1.8.4.1 FUNCTION |
321 |
| 3A.1.8.4.2 SYSTEM LAYOUT |
322 |
| 3A.1.8.4.3 OPERATION PERFORMED BY EMS |
323 |
| 3A.1.8.9: DTC Codes |
328 |
| 3B. ENGINE (QUADRAJET 90PS) |
336 |
| 3A.1.1.GENERAL INFORMATION |
341 |
| 3A 1.1.1. TECHNICAL SPECIFICATIONS |
341 |
| 3A.1.1.2 TIGHTENING TORQUES |
342 |
| 3A.1.1.3 SPECIAL TOOLS |
344 |
| 3A.1.1.4 MAINTENANCE , INSPECTION ANDTESTS |
349 |
| A. ENGINE OIL REPLACEMENT |
349 |
| B. ENGINE OIL FILTER CARTRIDGEREPLACEMENT |
350 |
| C. AIR FILTER INSPECTION AND CLEANING |
351 |
| D. AIR FILTER ASSY – REMOVAL |
353 |
| E. FUEL FILTER REPLACEMENT PROCEDURE |
354 |
| F. ON VEHICLE TIMING CHAIN REPLACEMENTPROCEDURE |
355 |
| 3A.1.2 ENGINE – MECHANICAL |
359 |
| 3A.1.2.1 REMOVAL OF ENGINE FROM
VEHICLE |
359 |
| CYLINDER HEAD ASSEMBLY |
363 |
| 3A.1.2.2.1 EXPLODED VIEW |
363 |
| 3A.1.2.2.2 REMOVAL OF CYLINDER HEADASSEMBLY AND OIL SUMP |
363 |
| 3A.1.2.2.4 CYLINDER HEAD – OVERHAUL |
372 |
| 3A.1.2.2.5 VALVE AND VALVE SPRING |
375 |
| A. EXPLODED VIEW |
375 |
| B. REMOVAL AND OVERHAUL |
375 |
| C. INSTALLATION |
377 |
| 3A.1.2.2.6 CYLINDER HEAD BLOCK |
378 |
| A. HEAD GASKET CORRECTION BASED ONCYLINDER HEAD BLOCK PLANARITY. |
378 |
| B. CAMSHAFT HOUSING INSPECTION ANDMEASUREMENT |
379 |
| C. CYLIDER HEAD BLOCK ASSEMBLY -REFITTING |
380 |
| 3A.1.2.2.6. SELECTION OF CYLINDER HEADGASKET |
381 |
| 3A.1.2.2.7 INSTALLATION OF CYLINDERHEAD ASSEMBLY AND OIL SUMP |
382 |
| 3A.1.2.3 ENGINE BLOCK |
388 |
| 3A.1.2.3.1 DISMANTLING |
388 |
| 3A.1.2.3.2 PISTON - REMOVAL & FITMENT |
392 |
| 3A.1.2.3.3 ENGINE OIL PUMP - REMOVALAND FITMENT |
393 |
| 3A.1.2.3.4 ENGINE BLOCK -MEASUREMENT, INSPECTION & GRADEDETERMINATION |
395 |
| 3A.1.2.3.5 ENGINE BLOCK – ASSEMBLY |
401 |
| 3A.1.3. ENGINE COOLING |
404 |
| A. SYSTEM DESCRIPTION |
404 |
| B. COMPONENTS: |
405 |
| 3A.1.4. LUBRICATING SYSTEM |
406 |
| A. COMPONENTS |
406 |
| B. CONSTRUCTION AND WORKING: |
406 |
| 3A.1.5 FUEL SUPPLY SYSTEM |
407 |
| 3A.1.5.1 INTRODUCTION |
407 |
| 3A.1.5.2 COMPONENTS |
408 |
| A. IMA CLASSIFICATION |
409 |
| 3A.1.5.2.3 SINGLE FUEL MANIFOLD PIPE |
410 |
| 3A.1.5.2.4 FUEL FEED SYSTEM |
411 |
| A. FUEL TANK |
413 |
| B. INTANK FUEL PUMP (TANK UNIT) |
417 |
| C. FUEL LEVEL SENSOR |
418 |
| E. FUEL LEVEL |
423 |
| F. FUEL FILTER |
424 |
| G. FUEL FILLER CAP |
425 |
| H. FUEL HOSES & LINES |
425 |
| I. ASSEMBLY FILLER NECK COMPLETE |
426 |
| 3A.1.6 INTAKE SYSTEM |
427 |
| 3.1.7 EXHAUST SYSTEM |
431 |
| A. DESCRIPTION |
431 |
| B. COMPONENTS |
431 |
| C. EXHAUST GAS RECIRCULATION (EGR) |
432 |
| D. E.G.R. SOLENOID VALVE |
433 |
| E. EXHAUST PIPE REMOVAL |
434 |
| 3A.1.8 ENGINE MANAGEMENT SYSTEM |
435 |
| 3A.1.8.1 SYSTEM OVERVIEW |
435 |
| 3A.1.8.2 FUNCTIONAL DESCRIPTION |
435 |
| 3A.1.8.3 SENSORS |
440 |
| 3A.1.8.4 DIESEL FUEL INJECTION SYSTEM |
448 |
| 3.1.8.4.1 FUNCTION |
448 |
| 3A.1.8.4.2 SYSTEM LAYOUT |
449 |
| 3A.1.8.4.3 OPERATION PERFORMED BY EMS |
450 |
| DTC CODES |
455 |
| 4. DRIVETRAIN-C 549 |
470 |
| 4.1.1 CLUTCH |
476 |
| 4.1.1.1 HYDRAULIC CLUTCH ACTUATION LAYOUT |
476 |
| 4.1.1.2. TECHNICAL SPECIFICATIONS |
478 |
| 4.1.1.3 MAINTENANCE |
479 |
| A. CLUTCH ASSEMBLY REMOVAL |
479 |
| B. HYDRAULLIC ACTUATOR - REMOVAL |
479 |
| C. CLUTCH SLAVE CYLINDER BLEEDINGPROCEDURE |
480 |
| D. CLUTCH MASTER CYLINDER - REMOVAL |
482 |
| E. CLUTCH PEDAL ASSEMBLY – REMOVAL |
483 |
| F CLUTCH SWITCH ADJUSTMENTPROCEDURE |
483 |
| G EXPLODED VIEW |
484 |
| 4.1.2 TRANSAXLE |
487 |
| 4.1.2.1 GENERAL INFORMATION |
487 |
| A. TECHNICAL SPECIFICATIONS |
487 |
| B. CONSTRUCTION AND SYSTEMDESCRIPTION |
488 |
| C Tightening Torque |
490 |
| D. SPECIAL TOOS |
491 |
| 4.1.2.2 MAINTENANCE |
497 |
| A. TRANSAXLE OIL REPLACEMENT |
497 |
| 4.1.2.3 REMOVAL AND INSTALLATION OFTRANSAXLE FROM VEHICLE |
497 |
| 4.1.2.4. TRANSAXLE – OVERHAUL |
501 |
| A. TRANSAXLE ASSEMBLY - DISMANTLING |
501 |
| B. FIFTH GEAR - DISMANTLING |
502 |
| C. REMOVAL OF SHAFTS, CONTROL RODSAND DIFFRENTIAL |
504 |
| D. LAY SHAFT - DISMANTLING |
507 |
| E. MAINSHAFT- DISMANTLING |
508 |
| F. MAINSHAFT – ASSEMBLY |
509 |
| G. LAYSHAFT – ASSEMBLY |
510 |
| H. TRANSAXLE AS+SEMBLYINSTALLATION |
512 |
| I. FIFTH GEAR - ASSEMBLY |
513 |
| 4.1.2.5. DIFFERENTIAL ASSEMBLY –OVERHAUL |
515 |
| 4 1.2.6. INPUT SHAFT SEAL REPLACEMENT |
517 |
| 4.1.3.DRIVE SHAFT |
517 |
| 4.1.3.1 INTRODUCTION |
517 |
| 4.1.3.2.MAINTENANCE |
518 |
| A. DRIVESHAFT REMOVAL – LH SIDE: |
518 |
| B. DRIVESHAFT REMOVAL – RH SIDE: |
519 |
| C. INTERMEDIATE SHAFT |
519 |
| 5. ZEST AMT (AUTOMATED MANUAL TRANSMISSION) |
521 |
| 5.1 INTRODUCTION |
529 |
| 5.2 SYSTEM COMPONENTS |
530 |
| 5.2.1 POWER UNIT |
531 |
| 5.2.1.1. ELECTRIC PUMP |
531 |
| 5.2.1.2. PRESSURE ACCUMULATOR |
531 |
| 5.2.1.3. OIL RESERVOIR |
532 |
| 5.2.2 ELECTRO HYDRAULIC UNIT |
532 |
| 5.3 HYDRAULIC DIAGRAM |
533 |
| 5.4 ELECTRICAL COMPONENTS OF THE HYDRAULIC UNIT |
534 |
| 5.4.1 PROPORTIONAL PRESSURE SOLENOID VALVE |
534 |
| 5.4.2 ON-OFF SOLENOID VALVES FOR CONTROLLING THE POSITION SELECTION ACTUATOR |
535 |
| 5.4.3 PROPORTIONAL FLOW RATE SOLENOID VALVE |
535 |
| 5.5 ELECTRICAL WIRING |
537 |
| 5.5.1 LINE PRESSURE SENSOR |
538 |
| 5.5.2 CLUTCH RPM SENSORS |
538 |
| 5.5.3 ENGAGEMENT AND SELECTION POSITION SENSORS |
538 |
| 5.5.4 CSC CLUTCH ACTUATOR |
538 |
| 5.5.5 PLCD CLUTCH POSITION SENSOR |
539 |
| 5.5.6 MECHANICAL COMPONENTS OF THE UNIT |
541 |
| 5.5.7 GEAR ENGAGEMENT AND SELECTION SHAFT |
541 |
| 5.5.8 ELECTRONIC CONTROL UNIT |
541 |
| 5.5.9 SYSTEM INPUT SIGNALS |
544 |
| 5.6 USER INTERFACES - SYSTEM |
544 |
| 5.6.1 SYSTEM OPERATION (IN THE ABSENCE OF FAULTS) |
545 |
| 5.6.2 PRESSURISATION OF THE HYDRAULIC CIRCUIT |
545 |
| 5.6.3 AUTOMATIC ENGAGEMENT OF THE CLUTCH DOWNHILL WITH THE ACCELERATOR PEDAL |
545 |
| 5.6.4 RELEASED |
545 |
| 5.6.5 VEHICLE SLOWDOWN |
545 |
| 5.6.6 TURNING OFF THE ENGINE AND SYSTEM |
545 |
| 5.6.7 FUNCTIONAL INTERACTION LOGICS WITH OTHER SYSTEMS |
545 |
| 5.6.8 INTERACTION WITH ENGINE MANAGEMENT |
545 |
| 5.6.9 ABS INTERACTION (FOR CAR VERSIONS/TRIM LEVELS WHERE PROVIDED) |
546 |
| 5.6.10 SPRINT DEPARTURE |
546 |
| 5.6.11 OPERATION |
546 |
| 5.6.12 VEHICLE STOPPED AND ENGINE OFF |
546 |
| 5.6.13 DOOR OPENING |
546 |
| 5.6.14 MEASURES BEFORE KEY ON |
546 |
| 5.6.15 KEY ON (+15) |
546 |
| 5.6.16 ENGINE ON AND/OR VEHICLE MOVING |
547 |
| 5.6.17 FIRST STARTING (+50) |
547 |
| 5.6.18 STARTING THE VEHICLE FROM STATIONARY |
547 |
| 5.6.19 ENGINE STARTED |
547 |
| 5.6.20 CHANGE IN MANUAL MODE |
547 |
| 5.6.21 GEAR CHANGE IN AUTOMATIC MODE |
547 |
| 5.6.22 REQUEST FOR NEUTRAL WITH THE VEHICLE MOVING |
548 |
| 5.6.23 REQUEST FOR REVERSE WITH THE VEHICLE MOVING REVERSE |
548 |
| 5.6.24 REVERSE DISENGAGEMENT |
548 |
| 5.7 SYSTEM SAFETY |
549 |
| 5.7.1 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) |
549 |
| 5.7.2 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) |
549 |
| 5.7.3 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) |
549 |
| 5.7.4 VEHICLE STATIONARY ENGINE RUNNING GEAR ENGAGED (TYPICALLY 1ST, 2ND OR R) |
549 |
| 5.7.5 VEHICLE STATIONARY, ENGINE RUNNING, GEARBOX IN A GEAR OTHER THAN NEUTRAL (N) KEY-OFF PROCEDURE |
549 |
| 5.8 SUMMARY OF BUZZER ACTIVATION REQUESTED BY THE SYSTEM |
549 |
| 5.8.1 AUTO CALIBRATIONS |
549 |
| 5.8.2 CLUTCH BLEEDING |
550 |
| 5.8.3 CLUTCH KISS POINT SELF TUNING |
551 |
| 5.8.4 GRID SELF-TUNING |
551 |
| 5.8.5 NEW ACTUATORS |
553 |
| 5.9 VERIFYING AND CHECKING PROCEDURES C510 |
554 |
| 5.9.1 OIL LEVEL CHECK |
554 |
| 5.9.2 OIL LEAK CHECK |
554 |
| 5.9.3 OIL PRESSURE CHECK |
554 |
| 5.9.4 ELECTRICAL PUMP SUPPLY CHECK |
554 |
| 5.9.5 BRAKE PEDAL SWITCH CHECK |
555 |
| 5.9.6 CLUTCH DRAG CHECK |
555 |
| 5.9.7 ELECTRO HYDRAULIC SELECTION GEARBOX ACTIVATION HYDRAULIC UNIT MOUNTING REMOVAL |
559 |
| 5.9.8 ELECTRO HYDRAULIC SELECTION GEARBOX ACTIVATION HYDRAULIC UNIT MOUNTING FITMENT |
560 |
| 5.9.9 ELECTRO HYDRAULIC CIRCUIT RESERVOIR AND SYSTEM PUMP REMOVAL |
560 |
| 5.9.10 ELECTRO HYDRAULIC CIRCUIT RESERVOIR AND SYSTEM PUMP FITMENT |
562 |
| 5.9.11 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED REMOVAL |
563 |
| 5.9.12 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED FITMENT |
563 |
| 5.9.13 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED REMOVAL VALID FOR VERSIONS WITH ROBOTISED GEARBOX |
564 |
| 5.9.14 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL WITH GEARBOX REMOVED FITMENT VALID FOR VERSIONS WITH ROBOTISED GEARBOX |
564 |
| 5.9.15 HEAT PROTECTION BULKHEAD ON GEARBOX HYDRAULIC CIRCUIT FLUID RESERVOIR WITH ELECTRO- HYDRAULIC SELECTION REMOVAL |
565 |
| 5.9.16 HEAT PROTECTION BULKHEAD ON GEARBOX HYDRAULIC CIRCUIT FLUID RESERVOIR WITH ELECTRO- HYDRAULIC SELECTION FITMENT |
565 |
| 5.9.17 PIPE FROM PUMP TO HYDRAULIC SPEED SELECTION ACTUATOR UNIT REMOVAL |
565 |
| 5.9.18 PIPE FROM PUMP TO HYDRAULIC SPEED SELECTION ACTUATOR UNIT FITMENT |
566 |
| 5.9.19 PIPE FROM HYDRAULIC SPEED SELECTION ACTUATOR UNIT TO FLUID RESERVOIR REMOVAL |
566 |
| 5.9.20 PIPE FROM HYDRAULIC SPEED SELECTION ACTUATOR UNIT TO FLUID RESERVOIR FITMENT |
566 |
| 5.9.21 HYDRAULIC UNIT/ELECTRO HYDRAULIC SELECTION GEARBOX ELECTRIC PUMP ASSEMBLY WITH GEARBOX REMOVED REMOVAL |
567 |
| 5.9.22 HYDRAULIC UNIT/ELECTRO HYDRAULIC SELECTION GEARBOX ELECTRIC PUMP ASSEMBLY WITH GEARBOX REMOVED FITMENT |
569 |
| 5.9.23 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH REMOVAL |
570 |
| 5.9.24 HYDRAULIC SPEED SELECTION HYDRAULIC ACTUATOR UNIT AND CLUTCH FITMENT |
572 |
| 5.9.25 PRESSURE ACCUMULATOR ON HYDRAULIC ACTUATOR UNIT REMOVAL |
573 |
| 5.9.26 PRESSURE ACCUMULATOR ON HYDRAULIC ACTUATOR UNIT FITMENT |
573 |
| 5.9.27 PIPE FROM CLUTCH MASTER CYLINDER TO CLUTCH RELEASE ACTUATOR REMOVAL |
574 |
| 5.9.28 PIPE FROM CLUTCH MASTER CYLINDER TO CLUTCH RELEASE ACTUATOR FITMENT |
574 |
| 5.9.29 ODD AND EVEN GEAR ENGAGEMENT SOLENOIDS REMOVAL |
575 |
| 5.9.30 ODD AND EVEN GEAR ENGAGEMENT SOLENOIDS FITMENT |
575 |
| 5.9.31 GEAR SELECTION SOLENOIDS REMOVAL |
576 |
| 5.9.32 GEAR SELECTION SOLENOIDS FITMENT |
577 |
| 5.9.33 CLUTCH CONTROL SOLENOID REMOVAL |
578 |
| 5.9.34 CLUTCH CONTROL SOLENOID FITMENT |
578 |
| 5.9.35 HYDRAULIC SELECTION GEARBOX SPEED SELECTION POSITION SENSOR REMOVAL |
579 |
| 5.9.36 HYDRAULIC SELECTION GEARBOX SPEED SELECTION POSITION SENSOR FITMENT |
579 |
| 5.9.37 HYDRAULIC SELECTION GEARBOX SHIFT POSITION SENSOR REMOVAL |
581 |
| 5.9.38 HYDRAULIC SELECTION GEARBOX SHIFT POSITION SENSOR FITMENT |
581 |
| 5.10 HYDRAULIC SELECTION GEARBOX CLUTCH POSITION SENSOR |
583 |
| 5.10.1 HYDRAULIC SELECTION GEARBOX CIRCUIT PRESSURE SENSOR REMOVAL |
583 |
| 5.10.2 HYDRAULIC SELECTION GEARBOX CIRCUIT PRESSURE SENSOR FITMENT |
583 |
| 5.10.3 HYDRAULIC SELECTION GEARBOX INPUT SHAFT SPEED SENSOR REMOVAL |
584 |
| 5.10.4 HYDRAULIC SELECTION GEARBOX INPUT SHAFT SPEED SENSOR FITMENT |
584 |
| 5.10.5 ELECTRO-HYDRAULIC SELECTION GEARBOX WIRING MOUNTING BRACKET REMOVAL |
584 |
| 5.10.6 ELECTRO-HYDRAULIC SELECTION GEARBOX WIRING MOUNTING BRACKET FITMENT |
585 |
| 5.10.7 WIRING FOR MANUAL GEARBOX HYDRAULIC SELECTION SYSTEM ON HYDRAULIC SELECTION UNIT REMOVAL |
585 |
| 5.10.8 WIRING FOR MANUAL GEARBOX HYDRAULIC SELECTION SYSTEM ON HYDRAULIC SELECTION UNIT FITMENT |
587 |
| 6. DRIVETRAIN-TA65 STAR |
588 |
| 6.1. PRECAUTIONS |
596 |
| 6.2. SPECIFICATIONS AND TIGHTENING TORQUES |
597 |
| 6.2. A. CLUTCH |
597 |
| 6.2. B. TRANSAXLE |
600 |
| 6.3. SPECIAL TOOLS |
602 |
| 6.3. A. CLUTCH |
602 |
| 6.3. B. TRANSAXLE |
602 |
| 6.4. DIAGNOSIS |
608 |
| 6.4. A. DIAGNOSIS OF CLUTCH: |
608 |
| 6.4. B. DIAGNOSIS OF TRANSAXLE |
611 |
| 6.5. MAINTENANCE, ADJUSTMENT ANDTESTS |
612 |
| 6.5. A PRELIMINARY INSPECTION OF CLUTCH |
612 |
| 6.5. B. DRIVESHAFT |
613 |
| 6.6. CLUTCH |
615 |
| A. THEORY OF DIAPHRAGM SPRING CLUTCH |
615 |
| B. CONSTRUCTIONAL DETAILS |
616 |
| C. FACTORS AFFECTING CLUTCHWEAR |
616 |
| D. CLUTCH CABLE REMOVAL ANDINSPECTION: |
617 |
| E. REMOVAL OF CLUTCH FROM THECAR: |
618 |
| F. INSTALLATION OF CLUTCH ON THECAR: |
618 |
| G. PROCEDURE FOR CLUTCH ADJUSTMENT |
619 |
| 6.7. TRANSAXLE |
620 |
| A. GENERAL DESCRIPTION |
620 |
| B. EXPLODED VIEW OF DIFFERENTIAL: |
627 |
| C. EXPLODED VIEW OF SHIFTER FORK |
629 |
| D. EXPLODED VIEW OF GEAR SHIFT LINKAGE ASSEMBLY: |
631 |
| E. REMOVAL OF TRANSAXLE FROMCAR |
634 |
| F. TRANSAXLE TA65 STAR (ON BENCH)DISASSEMBLY: |
635 |
| G. INPUT SHAFT SUB ASSEMBLY: |
640 |
| H. INPUT SHAFT ASSEMBLY: |
641 |
| I. DISASSEMBLY OF LAY SHAFT: |
641 |
| J. IDNETIFICATION OF COMPONENTS |
643 |
| K. SUB ASSEMBLIES: |
646 |
| L. LAY SHAFT ASSEMBLY: |
648 |
| M. DIFFERENTIAL ASSEMBLIES: |
650 |
| N. ASSEMBLIES OF TRANSAXLE: |
652 |
| O. ASSEMBLY OF TOP COVER: |
656 |
| P: INSTALLATION OF TRANSAXLE ONTHE CAR: |
660 |
| Q: REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE: |
661 |
| 6.8. DRIVE SHAFT |
663 |
| A. DRIVE SHAFT PARTS: |
663 |
| B. DISASSEMBLY AND ASSEMBLYPROCEDURE: |
664 |
| C. Disassembly and Assembly of CVJoint Assembly (Outer): |
667 |
| 7. SUSPENSION |
672 |
| 7.1 TECHNICAL SPECIFICATIONS AND TIGHTENING TORQUES |
680 |
| 7.1.1 SPECIFICATIONS: |
680 |
| 7.1.2 TIGHTENING TORQUES FOR SUSPENSION |
681 |
| 7.2 SPECIAL TOOLS |
682 |
| 7.3 DIAGNOSIS |
683 |
| 7.4 PRECAUTIONS |
684 |
| 7.5 SUSPENSION SYSTEM |
685 |
| 7.6 ASSEMBLY FRONT SUSPENSION |
689 |
| A) ASSEMBLY FRONT STRUT EXPLODED VIEW |
689 |
| B) ANTI ROLL BAR MOUNTING EXPLODED VIEW |
690 |
| C) LOWER LINK EXPLODED VIEW |
691 |
| D) FRONT AXLE ASSEMBLY EXPLODED VIEW |
692 |
| 7.7 FRONT SUSPENSION |
693 |
| 7.7.1 REMOVAL AND INSTALLATION OFSTRUT ASSEMBLY |
693 |
| 7.7.2 DISASSEMBLY AND ASSEMBLY OFFRONT STRUT |
694 |
| 7.7.3 REMOVAL AND INSTALLATION OFWHEEL HUB |
696 |
| 7.7.4 REMOVAL AND INSTALLATION OFSUBFRAME ASSEMBLY. |
699 |
| 7.7.4.1 REMOVAL AND INSTALLATION OFANTI ROLL BAR |
700 |
| 7.7.4.2 REMOVAL AND INSTALLATIONLOWER ARM BALL JOINT |
701 |
| 7.7.4.3 REMOVAL AND INSTALLATION OFLOWER ARM RUBBER BUSHES |
702 |
| 7.8 ASSEMBLY REAR SUSPENSION |
704 |
| A) REAR SHOCK ABSORBER AND SPRING EXPLODED VIEW |
704 |
| B) REAR HUB ASSEMBLY EXPLODED VIEW |
706 |
| C) PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW |
707 |
| 7.9 REAR SUSPENSION |
708 |
| 7.9.1 REMOVAL AND INSTALLATION OFREAR SHOCK ABSORBER AND COILSPRINGS: |
708 |
| 7.9.1.1 REMOVAL OF REAR SHOCKABSORBER AND COIL SPRINGS: |
708 |
| 7.9.1.2 DISASSEMBLY AND ASSEMBLY OFREAR SHOCK ABSORBER: |
710 |
| 7.9.1.3 INSTALLATION OF REAR SHOCKABSORBER AND COIL SPRINGS: |
711 |
| 7.9.2 REMOVAL AND INSTALLATION OFTORSION BEAM FROM CAR |
712 |
| 7.10 WHEELS AND TYRES |
717 |
| A) TYRE INSPECTION |
717 |
| B) REPLACEMENT OF TYRES: |
717 |
| C) REPLACEMENT OF WHEELS: |
717 |
| 7.10.1 HOW TO MEASURE WHEEL RUNOUT: |
717 |
| 7.10.2 INFLATION OF TYRES: |
718 |
| 7.10.3 TYRE ROTATION: |
719 |
| 7.10.4 WHEEL REMOVAL: |
719 |
| 7.10.5 TYRE MOUNTING AND DEMOUNTING: |
719 |
| 7.10.6 BALANCING WHEELS: |
720 |
| 7.10.7. TYRE CARE: |
720 |
| 8. BRAKES |
722 |
| 8.1 PRECAUTIONS |
728 |
| 8.2 TECHNICAL SPECIFICATIONS |
729 |
| 8.3 TIGHTENING TORQUES |
731 |
| 8.4 DIAGNOSIS |
732 |
| 8.5 NESSECITY OF ABS with EBD |
735 |
| 8.6. BRAKE HYDRAULIC LINES |
736 |
| 8.7 WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS): |
739 |
| 8.8 ABS COMPONENTS |
743 |
| 8.9 MAINTENANCE, ADJUSTMENTS &TEST |
748 |
| 8.10 REPAIRS |
762 |
| 8.10.1 FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT |
763 |
| 8.10.2 REMOVAL OF FRONT BRAKE DISC |
769 |
| 8.10.3 REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY |
770 |
| 8.10.4 REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY |
775 |
| 8.10.5 REMOVAL OF PARKING BRAKELEVER |
781 |
| 8.10.6 REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE |
781 |
| 8.10.7 PARKING BRAKE CABLEADJUSTMENT |
782 |
| 8.10.8 REMOVAL AND REFITMENT OF ABSECU / HCU |
783 |
| 8.10.9 REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR |
784 |
| 8.10.10 REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR |
785 |
| 8.11 DTC CODES |
787 |
| 8.12 TROUBLE SHOOTING & DIAGNOSIS |
789 |
| 9. STEERING |
793 |
| 9.1 GENERAL INFORMATION |
799 |
| 9.1.1 SPECIFICATIONS |
799 |
| 9.1.2 SYSTEM LAYOUT |
799 |
| 9.1.3 GENERAL DESCRIPTION |
800 |
| 9.1.4 TIGHTENING TORQUES |
801 |
| 9.1.5 SPECIAL TOOLS |
803 |
| 9.2. MAINTENANCE, INSPECTION ANDTEST |
804 |
| 9.2.1 PRELIMINARY INSPECTION |
804 |
| 9.2.2 REGULAR MAINTENANCE |
805 |
| 9.2.3 ON VEHICLE REPAIRS |
806 |
| 9.2.3.1 STEERING WHEEL REMOVAL |
806 |
| 9.2.3.2 STEERING COLUMN REMOVAL |
807 |
| 9.2.3.3 INTERMEADIATE SHAFT REMOVAL |
808 |
| 9.2.3.4 ECU REMOVAL |
809 |
| 9.2.3.5 RACK & PINION ASSEMBLYREMOVAL |
810 |
| 9.3. OVERHAULING |
812 |
| 9.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
812 |
| 9.3.2 PRECAUTIONS |
813 |
| 9.3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
813 |
| 9.3.3.1 DISASSEMBLY OF RACK & PINON |
813 |
| 9.3.3.2 INSPECTION OF DISMANTLED PARTS |
814 |
| 9.3.3.3 ASSEMBLY OF RACK & PINON |
814 |
| 9.3.3.4 OBJ ON-VEHICLE REMOVAL |
815 |
| 9.3.3.5 DO’S & DON’TS |
815 |
| 9.3.3.6 WHEEL ALIGNMENT |
816 |
| 9.4. TROUBLESHOOTING AND DIAGNOSIS |
818 |
| A. GENERAL TROUBLESHOOTING |
818 |
| B. ELECTRICAL TROUBLESHOOTING |
820 |
| C. MECHANICAL TROUBLESHOOTING |
821 |
| 9.5 STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS |
822 |
| 9.6 STEERING SYSTEM DTC CODES. |
825 |
| 9.7 (EPAS) ECU replacement and software updateprocedure in field |
827 |
| 10. BODY |
834 |
| 10.1 PRECAUTIONS |
842 |
| 10.2 TIGHTENING TORQUES: |
843 |
| 10.3 SPECIAL TOOL |
843 |
| 10.4. INTERIORS |
844 |
| 10.4.1 REMOVAL OF “A” PILLAR TRIM: |
844 |
| 10.4.2 REMOVAL OF “A” PILLAR LOWER TRIM: |
845 |
| 10.4.3 REMOVAL OF “B” PILLAR TRIMS: |
845 |
| 10.4.4 REMOVAL OF 'C' PILLAR TRIM: |
846 |
| 10.4.5 REMOVAL OF CENTRAL FLOORCONSOLE: |
847 |
| 10.4.6 REMOVAL OF GRAB HANDLE: |
848 |
| 10.4.7 REMOVAL OF SUNVISOR: |
848 |
| 10.4.8 REMOVAL OF REAR SCUFF PLATE: |
849 |
| 10.4.9 REMOVAL OF FRONT SEAT BELT: |
850 |
| 10.4.10 REMOVAL OF REAR SEAT BELT: |
851 |
| 10.4.11 REMOVAL OF REAR QUARTER TRIM: |
852 |
| 10.4.12 REMOVAL AND REFITMENT OF ROOFTRIM REMOVAL: |
852 |
| 10.5 SEATS |
853 |
| 10.5.1 REMOVAL OF FRONT SEAT: |
853 |
| 10.5.2 REMOVAL OF REAR SEAT: |
854 |
| 10.6 SECURITY AND LOCKS |
855 |
| 10.6.1 REMOVAL OF BONNET LOCK |
855 |
| 10.6.2 REMOVAL AND REFITMENT |
856 |
| 10.6.3 TAILGATE LATCH CABLE |
857 |
| 10.6.4 FUEL LID CABLE REMOVAL: |
857 |
| 10.7 GLASS / WINDOW / MIRROR |
859 |
| 10.7.1 FIXING OF WIND SCREEN GLASS &REAR QUARTER FIXED GLASS |
859 |
| 10.8 EXTERIOR TRIM |
860 |
| 10.8.1 REMOVAL OF TAILGATE TRIM: |
860 |
| 10.8.2 REMOVAL OF TAILGATE STRIKER: |
860 |
| 10.8.3 REMOVAL OF TAILGATE BALANCER: |
861 |
| 10.8.4 REMOVAL OF TAILGATE LATCH: |
861 |
| 10.8.5 REMOVAL OF SPOILER: |
862 |
| 10.8.6 REMOVAL OF REAR WIPER MOTOR: |
862 |
| 10.8.7 REMOVEL AND REFITMANT OF FRONTWIPER |
863 |
| 10.9 BUMPER AND FASCIA ASSEMBLY |
865 |
| 10.9.1 R+R of front bumper |
865 |
| 10.9.2 REMOVAL AND REFITMENT OF ENDMODULE: |
866 |
| 10.9.3 REMOVAL AND REFITMENT OF REARBUMPER |
867 |
| 10.9.4 REMOVAL OF COCKPIT SIDE COVER: |
868 |
| 10.9.5 SPEAKAR GRILL SERVICING |
869 |
| 10.10.6 TWEETER SERVICING |
869 |
| 10.9.7 SIDE AIR VENT SERVICING |
870 |
| 10.9.8 RADIO BLANK COVER SERVICING |
870 |
| 10.9.9 FASCIA INSTRUMENT CLUSTER |
871 |
| 10.9.10 SERVICING FASCIA CLUSTER: |
872 |
| 10.9.11 GLOVE BOX SERVICING |
873 |
| 10.9.12 STEERING COLUM COVER SERVICING |
873 |
| 10.9.13 CLIMATE CONTROL MODULE FIXINGS |
874 |
| 10.9.14 REMOVAL OF DASH BOARD |
875 |
| 10.9.15 WIRE HARNESS SERVICING |
877 |
| 10.10. HOOD / FENDER / DOORS |
881 |
| 10.10.1 R+R OF BONNET HOOD |
881 |
| 10.10.2 R+R of fender |
882 |
| 10.10.3 Removal and Refitment of Front Door |
883 |
| 10.10.4 Removal and Refitment of Rear Door |
889 |
| 10.11 PAINT AND COATINGS |
894 |
| 10.12 EXCLUSIVE DATA OF ZEST |
899 |
| 10.12.1. Front Bumper |
903 |
| 10.12.2. Rear Bumper |
906 |
| 10.12.3. ORVM |
908 |
| 10.12.4. Tailgate Garnish Trim |
910 |
| 10.12.5. Trunk Striker |
911 |
| 10.12.6. Trunk Lid Latch |
911 |
| 10.12.7. Microphone |
912 |
| 10.12.8. Headliner |
913 |
| 10.12.9. Parcel Shelf |
914 |
| 10.12.10. Rear Quarter Trim (RQT) |
915 |
| 10.12.11. Trunk Lid Sill Cover |
916 |
| 10.12.12. Wheel Arch Trim |
917 |
| 10.12.13. Wheel Arch Carpet |
918 |
| 10.12.14. Assembly Luggage Compartment Carpet |
920 |
| 10.12.15. Trunk Lid |
920 |
| 10.12.16. Tail Lamp |
921 |
| 10.12.17. Tail Lamp Bulb Re-fitment |
921 |
| 11. SRS |
923 |
| 11.1 COMPONENTS OF SRS |
929 |
| 11.2 COMPONENTS |
930 |
| 11.2.1 DRIVER AIRBAG (DAB) |
930 |
| 11.2.2 PASSENGER AIRBAG (PAB) MODULE |
930 |
| 11.2.3 FRONT SEAT MOUNTED SIDE AIRBAGS |
931 |
| 11.2.4 SRS ECU |
932 |
| 11.2.5 SRS WARNING LAMP |
933 |
| 11.2.6 SEAT BELT PRETENSIONERS WITHLOADLIMITERS |
933 |
| 11.2.7 FRONT REMOTE SENSING UNIT (RSU)OR FRONT IMPACT SENSOR |
935 |
| 11.2.8 SIDE REMOTE SENSING UNIT (RSU) ORSIDE IMPACT SENSOR (IF FITTED) |
936 |
| 11.2.9 PASSENGER AIRBAG (PAB)ACTIVATION AND DEACTIVATION SWITCH( IFFITTED) |
937 |
| 11.3 SRS OPERATION |
938 |
| 11.4 TIGHTENING TORQUES |
938 |
| 11.5 SAFETY PRECAUTIONS |
938 |
| 11.6 REPAIRS |
940 |
| 11.6.1 DRIVER AIRBAG (DAB) MODULE |
940 |
| 11.6.2 Clock spring |
942 |
| 11.6.3 PASSENGER AIRBAG (PAB) MODULE |
944 |
| 11.6.4 SRS ECU |
944 |
| 11.6.5 FRONT (RH) REMOTE SENSING UNIT(RSU) |
945 |
| 11.6.6 FRONT (LH) REMOTE SENSING UNIT(RSU) |
945 |
| 11.6.7 RETRACTOR PRETENSIONER ANDLOAD LIMITER CONFIGURATION BELTS(RPLL) |
946 |
| 11.6.8 SIDE RSU OR SIDE IMPACT SENSOR |
947 |
| 11.6.9 FRONT SEAT MOUNTED SIDE AIRBAG(IF FITTED) |
948 |
| 11.7 SRS ECU PIN OUTS: |
950 |
| 11.8 SRS ECU DTC CODES |
952 |
| 11.9. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT |
954 |
| 12. AIR CONDITIONING |
956 |
| 12.1 PRECAUTIONS |
964 |
| 12.2 TECHNICAL SPECIFICATIONS: |
965 |
| 12.2.1 TIGHTENING TORQUES: |
966 |
| 12.3 DIAGNOSIS |
967 |
| 12.4 MAINTENANCE, INSPECTION ANDTEST |
972 |
| 12.4.1 AC PERFORMANCE TEST |
972 |
| 12.5. SERVICING PROCEDURE FOR BEHR |
972 |
| 12.5.1 BOWDEN CABLE SERVICING (BEHR) |
972 |
| 12.5.2 REMOVAL AND REFITMENT OFCABLES FROM HVAC |
973 |
| 12.5.3 REMOVAL OF WIRING HARNESSCONNECTORS FROM CONTROL PANEL |
973 |
| 12.5.4 SERVICING OF BLOWER ASSEMBLY |
974 |
| 12.5.5 SERVICING OF HEATER ASSEMBLY |
974 |
| 12.5.6 SERVICING FILTER |
975 |
| 12.5.7 SERVICING OF KINEMATIC |
976 |
| 12.5.8 RESISTER SERVICING |
977 |
| 12.5.9 SERVICING OF THERMOSENSER/ |
977 |
| 12.5.10 SERVICING OF CONDENSER |
978 |
| 12.6 SERVICING PROCEDURE FORSUBROS IF FITTED |
980 |
| 12.6.1 REMOVAL AND REFITMENT OFCABLES FROM HVAC |
980 |
| 12.6.2 REMOVAL OF WIRING HARNESSCONNECTORS FROM CONTROL PANEL |
981 |
| 12.6.3 SERVICING OF BLOWER ASSEMBLY |
981 |
| 12.6.4. SERVICING OF HEATER ASSEMBLY |
982 |
| 12.6.5 SERVICING FILTER |
982 |
| 12.6.6 SERVICING OF KINEMATIC FOR AIRMODE |
983 |
| 12.6.7 RESISTER SERVICING |
984 |
| 12.6.8 SERVICING OF THERMOSENSER |
984 |
| 12.6.9 SERVICING OF CONDENSER |
985 |
| 12.7 SCHEMATIC DIAGRAM OF AC CYCLE. |
987 |
| 12.8 LAYOUT OF HVAC SYSTEM |
988 |
| 12.9 MAIN PARTS OF A.C. SYSTEM |
989 |
| 12.10 HVAC CONTROLS (Air Flow Pattern) |
991 |
| 12.11 EXPLODED VIEWS |
993 |
| 12.11 1 EXPLODED VIEWS OF HVAC (BEHR) |
993 |
| 12.11.2 EXPLODED VIEW OF HVAC (SUBROS) |
994 |
| 12.12 DISCHARGING THE SYSTEM |
995 |
| 12.13 SYSTEM CHARGING & EVACUATION |
996 |
| 12.14 FLUSHING THE A/C SYSTEM FORCONTAMINATION OF LUBRICATING OIL |
999 |
| 12.15 DO’s AND DON’T’s |
1001 |
| 12.16 SAFETY TIPS FOR AC SYSTEM |
1002 |
| 12.17 FUNCTION AND INSPECTION OF A.C.COMPONENTS: |
1003 |
| 12.18 FULLY AUTOMATIC TEMPERATURECONTROL (FATC) |
1004 |
| 12.18.1 SERVICING OF ACTUATOR FORDISTRIBUTION KINEMATICS |
1004 |
| 12.18.2 SERVICING OF ACTUATOR FORTEMPERATURE KINAMATICS |
1004 |
| 12.18.3 SERVICING OF THERMOSENSER/ |
1004 |
| 12.18.4 LAYOUT OF FATC SYSTEM |
1005 |
| 12.18.5 FATC CONTROLS (Air Flow Pattern) |
1006 |
| 12.18.6 FATC control Panel |
1007 |
| 12.18.7 EXPLODED VIEW OF FATC (BEHR) |
1011 |
| 12.18.8 Connector details: |
1013 |
| 12.18.9 FATC SENSORS AND ACTUATORS |
1015 |
| A SOLAR LOAD SENSOR: |
1015 |
| B OAT (Outside Ambient Temperature) |
1018 |
| C Evaporator Sensor |
1020 |
| D Mode Actuator |
1021 |
| E Temperature Actuator |
1021 |
| F Fresh / Recirculation: |
1022 |
| 12.18.10 Diagnosis Trouble Codes |
1023 |
| 13. ELECTRICAL (PART-1) |
1026 |
| 13.1 TECHNICAL SPECIFICATION |
1036 |
| 13.2 GENERAL PRECAUTIONS |
1038 |
| 13.3 GENERAL ELECTRICAL INFORMATION |
1041 |
| 13.3.1 HOW TO USE ELECTRICAL WIRING DIAGRAM |
1041 |
| 13.3.2 COLOUR CODING |
1044 |
| 13.3.3 SYMBOLS |
1045 |
| 13.4 FUSE BOX / RELAY LOCATIONS |
1053 |
| 13.5 BATTERY |
1054 |
| 13.6 ALTERNATOR |
1056 |
| 13.7 STARTER MOTOR |
1058 |
| 13.8 LIGHTING SYSTEM |
1063 |
| 13.8.1 BULB SPECIFICATIONS |
1063 |
| 13.8.2 FASTENERS TORQUE VALUE TABLE |
1063 |
| 13.8.3 GENERAL SYMPTOMS AND DIAGNOSTICS |
1064 |
| 13.8.4 HEAD LAMP |
1068 |
| 13.8.5 SIDE REPEATER LAMP |
1073 |
| 13.8.6 ROOF LAMP |
1074 |
| 13.8.7 HIGH MOUNTED STOP LAMP |
1075 |
| 13.8.8 TAIL LAMP |
1076 |
| 13.8.9 FRONT FOG LAMP |
1077 |
| 13.8.10 REAR FOG LAMP |
1078 |
| 13.9 HORN |
1079 |
| 13.10 WIPER & WASHER SYSTEM |
1082 |
| 13.10.1 FRONT AND REAR WIPER AND WAHSER SYSTEM LAYOUT |
1083 |
| 13.10.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
1084 |
| 13.10.3 WIPER AND WIPER CARE |
1088 |
| 13.11 ELECTRIC BUZZER (IF FITTED) |
1090 |
| 13.12 POWER SOCKETS |
1091 |
| 13.13 GLOW PLUG CONTROL UNIT |
1092 |
| 13.14 FUEL GAUGE AND FUEL LEVEL METER |
1094 |
| 13.15 COMBI-SWITCH |
1095 |
| 13.16 STEERING LOCK CUM IGNITIONSWITCH |
1099 |
| 13.17 FASCIA SWITCHES |
1101 |
| 13.18 INFOTAINMENT SYSTEM: (Iffitted) |
1105 |
| 13.19 SEAT BELT REMINDERSYSTEM |
1109 |
| 13.20 WINDOW WINDING MODULE: |
1111 |
| 13.21 POWER WINDOW SWITCHES |
1114 |
| 13.22. STEERING WHEEL SWITCHES |
1118 |
| 13.23 IGNITION E-KEY |
1119 |
| 13.24 INSTRUMENT CLUSTER |
1122 |
| 13.24.1 BASIC FUNCTIONAL MATRIX: |
1124 |
| 13.24.2 TELL TALES MATRIX: |
1125 |
| 13.24.3 DRIVER INFORMATION SYSTEM |
1130 |
| 13.24.4 CONNECTOR DETAILS: |
1135 |
| 13.24.5 FUEL GAUGE DETAILS: |
1137 |
| 13.24.6 TEMPERATURE BAR GRAPH DETAILS: |
1138 |
| 13.24.7 CHIMS TABLE: |
1139 |
| 13.24.8 DISPLY SCREEN FLOW AND SETTINGS |
1139 |
| 13.24.9 ENGINEERING TEST MODE (ETM) |
1142 |
| 13.25 IMMOBILIZER SYSTEM: |
1144 |
| 13.25.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB: |
1149 |
| 13.25.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU: |
1150 |
| 13.25.3 DIAGNOSTIC TROUBLE CODES FOR IMMOBILIZER |
1152 |
| 13.25.4 IGNITION KEY LEARNING PROCEDURE: |
1154 |
| 13.26 BODY CONTROL MODULE |
1157 |
| 13.26.1 BCM CONNECTOR PIN SIGNALS APLICABILITY MATRIX: |
1159 |
| 13.26.2 BCM FUNCTIONS: |
1168 |
| 13.27 CLUTCH PEDAL SENSOR |
1212 |
| 13.28 REVERSE PARK ASSIST SYSTEM |
1216 |
| 13.28.1. Park Assist: |
1220 |
| 13.28.2. Park Assist functionality overview: |
1220 |
| 13.28.3. Park Assist Activation Procedure: |
1220 |
| 13.28.4. Park Assist Deactivation Procedure: |
1221 |
| 13.28.5. Park Assist Audio Settings: |
1221 |
| 13.28.6. Park Assist Volume: |
1222 |
| 13.28.7. Mix With Audio: |
1222 |
| 13.28.8. Park Assist Tone: |
1222 |
| 13.28.9. Park Assist Delay Timer: |
1222 |
| 13.28.10. Park Assist Button LED Indications: |
1223 |
| 13.28.11. Park Assist HMI Indications: |
1223 |
| 13.28.12. Park Assist Limitations: |
1224 |
| 13.28.13. Park Assist System maintenance: |
1225 |
| 13.28.14. Park Assist System Architecture: |
1225 |
| 13.28.15. ECU to Sensor Electrical Interface: |
1226 |
| 13.28.16. ECU to Park Assist Switch Electrical Interface: |
1226 |
| 13.28.17. ECU Mounting: |
1226 |
| 13.28.18. Physical Images |
1227 |
| 13.28.19. Sensor Fitment to the bumper: |
1228 |
| 13.28.20. List of Diagnosis Troubleshooting Codes for Reverse Park Assist System (RPAS): |
1230 |