| NANO |
1 |
| NANO MY13 |
1 |
| 1. GENERAL |
7 |
| 1.1 AN OVERVIEW - NANO |
15 |
| 1.2 ABBREVIATIONS |
16 |
| 1.3 LIFTING, JACKING, TOWING POINTS |
19 |
| 1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
22 |
| 1.5 AGGREGATE NUMBERING SYSTEM |
23 |
| 1.6 TECHNICAL SPECIFICATIONS |
26 |
| 1.7 VEHICLE DIMENSIONS |
28 |
| 1.8 FUEL, LUBRICANTS & COOLANTS |
29 |
| 1.9 SERVICE SCHEDULE |
32 |
| 2. PRECAUTIONS |
35 |
| 2.1 GENERAL SAFETY PRECAUTIONS |
41 |
| 2.2 GENERAL SERVICE PRECAUTIONS |
45 |
| 3. ENGINE |
47 |
| 3.1 GENERAL INFORMATION |
55 |
| 3.1.1 TECHNICAL SPECIFICATIONS |
57 |
| 3.1.2 FEATURES OF 273 MPFI ENGINE |
58 |
| 3.1.3 TIGHTENING TORQUE |
59 |
| 3.1.4 SPECIAL TOOLS & EQUIPMENTS |
61 |
| 3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
| 3.2 ON VEHICLE PROCEDURES |
69 |
| 3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
| 3.2.2 ENGINE OIL REPLACEMENT |
73 |
| 3.2.3 OIL FILTER REPLACEMENT |
74 |
| 3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
| 3.2.5 FUEL FILTER REPLACEMENT |
76 |
| 3.2.6 TAPPET SETTING |
77 |
| 3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
| 3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
| 3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
| 3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
| 3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
| 3.3 ENGINE MECHANICAL |
91 |
| PRELIMINARY INSPECTION OF ENGINE |
93 |
| REMOVAL OF ENGINE FROM VEHICLE |
95 |
| 3.3.1 CYLINDER HEAD |
99 |
| 3.3.1.1 GENERAL DESCRIPTION |
101 |
| 3.3.1.2 EXPLODED VIEW |
102 |
| 3.3.1.3 CYLINDER HEAD OVERHAUL |
104 |
| 3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
| 3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
| 3.3.1.6 INSPECTION & REPAIR DATA |
111 |
| 3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
| 3.3.2 ENGINE BLOCK |
123 |
| 3.3.2.1 GENERAL DESCRIPTION |
125 |
| 3.3.2.2 EXPLODED VIEW |
126 |
| 3.3.2.3 ENGINE BLOCK OVERHAUL |
128 |
| 3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
| 3.3.2.5 INSPECTION & REPAIR DATA |
133 |
| 3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
| 3.3.2.7 REFITMENT OF ENGINE ACCESSORIES |
156 |
| 3.3.2.8 ENGINE TESTING |
158 |
| 3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE |
158 |
| 3.4 ACCELERATOR |
159 |
| 3.4.1 EXPLODED VIEWS & CABLE ROUTING |
161 |
| 3.4.2 SYSTEM MAINTENANCE |
163 |
| 3.5 COOLING SYSTEM |
167 |
| 3.5.1 GENERAL DESCRIPTION |
169 |
| 3.5.2 SYSTEM SCHEMATICS |
169 |
| 3.5.3 EXPLODED VIEWS |
170 |
| 3.5.4 SPECIFICATIONS |
172 |
| 3.5.5 SYSTEM COMPONENTS |
173 |
| 3.5.6 SYSTEM MAINTENANCE |
174 |
| 3.6 LUBRICATION SYSTEM |
183 |
| 3.6.1 GENERAL DESCRIPTION |
185 |
| 3.6.2 SYSTEM SCHEMATICS |
185 |
| 3.6.3 SPECIFICATIONS |
186 |
| 3.6.4 SYSTEM MAINTENANCE |
187 |
| 3.7 FUEL SYSTEM |
199 |
| 3.7.1 GENERAL DESCRIPTION |
201 |
| 3.7.2 SYSTEM SCHEMATICS |
201 |
| 3.7.3 EXPLODED VIEWS |
202 |
| 3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
| 3.7.5 SYSTEM COMPONENTS |
204 |
| 3.7.6 SYSTEM MAINTENANCE |
208 |
| 3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
| 3.8 INTAKE SYSTEM |
221 |
| 3.8.1 GENERAL DESCRIPTION |
223 |
| 3.8.2 EXPLODED VIEWS |
224 |
| 3.8.3 SYSTEM MAINTENANCE |
225 |
| 3.9 EXHAUST SYSTEM |
231 |
| 3.9.1 GENERAL DESCRIPTION |
233 |
| 3.9.2 EXPLODED VIEWS |
234 |
| 3.9.3 TIGHTENING TORQUE |
235 |
| 3.9.4 SYSTEM COMPONENTS |
236 |
| 3.9.5 SYSTEM MAINTENANCE |
238 |
| 3.10 IGNITION SYSTEM |
243 |
| 3.10.1 GENERAL DESCRIPTION |
245 |
| 3.10.2 SYSTEM SCHEMATICS |
245 |
| 3.10.3 SYSTEM MAINTENANCE |
246 |
| 3.11 ENGINE MANAGEMENT SYSTEM |
251 |
| ABBREVIATIONS |
251 |
| AN OVERVIEW |
254 |
| 3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
| 3.11.1.1 ECU BLOCK DIAGRAM |
256 |
| 3.11.1.2 ECU PIN ASSIGNMENT DETAILS |
257 |
| 3.11.1.3 ECU HANDLING AND CARE |
258 |
| 3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
| 3.11.2 SENSORS |
260 |
| 3.11.2.1 CRANK SHAFT POSITION SENSOR |
260 |
| 3.11.2.2 COOLANT TEMPERATURE SENSOR |
261 |
| 3.11.2.3 T-MAP SENSOR |
263 |
| 3.11.2.4 KNOCK SENSOR |
264 |
| 3.11.2.5 THROTTLE POSITION SENSOR |
265 |
| 3.11.2.6 LAMBDA (OXYGEN) SENSOR |
268 |
| 3.11.2.7 VEHICLE SPEED SENSOR |
269 |
| 3.11.3 ACTUATORS |
271 |
| 3.11.3.1 CANISTER PURGE VALVE |
271 |
| 3.11.3.2 FUEL INJECTOR |
272 |
| 3.11.3.3 IGNITION COIL |
274 |
| 3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) |
277 |
| 3.11.3.5 COMPONENT FITMENT DATA |
279 |
| 3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
| 3.11.4.1 DTC LIST |
283 |
| 3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER |
293 |
| 3.11.4.3 BLINK CODE |
308 |
| 3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
| 3.11.5.1 REPAIRING STEPS |
310 |
| 3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
| 3.11.5.3 SENSOR AND ACTUATOR TESTING |
312 |
| 3.11.5.4 EMERGENCY SERVICE TIPS |
314 |
| 4. DRIVETRAIN |
315 |
| 4.1 CLUTCH |
321 |
| 4.1.1 GENERAL INFORMATION |
323 |
| 4.1.1.1 TECHNICAL SPECIFICATIONS |
323 |
| 4.1.1.2 CONSTRUCTION |
326 |
| 4.1.1.3 PRECAUTIONS |
328 |
| 4.1.1.4 TIGHTENING TORQUES |
329 |
| 4.1.1.5 SPECIAL TOOLS |
330 |
| 4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
| 4.1.1.7 TROUBLE SHOOTING |
334 |
| 4.1.1.8 MAINTENANCE AND REPAIR |
335 |
| A. PRELIMINARY INSPECTION |
335 |
| B. CLUTCH SLIPPAGE TEST |
335 |
| C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
| D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
| E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
| 4.1.2 OVERHAUL |
337 |
| EXPLODED VIEWS |
337 |
| A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
| B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
| C. CLUTCH CABLE REPLACEMENT |
344 |
| 4.2 TRANSAXLE TA-59 |
347 |
| 4.2.1 GENERAL INFORMATION |
349 |
| 4.2.1.1 TECHNICAL SPECIFICATION |
349 |
| 4.2.1.2 CONSTRUCTION |
349 |
| 4.2.1.3 PRECAUTIONS |
350 |
| 4.2.1.4 TIGHTENING TORQUES |
351 |
| 4.2.1.5 SPECIAL TOOLS |
354 |
| 4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
358 |
| 4.2.1.7 TRANSAXLE OIL REPLACEMENT |
359 |
| 4.2.2 OVERHAUL |
360 |
| 4.2.2.1 EXPLODED VIEWS |
360 |
| 4.2.2.2 COMPONENT IDENTIFICATION |
367 |
| 4.2.2.3 PRECAUTIONS |
369 |
| 4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE |
369 |
| 4.2.2.5 TRANSAXLE DISMANTLING |
372 |
| 4.2.2.6 INPUT SHAFT ASSEMBLY |
376 |
| 4.2.2.7 LAY SHAFT ASSEMBLY |
381 |
| 4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK |
387 |
| 4.2.2.9 DIFFERENTIAL ASSEMBLY |
390 |
| 4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY |
394 |
| 4.2.2.11 REAR HALF HOUSING ASSEMBLY |
400 |
| 4.2.2.12 FRONT HALF HOUSING |
402 |
| 4.2.2.13 TRANSAXLE ASSEMBLY |
404 |
| A. SHIM SELECTION |
404 |
| B. ASSEMBLING THE TRANSAXLE |
405 |
| 4.2.2.14 GEAR SHIFTER LINKAGE |
409 |
| A. GEAR SHIFTER CABLE REPLACEMENT |
409 |
| B. GEAR SHIFTER ADJUSTMENT |
410 |
| 4.3 DRIVESHAFT |
411 |
| 4.3.1 GENERAL INFORMATION |
413 |
| 4.3.1.1 TIGHTENING TORQUE |
413 |
| 4.3.1.2 SPECIAL TOOL |
414 |
| 4.3.1.3 CONSTRUCTIONAL DETAILS |
415 |
| 4.3.1.4 EXPLODED VIEW - DRIVESHAFT |
415 |
| 4.3.1.5 COMPONENT DESCRIPTION |
416 |
| 4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS |
417 |
| 4.3.2 ON VEHICLE REPAIRS |
418 |
| 4.3.2.1 PRECAUTIONS |
418 |
| 4.3.2.2 REMOVAL FROM VEHICLE |
420 |
| 4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
| 5. SUSPENSION SYSTEM |
429 |
| 5.1 GENERAL INFORMATION |
435 |
| 5.1.1 TECHNICAL SPECIFICATIONS |
435 |
| 5.1.2 TIGHTENING TORQUES |
436 |
| 5.1.3 SPECIAL TOOLS |
439 |
| 5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
| 5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
| 5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
| 5.1.7 TROUBLESHOOTING AND DIAGNOSIS |
446 |
| 5.2 ON VEHICLE REPAIRS |
449 |
| 5.2.1 FRONT SUSPENSION COMPONENTS |
449 |
| 5.2.1.1 STRUT |
449 |
| 5.2.1.2 ANTI-ROLL BAR |
455 |
| 5.2.1.3 LOWER ARM |
456 |
| 5.2.1.4 WHEEL BEARING |
458 |
| 5.2.2 REAR SUSPENSION COMPONENTS |
461 |
| 5.2.2.1 SHOCK ABSORBER |
462 |
| 5.2.2.2 COIL SPRING |
463 |
| 5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT |
464 |
| 5.2.2.4 SEMI TRAILING ARM |
465 |
| 5.2.3 WHEEL HUB AND WHEEL BEARING |
468 |
| 5.3 WHEELS AND TYRES |
473 |
| 5.3.1 GENERAL INFORMATION |
473 |
| 5.3.1.1 TECHNICAL SPECIFICATIONS |
473 |
| 5.3.1.2 TIGHTENING TORQUE |
474 |
| 5.3.1.3 EXPLODED VIEW |
475 |
| 5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
| 5.3.2 ON VEHICLE REPAIRS |
477 |
| 5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
| 5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
| 5.3.2.3 WHEEL BALANCING |
480 |
| 5.3.2.4 WHEEL RUNOUT |
481 |
| 5.3.2.5 TYRE REPLACEMENT |
482 |
| 5.3.2.6 WHEEL ASSEMBLY REPLACEMENT |
483 |
| 5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE |
483 |
| 5.3.2.8 TYRE DIAGNOSIS |
484 |
| 6. BRAKE SYSTEM |
493 |
| 6.1 GENERAL INFORMATION |
499 |
| 6.1.1 TECHNICAL SPECIFICATIONS |
499 |
| 6.1.2 TIGHTENING TORQUES |
500 |
| 6.1.3 SPECIAL TOOLS |
504 |
| 6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
| 6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
| 6.2.1 FRONT DRUM BRAKES |
507 |
| 6.2.2 REAR DRUM BRAKES |
508 |
| 6.2.3 AUTO INCREMENTAL BRAKE |
509 |
| 6.2.4 TANDEM MASTER CYLINDER (TMC) |
510 |
| 6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
| 6.2.6 WHEEL CYLINDER |
514 |
| 6.2.7 PARKING BRAKES |
515 |
| 6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
| 6.3.1 BLEEDING OF HYDRAULIC SYSTEM |
521 |
| 6.3.2 TROUBLESHOOTING AND DIAGNOSIS |
523 |
| 6.4 ON VEHICLE REPAIRS |
530 |
| 6.4.1 FRONT BRAKE COMPONENTS |
531 |
| 6.4.2 FRONT BRAKE DRUM |
532 |
| 6.4.3 FRONT BRAKE SHOES |
534 |
| 6.4.4 FRONT BRAKE BACK PLATE |
539 |
| 6.4.5 REAR BRAKE COMPONENTS |
540 |
| 6.4.6 REAR BRAKE DRUM |
541 |
| 6.4.7 REAR BRAKE SHOES |
542 |
| 6.4.8 REAR BRAKE BACK PLATE |
544 |
| 6.4.9 TMC |
546 |
| 6.4.10 WHEEL CYLINDER |
555 |
| 6.4.11 PARKING BRAKES |
561 |
| 6.4.12 VACUUM BRAKE BOOSTER |
564 |
| 6.4.13 BRAKE HOSES/PIPES SCHEMATIC |
565 |
| 6.4.14 VACUUM LINES |
567 |
| 7. STEERING |
569 |
| 7.1 GENERAL INFORMATION |
575 |
| 7.1.1 TECHNICAL SPECIFICATIONS |
575 |
| 7.1.2 TIGHTENING TORQUES |
576 |
| 7.1.3 SPECIAL TOOLS |
578 |
| 7.1.4 EXPLODED VIEWS |
579 |
| 7.1.5 SCHEMATIC OF STEERING SYSTEM |
581 |
| 7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
| 7.3 ON VEHICLE REPAIRS |
584 |
| 7.3.1 STEERING WHEEL |
586 |
| 7.3.2 STEERING COLUMN ASSEMBLY |
587 |
| 7.3.3 STEERING UPPER COLUMN |
589 |
| 7.3.4 INTERMEDIATE SHAFT |
589 |
| 7.3.5 STEERING RACK AND PINION ASSEMBLY |
590 |
| 7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
| 7.3.7 WHEEL ALIGNMENT |
601 |
| 7.3.8 TROUBLESHOOTING AND DIAGNOSIS |
603 |
| 8. ELECTRICAL |
607 |
| 8.1 TECHNICAL SPECIFICATION |
613 |
| 8.2 GENERAL PRECAUTIONS |
614 |
| 8.3 BATTERY |
617 |
| 8.4 ALTERNATOR |
620 |
| 8.5 STARTER MOTOR |
641 |
| 8.6 LIGHTING SYSTEM |
659 |
| 8.7 HORN |
675 |
| 8.8 WIPER SYSTEM |
677 |
| 8.9 FLASHER |
686 |
| 8.10 FOG LAMP CONTROLLER |
687 |
| 8.11 BRAKE LAMP CHECK |
689 |
| 8.12 POWER SOCKET |
689 |
| 8.13 CIGARETTE LIGHTER (IF EQUIPPED) |
690 |
| 8.14 CENTRAL DOOR LOCKING |
691 |
| 8.15 POWER WINDOW SYSTEM |
694 |
| 8.16 INSTRUMENT CLUSTER |
697 |
| 8.17 ELECTRICAL SWITCHES |
700 |
| 8.18 ACCESSORY CONNECTORS |
710 |
| 8.19 FUSE BOX/RELAY LOCATION & DETAILS |
715 |
| 8.20 ELECTRIC WIRING AND FITMENT SCHEMATICS |
716 |
| 8.20.1 HARNESS & CONNECTOR DESCRIPTION |
716 |
| 8.20.2 UNDERSTANDING THE CIRCUIT SCHEMATIC |
718 |
| 8.20.3 CONNECTOR CODE/PIN NO./CONNECTOR LAYOUT |
719 |
| 8.20.4 ELECTRICAL SYMBOLS |
720 |
| 9. BODY |
721 |
| 9.1 GENERAL INFORMATION |
727 |
| 9.1.1 TECHNICAL SPECIFICATIONS |
727 |
| 9.1.2 TIGHTENING TORQUE |
728 |
| 9.2 ON VEHICLE REPAIRS |
732 |
| 9.2.1 EXPLODED VIEW - BUMPERS & HOOD |
732 |
| 9.2.2 FRONT BUMPER |
733 |
| 9.2.3 FENDER (SIDE BONNET) |
734 |
| 9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
735 |
| 9.2.5 FRONT DOOR |
739 |
| 9.2.6 REAR DOOR |
750 |
| 9.2.7 REAR SHELF |
759 |
| 9.2.8 TAILGATE |
759 |
| 9.2.9 REAR BUMPER |
760 |
| 9.2.10 DASHBOARD |
762 |
| 9.2.11 CENTER CONSOLE |
765 |
| 9.2.12 SEATS & BELTS |
766 |
| 9.2.13 OUTER REAR VIEW MIRROR (ORVM) |
776 |
| 9.2.14 SUN VISOR |
776 |
| 9.2.15 TRIMS |
777 |
| 9.2.16 FLOOR CARPET |
778 |
| 9.2.17 WINDSHIELD |
781 |
| 9.3 PAINT CARE |
783 |
| 9.4 BODY REPAIR DATA |
786 |
| 9.5 TROUBLESHOOTING AND DIAGNOSIS |
791 |
| 10. HVAC |
793 |
| 10.1 GENERAL INFORMATION |
799 |
| 10.1.1 TECHNICAL SPECIFICATIONS |
799 |
| 10.1.2 TIGHTENING TORQUES |
800 |
| 10.1.3 GENERAL PRECAUTIONS |
802 |
| 10.1.4 SYSTEM LAYOUTS |
804 |
| 10.1.5 COMPONENT DESCRIPTION |
808 |
| 10.2 MAINTENANCE OF AC/HVAC SYSTEM |
811 |
| 10.2.1 TROUBLESHOOTING AND DIAGNOSIS |
812 |
| 10.2.2 PRESSURE TEST USING MANIFOLD GAUGES |
825 |
| 10.2.3 FLUSHING OF AC SYSTEM |
830 |
| 10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
832 |
| 10.2.5 A/C SYSTEM PERFORMANCE TEST |
834 |
| 10.2.6 LEAK TEST SYSTEM |
834 |
| 10.3 ON VEHICLE REPAIRS |
835 |
| 10.3.1 CONTROL PANEL ASSEMBLY |
836 |
| 10.3.2 A/C COMPRESSOR |
837 |
| 10.3.3 HVAC UNIT |
848 |
| 10.3.4 BLOWER UNIT |
852 |
| 10.3.5 BLOWER RESISTER |
852 |
| 10.3.6 FILTER |
853 |
| 10.3.7 EVAPORATOR AND EXPANSION VALVE |
854 |
| 10.3.8 HEATER ASSEMBLY |
856 |
| 10.3.9 KINEMATICS |
857 |
| 10.3.10 PRESSURE SWITCH |
857 |
| 10.3.11 CONDENSER ASSEMBLY |
858 |
| 10.3.12 DRIER CARTRIDGE/R.D. BOTTLE |
860 |
| 10.3.13 CONDENSER FAN AND CONDENSER MOTOR |
862 |
| 10.3.14 REFRIGERANT LINES |
863 |
| 10.3.15 HEATER LINES |
865 |
| NANO AMT |
867 |
| 1. GENERAL |
7 |
| 1.1 AN OVERVIEW - NANO |
15 |
| 1.2 ABBREVIATIONS |
16 |
| 1.3 LIFTING, JACKING, TOWING POINTS |
19 |
| 1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
22 |
| 1.5 AGGREGATE NUMBERING SYSTEM |
23 |
| 1.6 TECHNICAL SPECIFICATIONS |
26 |
| 1.7 VEHICLE DIMENSIONS |
28 |
| 1.8 FUEL, LUBRICANTS & COOLANTS |
29 |
| 1.9 SERVICE SCHEDULE |
32 |
| 2. PRECAUTIONS |
35 |
| 2.1 GENERAL SAFETY PRECAUTIONS |
41 |
| 2.2 GENERAL SERVICE PRECAUTIONS |
45 |
| 3. ENGINE |
47 |
| 3.1 GENERAL INFORMATION |
55 |
| 3.1.1 TECHNICAL SPECIFICATIONS |
57 |
| 3.1.2 FEATURES OF 273 MPFI ENGINE |
58 |
| 3.1.3 TIGHTENING TORQUE |
59 |
| 3.1.4 SPECIAL TOOLS & EQUIPMENTS |
61 |
| 3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
| 3.2 ON VEHICLE PROCEDURES |
69 |
| 3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
| 3.2.2 ENGINE OIL REPLACEMENT |
73 |
| 3.2.3 OIL FILTER REPLACEMENT |
74 |
| 3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
| 3.2.5 FUEL FILTER REPLACEMENT |
76 |
| 3.2.6 TAPPET SETTING |
77 |
| 3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
| 3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
| 3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
| 3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
| 3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
| 3.3 ENGINE MECHANICAL |
91 |
| PRELIMINARY INSPECTION OF ENGINE |
93 |
| REMOVAL OF ENGINE FROM VEHICLE |
95 |
| 3.3.1 CYLINDER HEAD |
99 |
| 3.3.1.1 GENERAL DESCRIPTION |
101 |
| 3.3.1.2 EXPLODED VIEW |
102 |
| 3.3.1.3 CYLINDER HEAD OVERHAUL |
104 |
| 3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
| 3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
| 3.3.1.6 INSPECTION & REPAIR DATA |
111 |
| 3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
| 3.3.2 ENGINE BLOCK |
123 |
| 3.3.2.1 GENERAL DESCRIPTION |
125 |
| 3.3.2.2 EXPLODED VIEW |
126 |
| 3.3.2.3 ENGINE BLOCK OVERHAUL |
128 |
| 3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
| 3.3.2.5 INSPECTION & REPAIR DATA |
133 |
| 3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
| 3.3.2.7 REFITMENT OF ENGINE ACCESSORIES |
156 |
| 3.3.2.8 ENGINE TESTING |
158 |
| 3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE |
158 |
| 3.4 ACCELERATOR |
159 |
| 3.4.1 EXPLODED VIEWS & CABLE ROUTING |
161 |
| 3.4.2 SYSTEM MAINTENANCE |
163 |
| 3.5 ENGINE COMPONENTS |
869 |
| 3.5.1 RADIATOR LOCATION ON VEHICLE |
873 |
| 3.5.2 TECHNICAL SPECIFICATIONS |
874 |
| 3.5.3 RADIATOR REMOVAL AND RE-FITMENT ON VEHICLE |
875 |
| 3.5.4 RADIATOR FAN REMOVAL AND RE-FITMENT ON VEHICLE |
884 |
| 3.5.5 COOLANT TANK REMOVAL AND RE-FITMENT ON VEHICLE |
888 |
| 3.5.6 OIL FILTER REMOVAL AND RE-FITMENT ON VEHICLE |
890 |
| 3.5.7 CATCON REMOVAL AND RE-FITMENT PROCEDURES ON VEHICLE |
895 |
| 3.5.8 ELECTRONIC THROTTLE CONTROL BODY ORIENTATION |
903 |
| 3.5.9 THERMOSTAT |
904 |
| 3.6 LUBRICATION SYSTEM |
183 |
| 3.6.1 GENERAL DESCRIPTION |
185 |
| 3.6.2 SYSTEM SCHEMATICS |
185 |
| 3.6.3 SPECIFICATIONS |
186 |
| 3.6.4 SYSTEM MAINTENANCE |
187 |
| 3.7 FUEL SYSTEM |
199 |
| 3.7.1 GENERAL DESCRIPTION |
201 |
| 3.7.2 SYSTEM SCHEMATICS |
201 |
| 3.7.3 EXPLODED VIEWS |
202 |
| 3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
| 3.7.5 SYSTEM COMPONENTS |
204 |
| 3.7.6 SYSTEM MAINTENANCE |
208 |
| 3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
| 3.8 INTAKE SYSTEM |
221 |
| 3.8.1 GENERAL DESCRIPTION |
223 |
| 3.8.2 EXPLODED VIEWS |
224 |
| 3.8.3 SYSTEM MAINTENANCE |
225 |
| 3.9 EXHAUST SYSTEM |
231 |
| 3.9.1 GENERAL DESCRIPTION |
233 |
| 3.9.2 EXPLODED VIEWS |
234 |
| 3.9.3 TIGHTENING TORQUE |
235 |
| 3.9.4 SYSTEM COMPONENTS |
236 |
| 3.9.5 SYSTEM MAINTENANCE |
238 |
| 3.10 IGNITION SYSTEM |
243 |
| 3.10.1 GENERAL DESCRIPTION |
245 |
| 3.10.2 SYSTEM SCHEMATICS |
245 |
| 3.10.3 SYSTEM MAINTENANCE |
246 |
| 3.11 ENGINE MANAGEMENT SYSTEM |
251 |
| ABBREVIATIONS |
253 |
| AN OVERVIEW |
254 |
| 3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
| 3.11.1.1 ECU BLOCK DIAGRAM |
256 |
| 3.11.1.2 ECU PIN ASSIGNMENT DETAILS |
257 |
| 3.11.1.3 ECU HANDLING AND CARE |
258 |
| 3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
| 3.11.2 SENSORS |
260 |
| 3.11.2.1 CRANK SHAFT POSITION SENSOR |
260 |
| 3.11.2.2 COOLANT TEMPERATURE SENSOR |
261 |
| 3.11.2.3 T-MAP SENSOR |
263 |
| 3.11.2.4 KNOCK SENSOR |
264 |
| 3.11.2.5 THROTTLE POSITION SENSOR |
265 |
| 3.11.2.6 LAMBDA (OXYGEN) SENSOR |
268 |
| 3.11.2.7 VEHICLE SPEED SENSOR |
269 |
| 3.11.3 ACTUATORS |
271 |
| 3.11.3.1 CANISTER PURGE VALVE |
271 |
| 3.11.3.2 FUEL INJECTOR |
272 |
| 3.11.3.3 IGNITION COIL |
274 |
| 3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) |
277 |
| 3.11.3.5 COMPONENT FITMENT DATA |
279 |
| 3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
| 3.11.4.1 DTC LIST |
283 |
| 3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER |
293 |
| 3.11.4.3 BLINK CODE |
308 |
| 3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
| 3.11.5.1 REPAIRING STEPS |
310 |
| 3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
| 3.11.5.3 SENSOR AND ACTUATOR TESTING |
312 |
| 3.11.5.4 EMERGENCY SERVICE TIPS |
314 |
| 4. DRIVETRAIN |
315 |
| 4.1 CLUTCH |
906 |
| 4.1.1 GENERAL INFORMATION |
906 |
| 4.1.1.1 TECHNICAL SPECIFICATION |
906 |
| 4.1.1.2 CONSTRUCTION |
909 |
| 4.1.1.3 PRECAUTIONS |
911 |
| 4.1.1.4 TIGHTENING TORQUES |
912 |
| 4.1.1.5 SPECIAL TOOLS |
913 |
| 4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
914 |
| 4.1.1.7 TROUBLE SHOOTING |
916 |
| 4.1.1.8 MAINTENANCE AND REPAIRS |
917 |
| 4.1.2 OVERHAULING |
918 |
| 4.1.2.1 EXPLODED VIEW |
918 |
| 4.1.2.2 PROCEDURE |
919 |
| 4.1.2.2.1 REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
919 |
| 4.1.2.2.2 CLUTCH ACTUATION MECHANISM OVERHAUL |
920 |
| 4.2 5-SPEED TRANSAXLE |
923 |
| 4.2.1 GENERAL INFORMATION |
923 |
| 4.2.1.1 TECHNICAL SPECIFICATION |
923 |
| 4.2.1.2 PRECAUTIONS |
924 |
| 4.2.1.3 TIGHTENING TORQUES |
925 |
| 4.2.1.4 SPECIAL TOOLS |
929 |
| 4.2.1.5 GENERAL SYMPTOMS AND DIAGNOSIS |
932 |
| 4.2.1.6 TRANSAXLE OIL REPLACEMENT |
933 |
| 4.2.2 OVERHAULING (EXPLOADED VIEWS) |
934 |
| 4.2.2.1 TRANSAXLE HOUSING |
934 |
| 4.2.2.2 INPUT SHAFT AND LAY SHAFT |
936 |
| 4.2.2.3 SHIFER SHAFT AND SHIFTER SLEEVE |
937 |
| 4.2.2.4 DIFFERENTIAL |
938 |
| 4.2.2.5 TOP COVER ASSEMBLY |
939 |
| 4.2.2.6 SHIFTER LINKAGE |
940 |
| 4.2.3 COMPONENT IDENTIFICATION |
941 |
| 4.2.3.1 SHIFTER SHAFTS |
941 |
| 4.2.3.2 SHIFTER FORKS (DOGS) |
941 |
| 4.2.3.3 SHIFTER SLEEVE |
942 |
| 4.2.4 REMOVAL OF TRANSAXLE |
944 |
| 4.2.5 TRANSAXLE DISMANTLING |
945 |
| 4.2.6 INPUT SHAFT ASSEMBLY |
949 |
| 4.2.7 LAY SHAFT ASSEMBLY |
952 |
| 4.2.8 SHIFTER SHAFT AND SHIFTER FORK |
956 |
| 4.2.9 REVERSE GEAR SHIFTER BRACKET ASSEMBLY |
959 |
| 4.2.10 DIFFERENTIAL ASSEMBLY |
960 |
| 4.2.11 TOP COVER ASSEMBLY |
963 |
| 4.2.12 REAR HALF HOUSING ASSEMBLY |
966 |
| 4.2.13 FRONT HALF HOUSING ASSEMBLY |
967 |
| 4.2.14 TRANSAXLE ASSEMBLY |
969 |
| 4.2.14.1 SHIM SELECTION |
969 |
| 4.2.14.2 ASSEMBLING THE TRANSAXLE |
970 |
| 4.3 DRIVESHAFT |
411 |
| 4.3.1 GENERAL INFORMATION |
413 |
| 4.3.1.1 TIGHTENING TORQUE |
413 |
| 4.3.1.2 SPECIAL TOOL |
414 |
| 4.3.1.3 CONSTRUCTIONAL DETAILS |
415 |
| 4.3.1.4 EXPLODED VIEW - DRIVESHAFT |
415 |
| 4.3.1.5 COMPONENT DESCRIPTION |
416 |
| 4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS |
417 |
| 4.3.2 ON VEHICLE REPAIRS |
418 |
| 4.3.2.1 PRECAUTIONS |
418 |
| 4.3.2.2 REMOVAL FROM VEHICLE |
420 |
| 4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
| 4.4 AMT KIT |
974 |
| 4.4.1 AMT KIT LOCATION ON VEHICLE |
975 |
| 4.4.2 ABBREVIATION LIST |
976 |
| 4.4.3 PRECAUTION (DO’S AND DON’TS) |
977 |
| 4.4.4 TECHNICAL SPECIFICATIONS |
979 |
| 4.4.5 TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS |
980 |
| 4.4.6 TOOLS |
982 |
| 4.4.7 AMT UNIT REMOVAL AND INSTALLATION PROCEDURES ON VEHICLE |
984 |
| 4.4.8 MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT ON BENCH |
991 |
| 4.4.9 TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT ON BENCH |
994 |
| 4.4.10 OIL TANK REMOVAL AND RE-FITMENT ON BENCH |
998 |
| 4.4.11 DC MOTOR REMOVAL AND RE-FITMENT ON BENCH |
1000 |
| 4.4.12 CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT ON BENCH |
1001 |
| 4.4.13 HYDRAULIC OIL ACCUMLATOR |
1001 |
| 4.4.14 POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH |
1002 |
| 4.5 GEAR SHIFTER CONSOLE |
1004 |
| 4.5.1 AMT GEARBOX SHIFTER AND SHIFTING MECHANISM |
1004 |
| 4.5.2 GEAR SHIFTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE |
1006 |
| 5. SUSPENSION SYSTEM |
429 |
| 5.1 GENERAL INFORMATION |
435 |
| 5.1.1 TECHNICAL SPECIFICATIONS |
435 |
| 5.1.2 TIGHTENING TORQUES |
436 |
| 5.1.3 SPECIAL TOOLS |
439 |
| 5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
| 5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
| 5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
| 5.1.7 TROUBLESHOOTING AND DIAGNOSIS |
446 |
| 5.2 ON VEHICLE REPAIRS |
449 |
| 5.2.1 FRONT SUSPENSION COMPONENTS |
449 |
| 5.2.1.1 STRUT |
449 |
| 5.2.1.2 ANTI-ROLL BAR |
455 |
| 5.2.1.3 LOWER ARM |
456 |
| 5.2.1.4 WHEEL BEARING |
458 |
| 5.2.2 REAR SUSPENSION COMPONENTS |
461 |
| 5.2.2.1 SHOCK ABSORBER |
462 |
| 5.2.2.2 COIL SPRING |
463 |
| 5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT |
464 |
| 5.2.2.4 SEMI TRAILING ARM |
465 |
| 5.2.3 WHEEL HUB AND WHEEL BEARING |
468 |
| 5.3 WHEELS AND TYRES |
473 |
| 5.3.1 GENERAL INFORMATION |
473 |
| 5.3.1.1 TECHNICAL SPECIFICATIONS |
473 |
| 5.3.1.2 TIGHTENING TORQUE |
474 |
| 5.3.1.3 EXPLODED VIEW |
475 |
| 5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
| 5.3.2 ON VEHICLE REPAIRS |
477 |
| 5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
| 5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
| 5.3.2.3 WHEEL BALANCING |
480 |
| 5.3.2.4 WHEEL RUNOUT |
481 |
| 5.3.2.5 TYRE REPLACEMENT |
482 |
| 5.3.2.6 WHEEL ASSEMBLY REPLACEMENT |
483 |
| 5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE |
483 |
| 5.3.2.8 TYRE DIAGNOSIS |
484 |
| 6. BRAKE SYSTEM |
493 |
| 6.1 GENERAL INFORMATION |
499 |
| 6.1.1 TECHNICAL SPECIFICATIONS |
499 |
| 6.1.2 TIGHTENING TORQUES |
500 |
| 6.1.3 SPECIAL TOOLS |
504 |
| 6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
| 6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
| 6.2.1 FRONT DRUM BRAKES |
507 |
| 6.2.2 REAR DRUM BRAKES |
508 |
| 6.2.3 AUTO INCREMENTAL BRAKE |
509 |
| 6.2.4 TANDEM MASTER CYLINDER (TMC) |
510 |
| 6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
| 6.2.6 WHEEL CYLINDER |
514 |
| 6.2.7 PARKING BRAKES |
515 |
| 6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
| 6.3.1 BLEEDING OF HYDRAULIC SYSTEM |
521 |
| 6.3.2 TROUBLESHOOTING AND DIAGNOSIS |
523 |
| 6.4 ON VEHICLE REPAIRS |
530 |
| 6.4.1 FRONT BRAKE COMPONENTS |
531 |
| 6.4.2 FRONT BRAKE DRUM |
532 |
| 6.4.3 FRONT BRAKE SHOES |
542 |
| 6.4.4 FRONT BRAKE BACK PLATE |
539 |
| 6.4.5 REAR BRAKE COMPONENTS |
540 |
| 6.4.6 REAR BRAKE DRUM |
541 |
| 6.4.7 REAR BRAKE SHOES |
542 |
| 6.4.8 REAR BRAKE BACK PLATE |
544 |
| 6.4.9 TMC |
546 |
| 6.4.10 WHEEL CYLINDER |
555 |
| 6.4.11 PARKING BRAKES |
561 |
| 6.4.12 VACUUM BRAKE BOOSTER |
564 |
| 6.4.13 BRAKE HOSES/PIPES SCHEMATIC |
565 |
| 6.4.14 VACUUM LINES |
567 |
| 7. STEERING |
569 |
| 7.1 GENERAL INFORMATION |
575 |
| 7.1.1 TECHNICAL SPECIFICATIONS |
575 |
| 7.1.2 TIGHTENING TORQUES |
576 |
| 7.1.3 SPECIAL TOOLS |
578 |
| 7.1.4 EXPLODED VIEWS |
579 |
| 7.1.5 SCHEMATIC OF STEERING SYSTEM |
581 |
| 7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
| 7.3 ON VEHICLE REPAIRS |
584 |
| 7.3.1 STEERING WHEEL |
586 |
| 7.3.2 STEERING COLUMN ASSEMBLY |
587 |
| 7.3.3 STEERING UPPER COLUMN |
589 |
| 7.3.4 INTERMEDIATE SHAFT |
589 |
| 7.3.5 STEERING RACK AND PINION ASSEMBLY |
590 |
| 7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
| 7.3.7 WHEEL ALIGNMENT |
601 |
| 7.3.8 TROUBLESHOOTING AND DIAGNOSIS |
603 |
| 8. ELECTRICAL |
1010 |
| 8.1 EMS ECU AND AMT TCU CONNECTOR’S REMOVAL AND RE-FITMENT ON VEHICLE |
1012 |
| 8.1.1 PARTS LIST |
1012 |
| 8.1.2 EMS ECU CONNECTOR REMOVAL AND RE-FIMENT ON VEHICLE |
1014 |
| 8.1.3 AMT TCU UNIT CONNECTOR’S REMOVAL AND RE-FIMENT ON VEHICLE |
1019 |
| 8.2 FOG LAMP REMOVAL AND RE-FITMENT ON VEHICLE |
1023 |
| 8.3 HORN REMOVAL AND RE-FITMENT ON VEHICLE |
1026 |
| 8.4 AMBIENT TEMPERATURE SENSOR REMOVAL AND RE-FITMENT ON VEHICLE |
1029 |
| 8.5 TRANSMISSION INPUT SPEED SENSOR REMOVAL AND RE-FITMENT ON VEHICLE |
1033 |
| 8.6 EXHAUST FAN REMOVAL AND RE-FITMENT ON VEHICLE |
1035 |
| 8.7 DIAGNOSTIC TROUBLE CODES FOR ELECTRONIC POWER ASSISTED STEERING |
1038 |
| 8.8 BRAKE SWITCH FAILURE CASES AND RECOVERY ON VEHICLE |
1039 |
| 8.9 DIAGNOSTIC TROUBLE CODES FOR ENGINE MANAGEMENT SYSTEM |
1040 |
| 9. BODY |
721 |
| 9.1 GENERAL INFORMATION |
727 |
| 9.1.1 TECHNICAL SPECIFICATIONS |
727 |
| 9.1.2 TIGHTENING TORQUE |
728 |
| 9.2 ON VEHICLE REPAIRS |
732 |
| 9.2.1 EXPLODED VIEW - BUMPERS & HOOD |
732 |
| 9.2.2 FRONT BUMPER |
733 |
| 9.2.3 FENDER (SIDE BONNET) |
734 |
| 9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
735 |
| 9.2.5 FRONT DOOR |
739 |
| 9.2.6 REAR DOOR |
750 |
| 9.2.7 REAR SHELF |
759 |
| 9.2.8 TAILGATE |
759 |
| 9.2.9 REAR BUMPER |
760 |
| 9.2.10 DASHBOARD |
762 |
| 9.2.11 CENTER CONSOLE |
765 |
| 9.2.12 SEATS & BELTS |
766 |
| 9.2.13 OUTER REAR VIEW MIRROR (ORVM) |
776 |
| 9.2.14 SUN VISOR |
776 |
| 9.2.15 TRIMS |
777 |
| 9.2.16 FLOOR CARPET |
778 |
| 9.2.17 WINDSHIELD |
781 |
| 9.3 PAINT CARE |
783 |
| 9.4 BODY REPAIR DATA |
786 |
| 9.5 TROUBLESHOOTING AND DIAGNOSIS |
791 |
| 10. HVAC |
793 |
| 10.1 GENERAL INFORMATION |
799 |
| 10.1.1 TECHNICAL SPECIFICATIONS |
799 |
| 10.1.2 TIGHTENING TORQUES |
800 |
| 10.1.3 GENERAL PRECAUTIONS |
802 |
| 10.1.4 SYSTEM LAYOUTS |
804 |
| 10.1.5 COMPONENT DESCRIPTION |
808 |
| 10.2 MAINTENANCE OF AC/HVAC SYSTEM |
811 |
| 10.2.1 TROUBLESHOOTING AND DIAGNOSIS |
812 |
| 10.2.2 PRESSURE TEST USING MANIFOLD GAUGES |
825 |
| 10.2.3 FLUSHING OF AC SYSTEM |
830 |
| 10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
832 |
| 10.2.5 A/C SYSTEM PERFORMANCE TEST |
834 |
| 10.2.6 LEAK TEST SYSTEM |
834 |
| 10.3 ON VEHICLE REPAIRS |
835 |
| 10.3.1 CONTROL PANEL ASSEMBLY |
836 |
| 10.3.2 AC COMPRESSOR |
1068 |
| 10.3.2.1 AC COMPRESSOR LOCATION ON VEHICLE |
1071 |
| 10.3.2.2 TECHNICAL SPECIFICATIONS |
1072 |
| 10.3.2.3 TIGHTENING TORQUES |
1073 |
| 10.3.2.4 PRECAUTIONS |
1074 |
| 10.3.2.5 EXPLODED VIEW AND PART LIST |
1077 |
| 10.3.2.6 AC COMPRESSOR REMOVAL AND RE-FITMENT ON VEHICLE |
1078 |
| 10.3.3 HVAC UNIT |
848 |
| 10.3.4 BLOWER UNIT |
852 |
| 10.3.5 BLOWER RESISTER |
852 |
| 10.3.6 FILTER |
853 |
| 10.3.7 EVAPORATOR AND EXPANSION VALVE |
854 |
| 10.3.8 HEATER ASSEMBLY |
856 |
| 10.3.9 KINEMATICS |
857 |
| 10.3.10 PRESSURE SWITCH |
857 |
| 10.3.11 CONDENSER ASSEMBLY |
858 |
| 10.3.12 DRIER CARTRIDGE/R.D. BOTTLE |
860 |
| 10.3.13 CONDENSER FAN AND CONDENSER MOTOR |
862 |
| 10.3.14 REFRIGERANT LINES |
863 |
| 10.3.15 HEATER LINES |
865 |
| NANO CNG |
1084 |
| 1. GENERAL |
1090 |
| 1.1. INTRODUCTION TO CNG SYSTEM |
1094 |
| 1.2. BENEFITS OF CNG |
1094 |
| 1.3. FEATURES OF CNG BI-FUEL SYSTEM |
1094 |
| 1.4. GENERAL INSTRUCTION / PRECAUTIONSWHILE WORKING ON CNG VEHICLE |
1095 |
| 1.5. IN CASE OF LEAKAGE |
1097 |
| 1.6. TECHNICAL SPECIFICATIONS |
1099 |
| 1.7. TIGHTENING TORQUE |
1103 |
| 1.8. SPECIAL TOOLS |
1108 |
| 1.9. LIST OF APPROVED CNG CYLINDER TESTING STATION |
1109 |
| 1.10. SERVICE SCHEDULE |
1110 |
| 1.11. LUBRICANTS AND COOLANTS |
1114 |
| 2. PRECAUTIONS |
35 |
| 2.1 GENERAL SAFETY PRECAUTIONS |
41 |
| 2.2 GENERAL SERVICE PRECAUTIONS |
45 |
| 3. ENGINE |
1116 |
| 3.1. TECHNICAL SPECIFICATION |
1120 |
| 3.2. REPAIR DATA |
1121 |
| A. BELT TENSION VALUES |
1121 |
| 3.3. ENGINE CONTRUCTIONAL DETAIL |
1122 |
| A. ENGINE |
1122 |
| B. INTAKE MANIFOLD |
1122 |
| 3.4. GENERAL SYSTEM OVERVIEW OF Bi-FUEL ENGINE MANAGEMENT SYSTEM |
1123 |
| 3.5. REMOVAL AND REFITMENT OF ENGINEACCESS WINDOW AND ENGINE COVER |
1126 |
| 3.6. GAS INJECTOR |
1129 |
| 3.7. GAS RAIL |
1131 |
| 3.8. PRESSURE AND TEMPERATURE (P&T)SENSOR |
1133 |
| 3.9. DIAGNOSTIC USER MANUAL |
1135 |
| 4. DRIVETRAIN |
315 |
| 4.1 CLUTCH |
321 |
| 4.1.1 GENERAL INFORMATION |
323 |
| 4.1.1.1 TECHNICAL SPECIFICATIONS |
323 |
| 4.1.1.2 CONSTRUCTION |
326 |
| 4.1.1.3 PRECAUTIONS |
328 |
| 4.1.1.4 TIGHTENING TORQUES |
329 |
| 4.1.1.5 SPECIAL TOOLS |
330 |
| 4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
| 4.1.1.7 TROUBLE SHOOTING |
334 |
| 4.1.1.8 MAINTENANCE AND REPAIR |
335 |
| A. PRELIMINARY INSPECTION |
335 |
| B. CLUTCH SLIPPAGE TEST |
335 |
| C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
| D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
| E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
| 4.1.2 OVERHAUL |
337 |
| EXPLODED VIEWS |
337 |
| A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
| B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
| C. CLUTCH CABLE REPLACEMENT |
344 |
| 4.2 TRANSAXLE |
1156 |
| 4.2.1 GENERAL INFORMATION |
1162 |
| A. TECHNICAL SPECIFICATIONS |
1162 |
| B. PRECAUTIONS |
1163 |
| C. TIGHTENING TORQUES |
1164 |
| D. SPECIAL TOOLS |
1167 |
| E. GENERAL SYMPTOMS AND DIAGNOSIS |
1171 |
| F. TRANSAXLE OIL REPLACEMENT |
1172 |
| 4.2.2. OVERHAULING (EXPLODED VIEWS) |
1173 |
| A. TRANSAXLE HOUSING |
1173 |
| B. INPUT SHAFT AND LAY SHAFT |
1174 |
| C. SHIFTER SHAFT AND SHIFTER SLEEVE |
1175 |
| D. DIFFERENTIAL |
1176 |
| E. TOP COVER ASSEMBLY |
1177 |
| F. SHIFTER LINKAGE |
1178 |
| 4.2.3. COMPONENT IDENTIFICATION |
1180 |
| A. SHIFTER SHAFTS |
1180 |
| B. SHIFTER FORKS (DOGS) |
1180 |
| C. SHIFTER SLEEVE |
1181 |
| 4.2.4. REMOVAL OF TRANSAXLE FROM VEHICLE |
1182 |
| 4.2.5. TRANSAXLE DISMANTLING |
1185 |
| 4.2.6. INPUT SHAFT ASSEMBLY |
1189 |
| 4.2.7. LAYSHAFT ASSEMBLY |
1194 |
| 4.2.8. SHIFTER SHAFT AND SHIFTER FORK |
1200 |
| 4.2.9. REVERSE GEAR SHIFTER BRACKET - ASSEMBLY |
1201 |
| 4.2.10. DIFFERENTIAL ASSEMBLY |
1203 |
| 4.2.11. REAR HALF HOUSING TOP COVER ASSEMBLY |
1207 |
| 4.2.12. REAR HALF HOUSING ASSEMBLY |
1214 |
| 4.2.13. FRONT HALF HOUSING |
1216 |
| 4.2.14. TRANSAXLE ASSEMBLY |
1218 |
| A. SHIM SELECTION |
1218 |
| B. ASSEMBLING THE TRANSAXLE |
1219 |
| 4.2.15. GEAR SHIFTER LINKAGE |
1224 |
| A. GEAR SHIFTER CABLE REPLACEMENT |
1224 |
| B. GEAR SHIFTER ADJUSTMENT |
1226 |
| 4.3 DRIVESHAFT |
411 |
| 4.3.1 GENERAL INFORMATION |
413 |
| 4.3.1.1 TIGHTENING TORQUE |
413 |
| 4.3.1.2 SPECIAL TOOL |
414 |
| 4.3.1.3 CONSTRUCTIONAL DETAILS |
415 |
| 4.3.1.4 EXPLODED VIEW - DRIVESHAFT |
415 |
| 4.3.1.5 COMPONENT DESCRIPTION |
416 |
| 4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS |
417 |
| 4.3.2 ON VEHICLE REPAIRS |
418 |
| 4.3.2.1 PRECAUTIONS |
418 |
| 4.3.2.2 REMOVAL FROM VEHICLE |
420 |
| 4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
| 5. SUSPENSION SYSTEM |
429 |
| 5.1 GENERAL INFORMATION |
435 |
| 5.1.1 TECHNICAL SPECIFICATIONS |
435 |
| 5.1.2 TIGHTENING TORQUES |
436 |
| 5.1.3 SPECIAL TOOLS |
439 |
| 5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
| 5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
| 5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
| 5.1.7 TROUBLESHOOTING AND DIAGNOSIS |
446 |
| 5.2 ON VEHICLE REPAIRS |
449 |
| 5.2.1 FRONT SUSPENSION COMPONENTS |
449 |
| 5.2.1.1 STRUT |
449 |
| 5.2.1.2 ANTI-ROLL BAR |
455 |
| 5.2.1.3 LOWER ARM |
456 |
| 5.2.1.4 WHEEL BEARING |
458 |
| 5.2.2 REAR SUSPENSION COMPONENTS |
461 |
| 5.2.2.1 SHOCK ABSORBER |
462 |
| 5.2.2.2 COIL SPRING |
463 |
| 5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT |
464 |
| 5.2.2.4 SEMI TRAILING ARM |
465 |
| 5.2.3 WHEEL HUB AND WHEEL BEARING |
468 |
| 5.3 WHEELS AND TYRES |
473 |
| 5.3.1 GENERAL INFORMATION |
473 |
| 5.3.1.1 TECHNICAL SPECIFICATIONS |
473 |
| 5.3.1.2 TIGHTENING TORQUE |
474 |
| 5.3.1.3 EXPLODED VIEW |
475 |
| 5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
| 5.3.2 ON VEHICLE REPAIRS |
477 |
| 5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
| 5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
| 5.3.2.3 WHEEL BALANCING |
480 |
| 5.3.2.4 WHEEL RUNOUT |
481 |
| 5.3.2.5 TYRE REPLACEMENT |
482 |
| 5.3.2.6 WHEEL ASSEMBLY REPLACEMENT |
483 |
| 5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE |
483 |
| 5.3.2.8 TYRE DIAGNOSIS |
484 |
| 6. BRAKE SYSTEM |
493 |
| 6.1 GENERAL INFORMATION |
499 |
| 6.1.2 TECHNICAL SPECIFICATIONS |
499 |
| 6.1.3 TIGHTENING TORQUES |
500 |
| 6.1.4 SPECIAL TOOLS |
504 |
| 6.1.5 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
| 6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
| 6.2.1 FRONT DRUM BRAKES |
507 |
| 6.2.2 REAR DRUM BRAKES |
508 |
| 6.2.3 AUTO INCREMENTAL BRAKE |
509 |
| 6.2.4 TANDEM MASTER CYLINDER (TMC) |
510 |
| 6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
| 6.2.6 WHEEL CYLINDER |
514 |
| 6.2.7 PARKING BRAKES |
515 |
| 6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
| 6.3.1 BLEEDING OF HYDRAULIC SYSTEM |
521 |
| 6.3.2 TROUBLESHOOTING AND DIAGNOSIS |
523 |
| 6.4 ON VEHICLE REPAIRS |
530 |
| 6.4.1 FRONT BRAKE COMPONENTS |
531 |
| 6.4.2 FRONT BRAKE DRUM |
532 |
| 6.4.3 FRONT BRAKE SHOES |
534 |
| 6.4.4 FRONT BRAKE BACK PLATE |
539 |
| 6.4.5 REAR BRAKE COMPONENTS |
540 |
| 6.4.6 REAR BRAKE DRUM |
541 |
| 6.4.7 REAR BRAKE SHOES |
542 |
| 6.4.8 REAR BRAKE BACK PLATE |
544 |
| 6.4.8 TMC |
546 |
| 6.4.9 WHEEL CYLINDER |
555 |
| 6.4.10 PARKING BRAKES |
561 |
| 6.4.11 VACUUM BRAKE BOOSTER |
564 |
| 6.4.12 BRAKE HOSES/PIPES SCHEMATIC |
565 |
| 6.4.13 VACUUM LINES |
567 |
| 7. STEERING |
569 |
| 7.1 GENERAL INFORMATION |
575 |
| 7.1.1 TECHNICAL SPECIFICATIONS |
575 |
| 7.1.2 TIGHTENING TORQUES |
576 |
| 7.1.3 SPECIAL TOOLS |
578 |
| 7.1.4 EXPLODED VIEWS |
579 |
| 7.1.5 SCHEMATIC OF STEERING SYSTEM |
581 |
| 7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
| 7.3 ON VEHICLE REPAIRS |
584 |
| 7.3.1 STEERING WHEEL |
586 |
| 7.3.2 STEERING COLUMN ASSEMBLY |
587 |
| 7.3.3 STEERING UPPER COLUMN |
589 |
| 7.3.4 INTERMEDIATE SHAFT |
589 |
| 7.3.5 STEERING RACK AND PINION ASSEMBLY |
590 |
| 7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
| 7.3.7 WHEEL ALIGNMENT |
601 |
| 7.3.8 TROUBLESHOOTING AND DIAGNOSIS |
603 |
| 8. ELECTRICAL |
1262 |
| 8.1 TECHNICAL SPECIFICATION |
1266 |
| 8.2. LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE |
1267 |
| 8.3. INSTRUMENT CLUSTER |
1268 |
| 8.4. FUEL GAUGE |
1269 |
| 8.5. REMOVAL AND REFITTMENT OF BATTERY |
1270 |
| 8.6. STARTER MOTOR |
1271 |
| A. EXPLODED VIEW |
1271 |
| B. ON VEHICLE REMOVAL AND REFITTMENT OF STARTER MOTOR |
1271 |
| C. STARTER MOTOR OVER HAULING |
1272 |
| DTC CODES |
1278 |
| 9. BODY |
721 |
| 9.1 GENERAL INFORMATION |
727 |
| 9.1.1 TECHNICAL SPECIFICATIONS |
727 |
| 9.1.2 TIGHTENING TORQUE |
728 |
| 9.2 ON VEHICLE REPAIRS |
732 |
| 9.2.1 EXPLODED VIEW - BUMPERS & HOOD |
732 |
| 9.2.2 FRONT BUMPER |
733 |
| 9.2.3 FENDER (SIDE BONNET) |
734 |
| 9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
735 |
| 9.2.5 FRONT DOOR |
739 |
| 9.2.6 REAR DOOR |
750 |
| 9.2.7 REAR SHELF |
759 |
| 9.2.8 TAILGATE |
759 |
| 9.2.9 REAR BUMPER |
760 |
| 9.2.10 DASHBOARD |
762 |
| 9.2.11 CENTER CONSOLE |
765 |
| 9.2.12 SEATS & BELTS |
766 |
| 9.2.13 OUTER REAR VIEW MIRROR (ORVM) |
776 |
| 9.2.14 SUN VISOR |
776 |
| 9.2.15 TRIMS |
777 |
| 9.2.16 FLOOR CARPET |
778 |
| 9.2.17 WINDSHIELD |
781 |
| 9.3 PAINT CARE |
783 |
| 9.4 BODY REPAIR DATA |
786 |
| 9.5 TROUBLESHOOTING AND DIAGNOSIS |
791 |
| 10. HVAC |
793 |
| 10.1 GENERAL INFORMATION |
799 |
| 10.1.1 TECHNICAL SPECIFICATIONS |
799 |
| 10.1.2 TIGHTENING TORQUES |
800 |
| 10.1.3 GENERAL PRECAUTIONS |
802 |
| 10.1.4 SYSTEM LAYOUTS |
804 |
| 10.1.5 COMPONENT DESCRIPTION |
808 |
| 10.2 MAINTENANCE OF AC/HVAC SYSTEM |
811 |
| 10.2.1 TROUBLESHOOTING AND DIAGNOSIS |
812 |
| 10.2.2 PRESSURE TEST USING MANIFOLD GAUGES |
825 |
| 10.2.3 FLUSHING OF AC SYSTEM |
830 |
| 10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
832 |
| 10.2.5 A/C SYSTEM PERFORMANCE TEST |
834 |
| 10.2.6 LEAK TEST SYSTEM |
834 |
| 10.3 ON VEHICLE REPAIRS |
835 |
| 10.3.1 CONTROL PANEL ASSEMBLY |
836 |
| 10.3.2 A/C COMPRESSOR |
837 |
| 10.3.3 HVAC UNIT |
848 |
| 10.3.4 BLOWER UNIT |
852 |
| 10.3.5 BLOWER RESISTER |
852 |
| 10.3.6 FILTER |
853 |
| 10.3.7 EVAPORATOR AND EXPANSION VALVE |
854 |
| 10.3.8 HEATER ASSEMBLY |
856 |
| 10.3.9 KINEMATICS |
857 |
| 10.3.10 PRESSURE SWITCH |
857 |
| 10.3.11 CONDENSER ASSEMBLY |
858 |
| 10.3.12 DRIER CARTRIDGE/R.D. BOTTLE |
860 |
| 10.3.13 CONDENSER FAN AND CONDENSER MOTOR |
862 |
| 10.3.14 REFRIGERANT LINES |
863 |
| 10.3.15 HEATER LINES |
865 |
| 11. FUEL SYSTEM |
1228 |
| 11.1 INTRODUCTION |
1232 |
| A. CNG LAYOUT (ON VEHICLE) |
1233 |
| 11.2. CNG FUEL SYSTEM COMPONENTS |
1234 |
| A. CNG CYLINDER |
1234 |
| B. CYLINDER VALVE |
1236 |
| C. LOW PRESSURE CNG FILTER |
1241 |
| D. PRESSURE GAUGE |
1244 |
| E. PRESSURE REGULATOR |
1245 |
| F. HIGH PRESSURE (H.P) SENSOR |
1250 |
| G. CNG RECEPTACLE VALVE |
1252 |
| 11.3. CNG TUBE FITTINGS / JOINTS TIGHTENING INSTRUCTIONS |
1255 |
| A. SWAGING PROCEDURE |
1255 |
| B. PROCEDURE FOR NPT THREAD ASSEMBLY |
1257 |
| 11.4. CNG LEAK DETECTION TESTING |
1259 |
| 11.5. TROUBLE SHOOTING |
1260 |
| NANO ePAS |
1296 |
| 1. GENERAL |
7 |
| 1.1 AN OVERVIEW - NANO |
15 |
| 1.2 ABBREVIATIONS |
16 |
| 1.3 LIFTING, JACKING, TOWING POINTS |
19 |
| 1.4 TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
22 |
| 1.5 AGGREGATE NUMBERING SYSTEM |
23 |
| 1.6 TECHNICAL SPECIFICATIONS |
26 |
| 1.7 VEHICLE DIMENSIONS |
28 |
| 1.8 FUEL, LUBRICANTS & COOLANTS |
29 |
| 1.9 SERVICE SCHEDULE |
32 |
| 2. PRECAUTIONS |
35 |
| 2.1 GENERAL SAFETY PRECAUTIONS |
41 |
| 2.2 GENERAL SERVICE PRECAUTIONS |
45 |
| 3. ENGINE |
47 |
| 3.1 GENERAL INFORMATION |
55 |
| 3.1.1 TECHNICAL SPECIFICATIONS |
57 |
| 3.1.2 FEATURES OF 273 MPFI ENGINE |
58 |
| 3.1.3 TIGHTENING TORQUE |
59 |
| 3.1.4 SPECIAL TOOLS & EQUIPMENTS |
61 |
| 3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
| 3.2 ON VEHICLE PROCEDURES |
69 |
| 3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
| 3.2.2 ENGINE OIL REPLACEMENT |
73 |
| 3.2.3 OIL FILTER REPLACEMENT |
74 |
| 3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
| 3.2.5 FUEL FILTER REPLACEMENT |
76 |
| 3.2.6 TAPPET SETTING |
77 |
| 3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
| 3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
| 3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
| 3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
| 3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
| 3.3 ENGINE MECHANICAL |
91 |
| PRELIMINARY INSPECTION OF ENGINE |
93 |
| REMOVAL OF ENGINE FROM VEHICLE |
95 |
| 3.3.1 CYLINDER HEAD |
99 |
| 3.3.1.1 GENERAL DESCRIPTION |
101 |
| 3.3.1.2 EXPLODED VIEW |
102 |
| 3.3.1.3 CYLINDER HEAD OVERHAUL |
104 |
| 3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
| 3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
| 3.3.1.6 INSPECTION & REPAIR DATA |
111 |
| 3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
| 3.3.2 ENGINE BLOCK |
123 |
| 3.3.2.1 GENERAL DESCRIPTION |
125 |
| 3.3.2.2 EXPLODED VIEW |
126 |
| 3.3.2.3 ENGINE BLOCK OVERHAUL |
128 |
| 3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
| 3.3.2.5 INSPECTION & REPAIR DATA |
133 |
| 3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
| 3.3.2.7 REFITMENT OF ENGINE ACCESSORIES |
156 |
| 3.3.2.8 ENGINE TESTING |
158 |
| 3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE |
158 |
| 3.4 ACCELERATOR |
159 |
| 3.4.1 EXPLODED VIEWS & CABLE ROUTING |
161 |
| 3.4.2 SYSTEM MAINTENANCE |
163 |
| 3.5 COOLING SYSTEM |
167 |
| 3.5.1 GENERAL DESCRIPTION |
169 |
| 3.5.3 EXPLODED VIEWS |
170 |
| 3.5.4 SPECIFICATIONS |
172 |
| 3.5.5 SYSTEM COMPONENTS |
173 |
| 3.5.6 SYSTEM MAINTENANCE |
174 |
| 3.6 LUBRICATION SYSTEM |
183 |
| 3.6.1 GENERAL DESCRIPTION |
185 |
| 3.6.2 SYSTEM SCHEMATICS |
185 |
| 3.6.3 SPECIFICATIONS |
186 |
| 3.6.4 SYSTEM MAINTENANCE |
187 |
| 3.7 FUEL SYSTEM |
199 |
| 3.7.1 GENERAL DESCRIPTION |
201 |
| 3.7.2 SYSTEM SCHEMATICS |
201 |
| 3.7.3 EXPLODED VIEWS |
202 |
| 3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
| 3.7.5 SYSTEM COMPONENTS |
204 |
| 3.7.6 SYSTEM MAINTENANCE |
208 |
| 3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
| 3.8 INTAKE SYSTEM |
221 |
| 3.8.1 GENERAL DESCRIPTION |
223 |
| 3.8.2 EXPLODED VIEWS |
224 |
| 3.8.3 SYSTEM MAINTENANCE |
225 |
| 3.9 EXHAUST SYSTEM |
231 |
| 3.9.1 GENERAL DESCRIPTION |
233 |
| 3.9.2 EXPLODED VIEWS |
234 |
| 3.9.3 TIGHTENING TORQUE |
235 |
| 3.9.4 SYSTEM COMPONENTS |
236 |
| 3.9.5 SYSTEM MAINTENANCE |
238 |
| 3.10 IGNITION SYSTEM |
243 |
| 3.10.1 GENERAL DESCRIPTION |
245 |
| 3.10.2 SYSTEM SCHEMATICS |
245 |
| 3.10.3 SYSTEM MAINTENANCE |
246 |
| 3.11 ENGINE MANAGEMENT SYSTEM |
251 |
| ABBREVIATIONS |
251 |
| AN OVERVIEW |
254 |
| 3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
| 3.11.1.1 ECU BLOCK DIAGRAM |
256 |
| 3.11.1.2 ECU PIN ASSIGNMENT DETAILS |
257 |
| 3.11.1.3 ECU HANDLING AND CARE |
258 |
| 3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
| 3.11.2 SENSORS |
260 |
| 3.11.2.1 CRANK SHAFT POSITION SENSOR |
260 |
| 3.11.2.2 COOLANT TEMPERATURE SENSOR |
261 |
| 3.11.2.3 T-MAP SENSOR |
263 |
| 3.11.2.4 KNOCK SENSOR |
264 |
| 3.11.2.5 THROTTLE POSITION SENSOR |
265 |
| 3.11.2.6 LAMBDA (OXYGEN) SENSOR |
268 |
| 3.11.2.7 VEHICLE SPEED SENSOR |
269 |
| 3.11.3 ACTUATORS |
271 |
| 3.11.3.1 CANISTER PURGE VALVE |
271 |
| 3.11.3.2 FUEL INJECTOR |
272 |
| 3.11.3.3 IGNITION COIL |
274 |
| 3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) |
277 |
| 3.11.3.5 COMPONENT FITMENT DATA |
279 |
| 3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
| 3.11.4.1 DTC LIST |
283 |
| 3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER |
293 |
| 3.11.4.3 BLINK CODE |
308 |
| 3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
| 3.11.5.1 REPAIRING STEPS |
310 |
| 3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
| 3.11.5.3 SENSOR AND ACTUATOR TESTING |
312 |
| 3.11.5.4 EMERGENCY SERVICE TIPS |
314 |
| 4. DRIVETRAIN |
315 |
| 4.1 CLUTCH |
321 |
| 4.1.1 GENERAL INFORMATION |
323 |
| 4.1.1.1 TECHNICAL SPECIFICATIONS |
323 |
| 4.1.1.2 CONSTRUCTION |
326 |
| 4.1.1.3 PRECAUTIONS |
328 |
| 4.1.1.4 TIGHTENING TORQUES |
329 |
| 4.1.1.5 SPECIAL TOOLS |
330 |
| 4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
| 4.1.1.7 TROUBLE SHOOTING |
334 |
| 4.1.1.8 MAINTENANCE AND REPAIR |
335 |
| A. PRELIMINARY INSPECTION |
335 |
| B. CLUTCH SLIPPAGE TEST |
335 |
| C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
| D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
| E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
| 4.1.2 OVERHAUL |
337 |
| EXPLODED VIEWS |
337 |
| A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
| B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
| C. CLUTCH CABLE REPLACEMENT |
344 |
| 4.2 TRANSAXLE TA-59 |
347 |
| 4.2.1 GENERAL INFORMATION |
349 |
| 4.2.1.1 TECHNICAL SPECIFICATION |
349 |
| 4.2.1.2 CONSTRUCTION |
349 |
| 4.2.1.3 PRECAUTIONS |
350 |
| 4.2.1.4 TIGHTENING TORQUES |
351 |
| 4.2.1.5 SPECIAL TOOLS |
354 |
| 4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
358 |
| 4.2.1.7 TRANSAXLE OIL REPLACEMENT |
359 |
| 4.2.2 OVERHAUL |
360 |
| 4.2.2.1 EXPLODED VIEWS |
360 |
| 4.2.2.2 COMPONENT IDENTIFICATION |
367 |
| 4.2.2.3 PRECAUTIONS |
369 |
| 4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE |
369 |
| 4.2.2.5 TRANSAXLE DISMANTLING |
372 |
| 4.2.2.6 INPUT SHAFT ASSEMBLY |
376 |
| 4.2.2.7 LAY SHAFT ASSEMBLY |
381 |
| 4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK |
387 |
| 4.2.2.9 DIFFERENTIAL ASSEMBLY |
390 |
| 4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY |
394 |
| 4.2.2.11 REAR HALF HOUSING ASSEMBLY |
400 |
| 4.2.2.12 FRONT HALF HOUSING |
402 |
| 4.2.2.13 TRANSAXLE ASSEMBLY |
404 |
| A. SHIM SELECTION |
404 |
| B. ASSEMBLING THE TRANSAXLE |
405 |
| 4.2.2.14 GEAR SHIFTER LINKAGE |
409 |
| A. GEAR SHIFTER CABLE REPLACEMENT |
409 |
| B. GEAR SHIFTER ADJUSTMENT |
410 |
| 4.3 DRIVESHAFT |
411 |
| 4.3.1 GENERAL INFORMATION |
413 |
| 4.3.1.1 TIGHTENING TORQUE |
413 |
| 4.3.1.2 SPECIAL TOOL |
414 |
| 4.3.1.3 CONSTRUCTIONAL DETAILS |
415 |
| 4.3.1.4 EXPLODED VIEW - DRIVESHAFT |
415 |
| 4.3.1.5 COMPONENT DESCRIPTION |
416 |
| 4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS |
417 |
| 4.3.2 ON VEHICLE REPAIRS |
418 |
| 4.3.2.1 PRECAUTIONS |
418 |
| 4.3.2.2 REMOVAL FROM VEHICLE |
420 |
| 4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
| 5. SUSPENSION SYSTEM |
429 |
| 5.1 GENERAL INFORMATION |
435 |
| 5.1.1 TECHNICAL SPECIFICATIONS |
435 |
| 5.1.2 TIGHTENING TORQUES |
436 |
| 5.1.3 SPECIAL TOOLS |
439 |
| 5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
| 5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
| 5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
| 5.1.7 TROUBLESHOOTING AND DIAGNOSIS |
446 |
| 5.2 ON VEHICLE REPAIRS |
449 |
| 5.2.1 FRONT SUSPENSION COMPONENTS |
449 |
| 5.2.1.1 STRUT |
449 |
| 5.2.1.2 ANTI-ROLL BAR |
455 |
| 5.2.1.3 LOWER ARM |
456 |
| 5.2.1.4 WHEEL BEARING |
458 |
| 5.2.2 REAR SUSPENSION COMPONENTS |
461 |
| 5.2.2.1 SHOCK ABSORBER |
462 |
| 5.2.2.2 COIL SPRING |
463 |
| 5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT |
464 |
| 5.2.2.4 SEMI TRAILING ARM |
465 |
| 5.2.3 WHEEL HUB AND WHEEL BEARING |
468 |
| 5.3 WHEELS AND TYRES |
473 |
| 5.3.1 GENERAL INFORMATION |
473 |
| 5.3.1.1 TECHNICAL SPECIFICATIONS |
473 |
| 5.3.1.2 TIGHTENING TORQUE |
474 |
| 5.3.1.3 EXPLODED VIEW |
475 |
| 5.3.1.4 MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
| 5.3.2 ON VEHICLE REPAIRS |
477 |
| 5.3.2.1 WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
| 5.3.2.2 WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
| 5.3.2.3 WHEEL BALANCING |
480 |
| 5.3.2.4 WHEEL RUNOUT |
481 |
| 5.3.2.5 TYRE REPLACEMENT |
482 |
| 5.3.2.6 WHEEL ASSEMBLY REPLACEMENT |
483 |
| 5.3.2.7 REPAIRING TUBELESS TYRE PUNCTURE |
483 |
| 5.3.2.8 TYRE DIAGNOSIS |
484 |
| 6. BRAKE SYSTEM |
493 |
| 6.1 GENERAL INFORMATION |
499 |
| 6.1.1 TECHNICAL SPECIFICATIONS |
499 |
| 6.1.2 TIGHTENING TORQUES |
500 |
| 6.1.3 SPECIAL TOOLS |
504 |
| 6.1.4 SCHEMATIC OF BRAKE HYDRAULIC SYSTEM |
505 |
| 6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
| 6.2.1 FRONT DRUM BRAKES |
507 |
| 6.2.2 REAR DRUM BRAKES |
508 |
| 6.2.3 AUTO INCREMENTAL BRAKE |
509 |
| 6.2.4 TANDEM MASTER CYLINDER (TMC) |
510 |
| 6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
| 6.2.6 WHEEL CYLINDER |
514 |
| 6.2.7 PARKING BRAKES |
515 |
| 6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
| 6.3.1 BLEEDING OF HYDRAULIC SYSTEM |
521 |
| 6.3.2 TROUBLESHOOTING AND DIAGNOSIS |
523 |
| 6.4 ON VEHICLE REPAIRS |
530 |
| 6.4.1 FRONT BRAKE COMPONENTS |
531 |
| 6.4.2 FRONT BRAKE DRUM |
532 |
| 6.4.3 FRONT BRAKE SHOES |
534 |
| 6.4.4 FRONT BRAKE BACK PLATE |
539 |
| 6.4.5 REAR BRAKE COMPONENTS |
540 |
| 6.4.6 REAR BRAKE DRUM |
541 |
| 6.4.7 REAR BRAKE SHOES |
542 |
| 6.4.8 REAR BRAKE BACK PLATE |
544 |
| 6.4.9 TMC |
546 |
| 6.4.10 WHEEL CYLINDER |
555 |
| 6.4.11 PARKING BRAKES |
561 |
| 6.4.12 VACUUM BRAKE BOOSTER |
564 |
| 6.4.13 BRAKE HOSES/PIPES SCHEMATIC |
565 |
| 6.4.14 VACUUM LINES |
567 |
| 7. STEERING |
1302 |
| 7.1 GENERAL INFORMATION |
1307 |
| 7.1.1 SPECIFICATIONS |
1307 |
| 7.1.2 SYSTEM LAYOUT |
1307 |
| 7.1.3 GENERAL DESCRIPTION |
1308 |
| 7.1.4 TIGHTENING TORQUES |
1309 |
| 7.1.5 SPECIAL TOOLS |
1311 |
| 7.2. MAINTENANCE, INSPECTION AND TEST |
1312 |
| 7.2.1 PRELIMINARY INSPECTION |
1312 |
| 7.2.2 REGULAR MAINTENANCE |
1313 |
| 7.2.3 ON VEHICLE REPAIRS |
1315 |
| 7.2.3.1 STEERING WHEEL REMOVAL |
1315 |
| 7.2.3.2 STEERING COLUMN REMOVAL |
1316 |
| 7.2.3.3 INTERMEDIATE SHAFT REMOVAL |
1317 |
| 7.2.3.4 ECU REMOVAL |
1318 |
| 7.2.3.5 RACK & PINION ASSEMBLY REMOVAL |
1319 |
| 7.3. OVERHAULING |
1321 |
| 7.3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
1321 |
| 7.3.2 PRECAUTIONS |
1322 |
| 7.3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
1322 |
| 7.3.3.1 DISASSEMBLY OF RACK & PINON |
1322 |
| 7.3.3.2 INSPECTION OF DISMANTLED PARTS |
1323 |
| 7.3.3.3 ASSEMBLY OF RACK & PINON |
1324 |
| 7.3.3.4 OBJ ON-VEHICLE REMOVAL |
1325 |
| 7.3.3.5 DO’S & DON’TS |
1326 |
| 7.3.3.6 WHEEL ALIGNMENT |
1326 |
| 7.3.4 TROUBLESHOOTING AND DIAGNOSIS |
1328 |
| 8. ELECTRICAL |
1334 |
| 8.1. TECHNICAL SPECIFICATION |
1340 |
| 8.2. INSTRUMENT CLUSTER |
1342 |
| 8.2.1. ART WORK |
1342 |
| 8.2.2. TELL TALES |
1342 |
| 8.2.3. SPECIFICATION |
1343 |
| 8.2.4. CONNECTION DETAILS |
1343 |
| 8.2.5. CONNECTOR DETAILS |
1343 |
| 8.2.6. PINOUT DETAILS |
1343 |
| 8.2.7 FREQUENTLY ASKED QUESTIONSDistance to Empty (DTE) |
1344 |
| 8.2.8 SEASON ODOMETER WRITING /UPDATING PROCEDURE |
1346 |
| 8.3. EPAS ECU |
1347 |
| 8.3.1. SPECIFICATION |
1347 |
| 8.3.2. LOCATION |
1347 |
| 8.3.3. CONNECTION DETAILS |
1348 |
| 8.3.4. PINOUT DETAILS |
1348 |
| 8.4. FUSEBOX & RELAY DETAILS |
1349 |
| 8.4.1 LOCATION OF FUSE / RELAY / CONTROLLERS ON VEHICLE |
1349 |
| 8.4.2. BATTERY MOUNTED FUSE BOX DETAILS (FOR NANO CNG AND MY13) |
1349 |
| 8.4.3. CABIN FUSE BOX DETAILS(NANO MY13 EPAS) |
1350 |
| 8.4.4. RELAY BOX DETAILS (FOR NANO CNG AND MY13) |
1352 |
| 8.4.5. DIAGNOSTIC CONNECTOR LOCATION |
1352 |
| 8.4.6 ECU AND STEERING COLUMN PAIRING PROCESS |
1353 |
| 8.5 DIAGNOSTIC USER MANUAL |
1354 |
| 8.6 DIAGNOSTIC TROUBLE CODES - EPAS |
1364 |
| 8.7 DIAGNOSTIC TROUBLE CODES – EMS ECU |
1371 |
| 9. BODY |
721 |
| 9.1 GENERAL INFORMATION |
727 |
| 9.1.1 TECHNICAL SPECIFICATIONS |
727 |
| 9.1.2 TIGHTENING TORQUE |
728 |
| 9.2 ON VEHICLE REPAIRS |
732 |
| 9.2.1 EXPLODED VIEW - BUMPERS & HOOD |
732 |
| 9.2.2 FRONT BUMPER |
733 |
| 9.2.3 FENDER (SIDE BONNET) |
734 |
| 9.2.4 HOOD, HOOD LATCH, HOOD LATCH CABLE AND HOOD STRIKER |
735 |
| 9.2.5 FRONT DOOR |
739 |
| 9.2.6 REAR DOOR |
750 |
| 9.2.7 REAR SHELF |
759 |
| 9.2.8 TAILGATE |
759 |
| 9.2.9 REAR BUMPER |
760 |
| 9.2.10 DASHBOARD |
762 |
| 9.2.11 CENTER CONSOLE |
765 |
| 9.2.12 SEATS & BELTS |
766 |
| 9.2.13 OUTER REAR VIEW MIRROR (ORVM) |
776 |
| 9.2.14 SUN VISOR |
776 |
| 9.2.15 TRIMS |
777 |
| 9.2.16 FLOOR CARPET |
778 |
| 9.2.17 WINDSHIELD |
781 |
| 9.3 PAINT CARE |
783 |
| 9.4 BODY REPAIR DATA |
786 |
| 9.5 TROUBLESHOOTING AND DIAGNOSIS |
791 |
| 10. HVAC |
793 |
| 10.1 GENERAL INFORMATION |
799 |
| 10.1.1 TECHNICAL SPECIFICATIONS |
799 |
| 10.1.2 TIGHTENING TORQUES |
800 |
| 10.1.3 GENERAL PRECAUTIONS |
802 |
| 10.1.4 SYSTEM LAYOUTS |
804 |
| 10.1.5 COMPONENT DESCRIPTION |
808 |
| 10.2 MAINTENANCE OF AC/HVAC SYSTEM |
811 |
| 10.2.1 TROUBLESHOOTING AND DIAGNOSIS |
812 |
| 10.2.2 PRESSURE TEST USING MANIFOLD GAUGES |
825 |
| 10.2.3 FLUSHING OF AC SYSTEM |
830 |
| 10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
832 |
| 10.2.5 A/C SYSTEM PERFORMANCE TEST |
834 |
| 10.2.6 LEAK TEST SYSTEM |
834 |
| 10.3 ON VEHICLE REPAIRS |
835 |
| 10.3.1 CONTROL PANEL ASSEMBLY |
836 |
| 10.3.2 A/C COMPRESSOR |
837 |
| 10.3.3 HVAC UNIT |
848 |
| 10.3.4 BLOWER UNIT |
852 |
| 10.3.5 BLOWER RESISTER |
852 |
| 10.3.6 FILTER |
853 |
| 10.3.7 EVAPORATOR AND EXPANSION VALVE |
854 |
| 10.3.8 HEATER ASSEMBLY |
856 |
| 10.3.9 KINEMATICS |
857 |
| 10.3.10 PRESSURE SWITCH |
857 |
| 10.3.11 CONDENSER ASSEMBLY |
858 |
| 10.3.12 DRIER CARTRIDGE/R.D. BOTTLE |
860 |
| 10.3.13 CONDENSER FAN AND CONDENSER MOTOR |
862 |
| 10.3.14 REFRIGERANT LINES |
863 |
| 10.3.15 HEATER LINES |
865 |
| NANO OTG |
1383 |
| 1. GENERAL |
1387 |
| 1.1 TECHNICAL SPECIFICATION |
1391 |
| 1.2 FUEL, LUBRICANTS AND COOLANTS |
1393 |
| 1.3 SERVICE SCHEDULE |
1394 |
| 2. PRECAUTIONS |
35 |
| 2.1 GENERAL SAFETY PRECAUTIONS |
41 |
| 2.2 GENERAL SERVICE PRECAUTIONS |
45 |
| 3. ENGINE |
47 |
| 3.1 GENERAL INFORMATION |
55 |
| 3.1.1 TECHNICAL SPECIFICATIONS |
57 |
| 3.1.2 FEATURES OF 273 MPFI ENGINE |
58 |
| 3.1.3 TIGHTENING TORQUE |
59 |
| 3.1.4 SPECIAL TOOLS & EQUIPMENTS |
61 |
| 3.1.5 GENERAL SYMPTOMS & DIAGNOSTICS |
65 |
| 3.2 ON VEHICLE PROCEDURES |
69 |
| 3.2.1 IMPORTANT ON VEHICLE MAINTENANCE PROCEDURES |
71 |
| 3.2.2 ENGINE OIL REPLACEMENT |
73 |
| 3.2.3 OIL FILTER REPLACEMENT |
74 |
| 3.2.4 AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
75 |
| 3.2.5 FUEL FILTER REPLACEMENT |
76 |
| 3.2.6 TAPPET SETTING |
77 |
| 3.2.7 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE |
78 |
| 3.2.8 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE |
79 |
| 3.2.9 TIMING BELT - REMOVAL & REFITMENT PROCEDURE |
81 |
| 3.2.10 CYLINDER HEAD - REMOVAL & REFITMENT PROCEDURE |
86 |
| 3.2.11 COMPRESSION PRESSURE CHECKING PROCEDURE |
89 |
| 3.3 ENGINE MECHANICAL |
91 |
| PRELIMINARY INSPECTION OF ENGINE |
93 |
| REMOVAL OF ENGINE FROM VEHICLE |
95 |
| 3.3.1 CYLINDER HEAD |
99 |
| 3.3.1.1 GENERAL DESCRIPTION |
101 |
| 3.3.1.2 EXPLODED VIEW |
102 |
| 3.3.1.3 CYLINDER HEAD OVERHAUL |
104 |
| 3.3.1.4 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK |
104 |
| 3.3.1.5 DISMANTLING OF CYLINDER HEAD SUBASSEMBLIES |
108 |
| 3.3.1.6 INSPECTION & REPAIR DATA |
111 |
| 3.3.1.7 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
118 |
| 3.3.2 ENGINE BLOCK |
123 |
| 3.3.2.1 GENERAL DESCRIPTION |
125 |
| 3.3.2.2 EXPLODED VIEW |
126 |
| 3.3.2.3 ENGINE BLOCK OVERHAUL |
128 |
| 3.3.2.4 DISMANTLING OF ENGINE BLOCK SUBASSEMBLIES |
128 |
| 3.3.2.5 INSPECTION & REPAIR DATA |
133 |
| 3.3.2.6 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES |
143 |
| 3.3.2.7 REFITMENT OF ENGINE ACCESSORIES |
156 |
| 3.3.2.8 ENGINE TESTING |
158 |
| 3.3.2.9 INSTALLATION OF ENGINE ON VEHICLE |
158 |
| 3.4 ACCELERATOR |
159 |
| 3.4.1 EXPLODED VIEWS & CABLE ROUTING |
161 |
| 3.4.2 SYSTEM MAINTENANCE |
163 |
| 3.5 COOLING SYSTEM |
167 |
| 3.5.1 GENERAL DESCRIPTION |
169 |
| 3.5.2 SYSTEM SCHEMATICS |
169 |
| 3.5.3 EXPLODED VIEWS |
170 |
| 3.5.4 SPECIFICATIONS |
172 |
| 3.5.5 SYSTEM COMPONENTS |
173 |
| 3.5.6 SYSTEM MAINTENANCE |
174 |
| 3.6 LUBRICATION SYSTEM |
183 |
| 3.6.1 GENERAL DESCRIPTION |
185 |
| 3.6.2 SYSTEM SCHEMATICS |
185 |
| 3.6.3 SPECIFICATIONS |
186 |
| 3.6.4 SYSTEM MAINTENANCE |
187 |
| 3.7 FUEL SYSTEM |
199 |
| 3.7.1 GENERAL DESCRIPTION |
201 |
| 3.7.2 SYSTEM SCHEMATICS |
201 |
| 3.7.3 EXPLODED VIEWS |
202 |
| 3.7.4 PRECAUTIONS, SPECIFICATIONS AND TIGHTENING TORQUE |
203 |
| 3.7.5 SYSTEM COMPONENTS |
204 |
| 3.7.6 SYSTEM MAINTENANCE |
208 |
| 3.7.7 EVAPORATIVE EMISSION CONTROL SYSTEM |
218 |
| 3.8 INTAKE SYSTEM |
221 |
| 3.8.1 GENERAL DESCRIPTION |
223 |
| 3.8.2 EXPLODED VIEWS |
224 |
| 3.8.3 SYSTEM MAINTENANCE |
225 |
| 3.9 EXHAUST SYSTEM |
231 |
| 3.9.1 GENERAL DESCRIPTION |
233 |
| 3.9.2 EXPLODED VIEWS |
234 |
| 3.9.3 TIGHTENING TORQUE |
235 |
| 3.9.4 SYSTEM COMPONENTS |
236 |
| 3.9.5 SYSTEM MAINTENANCE |
238 |
| 3.10 IGNITION SYSTEM |
243 |
| 3.10.1 GENERAL DESCRIPTION |
245 |
| 3.10.2 SYSTEM SCHEMATICS |
245 |
| 3.10.3 SYSTEM MAINTENANCE |
246 |
| 3.11 ENGINE MANAGEMENT SYSTEM |
251 |
| ABBREVIATIONS |
253 |
| AN OVERVIEW |
254 |
| 3.11.1 ECU (ELECTRONIC CONTROL UNIT) |
255 |
| 3.11.1.1 ECU BLOCK DIAGRAM |
256 |
| 3.11.1.2 ECU PIN ASSIGNMENT DETAILS |
257 |
| 3.11.1.3 ECU HANDLING AND CARE |
258 |
| 3.11.1.4 ECU ON VEHICLE REMOVAL, INSPECTION AND REFITMENT PROCEDURE |
259 |
| 3.11.2 SENSORS |
260 |
| 3.11.2.1 CRANK SHAFT POSITION SENSOR |
260 |
| 3.11.2.2 COOLANT TEMPERATURE SENSOR |
261 |
| 3.11.2.3 TMAP SENSOR |
263 |
| 3.11.2.4 KNOCK SENSOR |
264 |
| 3.11.2.5 THROTTLE POSITION SENSOR |
265 |
| 3.11.2.6 LAMBDA (OXYGEN) SENSOR |
268 |
| 3.11.2.7 VEHICLE SPEED SENSOR |
269 |
| 3.11.3 ACTUATORS |
271 |
| 3.11.3.1 CANISTER PURGE VALVE |
271 |
| 3.11.3.2 FUEL INJECTOR |
272 |
| 3.11.3.3 IGNITION COIL |
274 |
| 3.11.3.4 INTAKE AIR CONTROL VALVE (IACV) |
277 |
| 3.11.3.5 COMPONENT FITMENT DATA |
279 |
| 3.11.4 DTC (DIAGNOSTIC TROUBLE CODE) |
283 |
| 3.11.4.1 DTC LIST |
283 |
| 3.11.4.2 LAPTOP BASED DIAGNOSTIC TESTER |
293 |
| 3.11.4.3 BLINK CODE |
308 |
| 3.11.5 TROUBLE SHOOTING AND DIAGNOSIS |
310 |
| 3.11.5.1 REPAIRING STEPS |
310 |
| 3.11.5.2 VEHICLE TROUBLE SHOOTING FLOW CHART |
311 |
| 3.11.5.3 SENSOR AND ACTUATOR TESTING |
312 |
| 3.11.5.4 EMERGENCY SERVICE TIPS |
314 |
| 4. DRIVETRAIN |
315 |
| 4.1 CLUTCH |
321 |
| 4.1.1 GENERAL INFORMATION |
323 |
| 4.1.1.1 TECHNICAL SPECIFICATIONS |
323 |
| 4.1.1.2 CONSTRUCTION |
326 |
| 4.1.1.3 PRECAUTIONS |
328 |
| 4.1.1.4 TIGHTENING TORQUES |
329 |
| 4.1.1.5 SPECIAL TOOLS |
330 |
| 4.1.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
331 |
| 4.1.1.7 TROUBLE SHOOTING |
334 |
| 4.1.1.8 MAINTENANCE AND REPAIR |
335 |
| A. PRELIMINARY INSPECTION |
335 |
| B. CLUTCH SLIPPAGE TEST |
335 |
| C. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST |
335 |
| D. CLUTCH PEDAL PLAY ADJUSTMENT |
335 |
| E. CLUTCH PEDAL FREE PLAY ADJUSTMENT |
336 |
| 4.1.2 OVERHAUL |
337 |
| EXPLODED VIEWS |
337 |
| A. REPLACEMENT OF CLUTCH DISC AND CLUTCH COVER |
340 |
| B. CLUTCH ACTUATION MECHANISM OVERHAUL |
341 |
| C. CLUTCH CABLE REPLACEMENT |
344 |
| 4.2 TRANSAXLE TA-59 |
347 |
| 4.2.1 GENERAL INFORMATION |
349 |
| 4.2.1.1 TECHNICAL SPECIFICATION |
349 |
| 4.2.1.2 CONSTRUCTION |
349 |
| 4.2.1.3 PRECAUTIONS |
350 |
| 4.2.1.4 TIGHTENING TORQUES |
351 |
| 4.2.1.5 SPECIAL TOOLS |
354 |
| 4.2.1.6 GENERAL SYMPTOMS AND DIAGNOSIS |
358 |
| 4.2.1.7 TRANSAXLE OIL REPLACEMENT |
359 |
| 4.2.2 OVERHAUL |
360 |
| 4.2.2.1 EXPLODED VIEWS |
360 |
| 4.2.2.2 COMPONENT IDENTIFICATION |
367 |
| 4.2.2.3 PRECAUTIONS |
369 |
| 4.2.2.4 REMOVAL OF TRANSAXLE FROM VEHICLE |
369 |
| 4.2.2.5 TRANSAXLE DISMANTLING |
372 |
| 4.2.2.6 INPUT SHAFT ASSEMBLY |
376 |
| 4.2.2.7 LAY SHAFT ASSEMBLY |
381 |
| 4.2.2.8 SHIFTER SHAFT AND SHIFTER FORK |
387 |
| 4.2.2.9 DIFFERENTIAL ASSEMBLY |
390 |
| 4.2.2.10 REAR HALF HOUSING TOP COVER ASSEMBLY |
394 |
| 4.2.2.11 REAR HALF HOUSING ASSEMBLY |
400 |
| 4.2.2.12 FRONT HALF HOUSING |
402 |
| 4.2.2.13 TRANSAXLE ASSEMBLY |
404 |
| A. SHIM SELECTION |
404 |
| B. ASSEMBLING THE TRANSAXLE |
405 |
| 4.2.2.14 GEAR SHIFTER LINKAGE |
409 |
| A. GEAR SHIFTER CABLE REPLACEMENT |
409 |
| B. GEAR SHIFTER ADJUSTMENT |
410 |
| 4.3 DRIVESHAFT |
411 |
| 4.3.1 GENERAL INFORMATION |
413 |
| 4.3.1.1 TIGHTENING TORQUE |
413 |
| 4.3.1.2 SPECIAL TOOL |
414 |
| 4.3.1.3 CONSTRUCTIONAL DETAILS |
415 |
| 4.3.1.4 EXPLODED VIEW - DRIVESHAFT |
415 |
| 4.3.1.5 COMPONENT DESCRIPTION |
416 |
| 4.3.1.6 TROUBLESHOOTING AND DIAGNOSIS |
417 |
| 4.3.2 ON VEHICLE REPAIRS |
418 |
| 4.3.2.1 PRECAUTIONS |
418 |
| 4.3.2.2 REMOVAL FROM VEHICLE |
420 |
| 4.3.2.3 DRIVESHAFT DISMANTLING / ASSEMBLY |
423 |
| 5. SUSPENSION SYSTEM |
429 |
| 5.1 GENERAL INFORMATION |
435 |
| 5.1.1 TECHNICAL SPECIFICATIONS |
435 |
| 5.1.2 TIGHTENING TORQUES |
436 |
| 5.1.3 SPECIAL TOOLS |
439 |
| 5.1.4 LAY OUT OF FRONT SUSPENSION SYSTEM |
441 |
| 5.1.5 LAY OUT OF REAR SUSPENSION SYSTEM |
442 |
| 5.1.6 MAINTENANCE AND INSPECTION OF SUSPENSION SYSTEM |
443 |
| 5.1.7 TROUBLESHOOTING AND DIAGNOSIS |
446 |
| 5.2 ON VEHICLE REPAIRS |
449 |
| 5.2.1 FRONT SUSPENSION COMPONENTS |
449 |
| 5.2.1.1 STRUT |
449 |
| 5.2.1.2 ANTI-ROLL BAR |
455 |
| 5.2.1.3 LOWER ARM |
456 |
| 5.2.1.4 WHEEL BEARING |
458 |
| 5.2.2 REAR SUSPENSION COMPONENTS |
461 |
| 5.2.2.1 SHOCK ABSORBER |
462 |
| 5.2.2.2 COIL SPRING |
463 |
| 5.2.2.3 BUMP STOPPER AND SPRING UPPER SEAT |
464 |
| 5.2.2.4 SEMI TRAILING ARM |
465 |
| 5.2.3 WHEEL HUB AND WHEEL BEARING |
468 |
| 5.3 WHEELS AND TYRES |
473 |
| 5.3.1 GENERAL INFORMATION |
473 |
| TECHNICAL SPECIFICATIONS |
473 |
| TIGHTENING TORQUE |
474 |
| EXPLODED VIEW |
475 |
| MAINTENANCE AND INSPECTION OF TYRE/WHEEL ASSEMBLY |
476 |
| 5.3.2 ON VEHICLE REPAIRS |
477 |
| WHEEL REMOVAL FROM VEHICLE (ON HOIST) |
478 |
| WHEEL REMOVAL FROM VEHICLE (WITH JACK) |
479 |
| WHEEL BALANCING |
480 |
| WHEEL RUNOUT |
481 |
| TYRE REPLACEMENT |
482 |
| WHEEL ASSEMBLY REPLACEMENT |
483 |
| REPAIRING TUBELESS TYRE PUNCTURE |
483 |
| TYRE DIAGNOSIS |
484 |
| 6. BRAKE SYSTEM |
493 |
| 6.1 GENERAL INFORMATION |
499 |
| 6.1.1 TECHNICAL SPECIFICATIONS |
499 |
| 6.1.2 TIGHTENING TORQUES |
500 |
| 6.1.3 SPECIAL TOOLS |
504 |
| 6.1.4 BRAKE CIRCUIT |
1427 |
| 6.2 COMPONENT DESCRIPTION OF BRAKE SYSTEM |
507 |
| 6.2.1 FRONT DRUM BRAKES |
507 |
| 6.2.2 REAR DRUM BRAKES |
508 |
| 6.2.3 AUTO INCREMENTAL BRAKE |
509 |
| 6.2.4 TANDEM MASTER CYLINDER (TMC) |
510 |
| 6.2.5 TMC WITH VACUUM BOOSTER ASSEMBLY |
511 |
| 6.2.6 WHEEL CYLINDER |
514 |
| 6.2.7 PARKING BRAKES |
515 |
| 6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTION |
516 |
| 6.3.1 BLEEDING OF HYDRAULIC SYSTEM |
521 |
| 6.3.2 TROUBLESHOOTING AND DIAGNOSIS |
523 |
| 6.4 ON VEHICLE REPAIRS |
530 |
| 6.4.1 FRONT BRAKE COMPONENTS |
531 |
| 6.4.2 FRONT BRAKE DRUM |
532 |
| 6.4.3 FRONT BRAKE SHOES |
534 |
| 6.4.4 FRONT BRAKE BACK PLATE |
539 |
| 6.4.5 REAR BRAKE COMPONENTS |
540 |
| 6.4.6 REAR BRAKE DRUM |
541 |
| 6.4.7 REAR BRAKE SHOES |
542 |
| 6.4.8 REAR BRAKE BACK PLATE |
544 |
| 6.4.9 TMC |
546 |
| 6.4.10 WHEEL CYLINDER |
555 |
| 6.4.11 PARKING BRAKES |
561 |
| 6.4.12 VACUUM BRAKE BOOSTER |
564 |
| 6.4.13 BRAKE HOSES/PIPES SCHEMATIC |
565 |
| 6.4.14 VACUUM LINES |
567 |
| 7. STEERING |
569 |
| 7.1 GENERAL INFORMATION |
575 |
| 7.1.1 TECHNICAL SPECIFICATIONS |
575 |
| 7.1.2 TIGHTENING TORQUES |
576 |
| 7.1.3 SPECIAL TOOLS |
578 |
| 7.1.4 EXPLODED VIEWS |
579 |
| 7.1.5 SCHEMATIC OF STEERING SYSTEM |
581 |
| 7.2 MAINTENANCE AND INSPECTION OF STEERING SYSTEM |
583 |
| 7.3 ON VEHICLE REPAIRS |
584 |
| 7.3.1 STEERING WHEEL |
586 |
| 7.3.2 STEERING COLUMN ASSEMBLY |
587 |
| 7.3.3 STEERING UPPER COLUMN |
589 |
| 7.3.4 INTERMEDIATE SHAFT |
589 |
| 7.3.5 STEERING RACK AND PINION ASSEMBLY |
590 |
| 7.3.6 OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
592 |
| 7.3.7 WHEEL ALIGNMENT |
601 |
| 7.3.8 TROUBLESHOOTING AND DIAGNOSIS |
603 |
| 8. ELECTRICAL |
607 |
| 8.1 TECHNICAL SPECIFICATION |
613 |
| 8.2 GENERAL PRECAUTIONS |
614 |
| 8.3 BATTERY |
617 |
| 8.4 ALTERNATOR |
620 |
| 8.5 STARTER MOTOR |
641 |
| 8.6 LIGHTING SYSTEM |
659 |
| 8.7 HORN |
675 |
| 8.8 WIPER SYSTEM |
677 |
| 8.9 FLASHER |
686 |
| 8.10 FOG LAMP CONTROLLER |
687 |
| 8.11 BRAKE LAMP CHECK |
689 |
| 8.12 POWER SOCKET |
689 |
| 8.13 CIGARETTE LIGHTER (IF EQUIPPED) |
690 |
| 8.14 CENTRAL DOOR LOCKING |
691 |
| 8.15 POWER WINDOW SYSTEM |
694 |
| 8.16 INSTRUMENT CLUSTER |
697 |
| 8.17 ELECTRICAL SWITCHES |
700 |
| 8.18 ACCESSORY CONNECTORS |
710 |
| 8.19 FUSE BOX/RELAY LOCATION & DETAILS |
715 |
| 8.20 ELECTRIC WIRING AND FITMENT SCHEMATICS |
716 |
| 8.20.1 HARNESS & CONNECTOR DESCRIPTION |
716 |
| 8.20.2 UNDERSTANDING THE CIRCUIT SCHEMATIC |
718 |
| 8.20.3 CONNECTOR CODE/PIN NO./CONNECTOR LAYOUT |
719 |
| 8.20.4 ELECTRICAL SYMBOLS |
720 |
| 9. BODY |
1397 |
| 9.1 TIGHTENING TORQUES |
1401 |
| 9.2 FRONT BUMPER REMOVAL AND REFITMENT |
1402 |
| 9.3 REAR BUMPER REMOVAL AND REFITMENT |
1403 |
| 9.4 TAILGATE REMOVAL AND REFITMENT |
1404 |
| 9.5 TAIL LAMP ASSEMBLY REMOVAL ANDREFITMENT |
1407 |
| 9.6 FRONT FOG LAMP REMOVAL AND REFITMENT |
1408 |
| 9.7 LIGHT STALK REMOVAL AND REFITMENT |
1409 |
| 9.8 COMBINATION SWITCH REMOVAL AND REFITMENT |
1411 |
| 10. HVAC |
793 |
| 10.1 GENERAL INFORMATION |
799 |
| 10.1.1 TECHNICAL SPECIFICATIONS |
799 |
| 10.1.2 TIGHTENING TORQUES |
800 |
| 10.1.3 GENERAL PRECAUTIONS |
802 |
| 10.1.4 SYSTEM LAYOUTS |
804 |
| 10.1.5 COMPONENT DESCRIPTION |
808 |
| 10.2 MAINTENANCE OF AC/HVAC SYSTEM |
811 |
| 10.2.1 TROUBLESHOOTING AND DIAGNOSIS |
812 |
| 10.2.2 PRESSURE TEST USING MANIFOLD GAUGES |
825 |
| 10.2.3 FLUSHING OF AC SYSTEM |
830 |
| 10.2.4 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
832 |
| 10.2.5 A/C SYSTEM PERFORMANCE TEST |
834 |
| 10.2.6 LEAK TEST SYSTEM |
834 |
| 10.3 ON VEHICLE REPAIRS |
835 |
| 10.3.1 CONTROL PANEL ASSEMBLY |
836 |
| 10.3.2 A/C COMPRESSOR |
837 |
| 10.3.3 HVAC UNIT |
848 |
| 10.3.4 BLOWER UNIT |
852 |
| 10.3.5 BLOWER RESISTER |
852 |
| 10.3.6 FILTER |
853 |
| 10.3.7 EVAPORATOR AND EXPANSION VALVE |
854 |
| 10.3.8 HEATER ASSEMBLY |
856 |
| 10.3.9 KINEMATICS |
857 |
| 10.3.10 PRESSURE SWITCH |
857 |
| 10.3.11 CONDENSER ASSEMBLY |
858 |
| 10.3.12 DRIER CARTRIDGE/R.D. BOTTLE |
860 |
| 10.3.13 CONDENSER FAN AND CONDENSER MOTOR |
862 |
| 10.3.14 REFRIGERANT LINES |
863 |
| 10.3.15 HEATER LINES |
865 |
| 11. FUEL SYSTEM |
1415 |
| 11.1 INTRODUCTION |
1419 |
| 11.2 PRECAUTIONS |
1419 |
| 11.3 SPECIFICATIONS |
1419 |
| 11.4 TIGHTENING TORQUE |
1420 |
| 11.5 FUEL TANK UNIT REMOVAL AND REFITMENT |
1421 |
| 11.6 FUEL TANK REMOVAL AND REFITMENT |
1422 |