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HARRIER BSVI MCE - SERVICE MANUAL

HARRIER BS VI - Service Manual 1
KRYOTEC ENGINE 6
TABLE OF CONTENTS 7
1. GENERAL INFORMATION 9
A. ENGINE INTRODUCTION 9
B. TECHNICAL SPECIFICATION 10
C. ASSEMBLY CLEARANCES 11
D. LEAKAGE RATES 14
2. TROUBLESHOOTING 18
3. CONSTRUCTIONAL AND SERVICE DETAILS 26
4. EXPLODED VIEW 31
5. ENGINE TESTS AND DIAGNOSIS 71
A. ENGINE TESTS 71
B. REGULAR MAINTENANCE 75
i. ENGINE OIL AND FILTER CHANGE 75
ii. ENGINE COOLANT REPLACEMENT 76
iii. AIR FILTER ELEMENT REPLACEMENT 77
iv. FUEL FILTER REPLACEMENT 78
v. DRAINING WATER FROM FUEL FILTER 79
vi. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT 80
vii. DIESEL PARTICULATE FILTER (DPF) REGENERATION / CLEANING 81
viii. HYDROSTATIC LOCKED ENGINE 81
ix. CHECKING ENGINE OIL PRESSURE 82
6. REPAIR AND INSPECTION DETAILS 83
A. TIMING BELT 83
B. FUEL TANK 84
C. CYLINDER HEAD 85
D. CYLINDER HEAD GASKET 86
E. VALVE SPRING 87
F. CYLINDER BORE DEGLAZING 88
G. MEASURING BEARING CLEARANCE USING PLASTIGAGE 89
82H. EXHAUST PIPE 90
7. ENGINE ON VEHICLE SERVICE 91
A. ENGINE REMOVAL 91
B. ENGINE FITMENT 96
C. CYLINDER HEAD 98
E. BALANCE SHAFT 106
F. VIBRATION DAMPER 108
G. OIL COOLER 109
H. ENGINE OIL FILTER 111
I. OIL PAN 112
J. DIESEL WARNING LIGHT 114
K. DIESEL HIGH PRESSURE 116
L. ENGINE OIL PUMP 117
M. OIL PRESSURE REGULATOR 118
N. EXHAUST MANIFOLD 119
O. INTAKE MANIFOLD 120
P. EXHAUST SYSTEM 125
Q. FUEL SYSTEM 137
8. ENGINE ON STAND 146
A. CLUTCH 146
B. ENGINE - POSITION ON STAND AND REMOVE 148
C. ENGINE (MANUAL TRANSMISSION) SEPARATION AND REASSEMBLY 149
D. DISASSEMBLY AND REASSEMBLY FOLLOWING INSPECTION 154
E. CYLINDER HEAD AND OIL PAN FOR INSPECTION 169
F. CYLINDER HEAD 177
G. CAMSHAFT 181
H. PISTON 184
C635 TRANSAXLE 186
1. TECHNICAL SPECIFICATION 188
2. PRECAUTIONS 188
3. COMMON PROBLEM CAUSES OR PRE-DIAGNOSTIC INSPECTION 189
4. TIGHTENING TORQUES 195
5. SPECIAL TOOLS 201
6. DISASSEMBLY OF TRANSAXLE FROM VEHICLE 204
7. ASSEMLY OF TRANSAXLE ON VEHICLE 207
8. FLUID 211
9. TRANSAXLE DISASSEMBLY ON BENCH 212
10. TRANSAXLE ASSEMBLY ON BENCH 217
11. DIFFERENTIAL BEARING REMOVAL 223
12. DIFFERENTIAL BEARING ASSEMBLY 223
13. DISASSEMBLY GEARSHIFT CONTROL CABLE 224
14. ASSEMBLY GEARSHIFT CONTROL CABLE 226
15. REMOVAL GEARSHIFT MECHANISM 230
16. ASSEMBLY GEARSHIFT MECHANISM 232
17. ASSEMBLY DIFFERENTIAL OIL SEAL 232
18. INPUT SHAFT DISASSEMBLY 233
19. INPUT SHAFT ASSEMBLY 234
20. DISASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th) 236
21. ASSEMBLY OF OUTPUT SHAFT1 (1st ,2nd ,5th and 6th) 238
22. DISASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.) 242
23. ASSEMBLY OF OUTPUT SHAFT2 (3RD, 4th and REV.) 244
24. REMOVAL BACKUP (REVERSE) LAMP SWITCH 247
25. ASSEMBLY BACKUP (REVERSE) LAMP SWITCH 248
DRIVESHAFT 249
1.1. GENERAL INFORMATION 251
1.2. GENERAL GUIDELINES FOR TESTING 252
1.3. DRIVE SHAFT PARTS 253
1.4. TIGHTENING TORQUES 254
1.5. SPECIAL TOOL 256
1.6 ON BENCH PROCEDURE 257
1.7 ON VEHICLE PROCEDURE 259
A. DRIVE SHAFT LH REMOVAL 259
B. RH DRIVE SHAFT REMOVAL 263
6F33 TRANSAXLE 267
1. TECHNICAL SPECIFICATIONS 269
2. TIGHTENING TORQUE 273
73. SPECIAL TOOLS 275
4. GENERAL INFORMATION 276
5. COMPONENTS (FOR INFORMATION) 277
6. DETAIL OF A/T COMPONENTS (FOR INFORMATION) 279
7. EXPLODED VIEWS 284
8. REMOVAL AND RE-FITMENT 286
9. TOWING SERVICE 293
10. AUTO TRANSAXLE FLUID CHECK AND CHANGE INTERVAL 294
11. REMOVAL OF TRANSAXLE FROM VEHICLE 296
12. ASSEMBLY OF TRANSAXLE ON VEHICLE 299
13. REMOVAL OF GEAR SHIFTING CABLE ONVEHICLE 302
14. ASSEMBLY GEARSHIFT CONTROL CABLE 305
15. REMOVAL GEARSHIFT MECHANISM 308
16. ASSEMBLY GEARSHIFT MECHANISM 310
17. OIL COOLER HOSES REMOVAL 311
18. OIL COOLER HOSES REFITMENT 312
19. TCU (TRANSMISSION CONTROL UNIT) 313
DRIVESHAFT (AT) 314
1. GENERAL INFORMATION 316
2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 317
3. DRIVE SHAFT PARTS 318
4. TIGHTENING TORQUES 319
5. SPECIAL TOOL 322
6. ON BENCH PROCEDURE 323
7. ON VEHICLE PROCEDURE 328
CLUTCH 337
1. GENERAL INFORMATION 339
2. TECHNICAL SPECIFICATION 339
3. LUBRICANT SPECIFICATION 339
4. CLUTCH PRESSURE PLATE 340
5. CLUTCH DISC ASSEMBLY 340
6. EXPLODED VIEW 341
7. TIGHTENING TORQUE 342
8. SPECIAL TOOLS 342
9. GENERAL SYMPTOMS DIAGNOSIS 343
A. CLUTCH GRAB / CHATTER 343
B. CLUTCH SLIPS 343
C. CLUTCH PEDAL NOISE 344
10. ON VEHICLE PROCEDURES 345
A. SPECIAL TOOL ASSEMBLY 345
B. DISASSEMBLY PROCEDURE 345
C. ASSEMBLY PROCEDURE 347
CLUTCH RELEASE SYSTEM 348
1. CLUTCH SYSTEM LAYOUT 350
2. CLUTCH SYSTEM COMPONENTS 351
3. REGULAR MAINTENANCE 352
4. CLUTCH PEDAL ASSEMBLY 353
5. BRAKE PEDAL ASSEMBLY 354
6. REMOVAL OF ACCELERATOR PEDAL 355
7. REMOVAL OF CLUTCH CONTROL BRACKET 356
8. ASSEMBLY OF CLUTCH CONTROL BRACKET 358
9. BRAKE SWITCH INSTALLTION PROCEDURE 360
SUSPENSION 361
1. GENERAL INFORMATION 363
2. TECHNICAL SPECIFICATIONS 366
3. TIGHTENING TORQUES 367
4. SPECIAL TOOLS 372
5. DIAGNOSIS 375
6. PRECAUTIONS 376
7. EXPLODED VIEWS OF FRONT SUSPENSION 377
8. EXPLODED VIEWS REAR SUSPENSION 380
9. ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY 381
10. ON BENCH FRONT STRUT DISASSEMBLY 384
11. ON BENCH FRONT STRUT ASSEMBLY 385
12. REMOVAL AND ASSEMBLY OF WHEEL DISC 388
13. ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB 389
14. REMOVAL OF SUBFRAME ASSEMBLY 390
15. INSTALLATION OF SUBFRAME ASSEMBLY 392
16. LCA REAR HYDRA-BUSH INSTALLATION 392
17. REMOVAL OF ANTI ROLL BAR 393
18. REMOVAL AND ASSEMBLY OF REAR DAMPER ASSEMBLY AND COIL SPRINGS 394
19. ECIE CONDITION 394
20. INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS 395
21. REAR SUSPENSION DISMANTLING OR INSTALLATION 396
22. RTB BUSH INSTALLATION 399
23. PAN HARD ROD BUSH INSTALLATION AND REMOVAL 400
24. INSTALLATION AND REMOVAL OF DAMPER BOTTOM BUSH 401
BRAKES 402
1. SPECIFICATION 404
2. SYSTEM DETAILS 405
3. TIGHTENING TORQUES 407
4. GENERAL SYMPTOMS DIAGNOSIS 411
5. NECESSITY OF ABS with EBD 413
6. VACUUM BRAKE BOOSTER 413
7. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 415
8. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 418
9. WHEEL SPEED SENSOR 420
10. ABS SYSTEM FAILURE WARNING LIGHT 421
11. MAINTENANCE, INSPECTION AND TEST 422
12. REAR DRUM BRAKES 423
13. REMOVAL OF SHOES 426
14. REGULAR MAINTENANCE 430
15. ON VEHICLE REPAIRS 436
16. DISMANTLING, INSPECTION AND ASSEMBLY 446
HVAC 451
1. HVAC SYSTEM LAYOUT 453
2. SPECIFICATIONS: HVAC UNIT 454
3. TIGHTENING TORQUES 460
4. PRECAUTIONS 464
5. HVAC SYSTEM LAYOUT AND WORKING 465
6. CONTROL PANEL 468
7. FRONT HVAC UNIT 470
8. TRINARY PRESSURE SWITCH 472
9. MODE & TEMPRATURE CONTROL AC-TUATOR 473
10. COMPRESSOR 474
11. CONDENSER 476
12. RECEIVER DRIER (R.D) 476
13. INSPECTION OF MODE AND TEMPERATURE ACTUATOR 477
14. TROUBLESHOOTING 479
15. MAINTENANCE 490
16. ON VEHICLE REPAIRS 498
17. DO’S AND DONT’S FOR A/C SYSTEM 507
FATC 508
1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM 510
2. TECHNICAL SPECIFICATIONS 512
3. TIGHTENING TORQUES 518
4. PRECAUTIONS 522
5. HMI CLIMATE CONTRL DISPLAY 523
6. CONTROL PANEL 524
7. CONTROL PANEL MODULE CONNECTOR DETAILS 529
8. FATC UNIT 531
9. FATC SENSOR & ACTUATOR 533
10. COMPRESSOR 539
11. CONDENSER 540
12. RECEIVER DRIER (R.D) 540
13. REMOVAL OF INFOTAINMENT SYSTEM 541
14. TROUBLESHOOTING 542
15. MAINTENANCE 553
16. ON VEHICLE REPAIR 561
17. DO’S AND DONT’S FOR A/C SYSTEM 570
BODY 571
1.1 GENERAL INFORMATION 574
1.2 TIGHTENING TORQUES 575
1.3 SPECIAL TOOL 578
1.4 ON VEHICLE REPAIRS 579
1.4.1 BONNET 579
1.4.2 ARM REST 581
1.4.3 FLOOR CONSOLE 582
1.4.4 DASHBOARD SKIN 583
1.4.5 GLOVE BOX 591
1.4.6 SIDE AIR VENTS 591
1.4.7 FRONT BUMPER 593
1.4.8 REAR BUMPER 595
1.4.9 FRONT DOOR 597
1.4.10 FRONT DOOR TRIMS 598
1.4.11 DOOR INNER LOCK HANDLE 599
1.4.12 FRONT OUTER DOOR LOCK 600
1.4.13 FRONT DOOR LATCH 601
1.4.14 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 602
1.4.15 REAR DOOR 603
1.4.16 REAR DOOR TRIM 604
1.4.17 REAR OUTER DOOR LOCK 605
1.4.18 DOOR LATCH REAR 606
1.4.19 TAIL GATE 607
1.4.20 TAIL GATE TRIM 609
1.4.21 ORVM 610
1.4.23 FRONT ROW SEAT 611
1.4.24 REAR ROW SEAT 612
1.4.25 FRONT SEAT BELT 613
1.4.26 REAR SEAT BELT 615
1.4.27 “A” PILLAR TRIM 616
1.2.28. FRONT SCUFF PLATE 616
1.4.29 “B” PILLAR TRIMS: 617
1.2.30.REAR SCUFF PLATE 617
1.4.31 REAR QUARTER TRIM 618
1.4.32 “C” PILLAR TRIMS 619
1.4.33 GRAB HANDLE: 619
1.4.34 SUNVISOR 620
1.4.35 ROOF LINEAR 620
1.4.36 PLENUM COVER: 621
1.4.37 GEAR LEVER BOOT 621
1.4.38 BONNET INSULATION 621
1.4.39 GLASS 621
1.4.40 FUEL FILLER ASSEMBLY. 623
1.4.41 FRONT WHEEL ARCH LINER 624
1.4.42 REAR WHEEL ARCH LINER 625
1.4.43 FRONT FENDER 626
1.4.44 REAR WIPER MOTOR 627
1.4.45 FRONT WIPER 628
1.4.46 SUNROOF 629
1.4.47 WIND DEFLECTOR 630
1.4.48 FRONT GLASS PANEL 631
1.4.50 SUNSHADE ROLLO ASSEMBLY 633
1.4.51 MECHANISM ELECTRIC DRIVE ASSEMBLY 634
1.4.52 ROLLO ELECTRIC DRIVE ASSEMBLYREMOVAL 634
1.4.53 MECHANISM MAINTENANCE 635
1.4.54 WATER CHANNEL MAINTENANCE 638
1.4.55 SUNROOF RESET PROCEDURE - INITIALIZING THE POWER SUNROOF 638
1.4.56 SUNROOF RESET PROCEDURE - SELF LEARNING THE POWER SUNROOF 639
ELECTRICAL 640
1. INSTRUMENT CLUSTER 643
1.1. BASIC FUNCTIONAL MATRIX 645
1.2. TELL TALES INFORMATION 646
1.3 GAUGES 651
1.4 Driver Information System (For Q5 7" Instrument Cluster) 657
1.5 Display Messages for TFT Screen 666
1.6 DRIVER INFORMATION SYSTEM (For Q5 4" Instrument Cluster) 671
1.7 DISPLAY MESSAGE ON LCD SCREEN 675
1.8 REMINDER FEATURES 676
2. MAIN CONNECTOR PIN-OUTS 677
3. FUEL GAUGE DETAILS 679
4. TEMPERATURE BAR GRAPH DETAILS 680
5. Reminder Features (Audible) 681
6. INSTRUMENT CLUSTER REMOVAL 682
7. IMMOBILIZER SYSTEM (IF APPLICABLE) 683
8 FUEL GAUGE DETAILS 691
9. TEMPERATURE BAR GRAPH DETAILS 692
10. CHIME TABLE 693
11. DISPLAY SCREEN FLOW AND SETTINGS 693
12. IGNITION KEY LEARNING PROCEDURE 696
13. BODY CONTROL MODULE (BCM) 699
13.1 REMOVAL OF BCM 699
13.2 CONNECTION DETAILS 700
13.3 BCM SPECIFICATION 705
13.4 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 706
14. FUSE AND RELAY BOX DETAILS 712
14.1 CHECKING FUSES 712
14.2 CHECKING RELAYS 712
14.3 FUSE AND RELAY BOX LAYOUT 714
14.4 BATTERY MOUNTED FUSE BOX 715
14.5 ENGINE FUSE AND RELAY BOX 715
14.6 CABIN FUSE AND RELAY BOX 718
15. REVERSE PARK ASSIST SYSTEM 720
15.1 REAR VIEW CAMERA (If Applicable) 724
15.2 BCM TO SENSOR ELECTRICAL INTERFACE 727
15.3 REVERSE PARK ASSIST SYSTEM 732
15.4 REAR VIEW CAMERA REMOVAL 734
15.5 TROUBLESHOOTING 735
16. PASSIVE ENTRY PASSIVE START (PEPS) 736
16.1 PEPS ECU 737
16.2 START STOP SWITCH 739
16.3 ELECTRONIC STEERING COLUMN LOCK (ESCL) 740
16.4 DOOR AND TAILGATE HANDLE SWITCHES WITH HARNESS 742
16.5 LF ANTENNAS 743

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