TATA PUNCH SERVICE MANUAL

PETROL ENGINE (1.2 L NG NA)	6
1. GENERAL INFORMATION	12
A ENGINE INTRODUCTION	12
B ELECTRONIC FUEL INJECTION CONTROL	13
C TECHNICAL SPECIFICATION	14
D SPECIAL TOOLS	15
E ASSEMBLY CLEARANCES	18
F SEALANTS	18
G LEAKAGE RATES	18
H OIL & LUBRICANTS	19
I SERVICE SCHEDULE	20
2. TROUBLESHOOTING	22
3. CONSTRUCTIONAL AND SERVICE DETAILS	28
A ENGINE LIFTING	28
B INTAKE MANIFOLD	29
C CYLINDER HEAD AND COVER	31
D CYLINDER HEAD-A	33
E CYLINDER HEAD-B	35
F CYLINDER BLOCK	36
G OIL SUMP	38
H MOVING PARTS	39
I ENGINE TIMING	41
J EXHAUST MANIFOLD	43
K FUEL INJECTION EQUIPMENT	44
L LUBRICATION PUMP AND COMPONENTS	45
M AIR INTAKE SYSTEM	47
N SPECIAL INSTALLATION	49
O ENGINE SUSPENSION	52
4. ENGINE TESTS AND MAINTENANCE	54
A PRELIMINARY INSPECTION	54
B ENGINE TESTS	55
I ENGINE COMPRESSION TEST	55
II ENGINE OIL CONSUMPTION TEST	56
III ENGINE OIL PRESSURE TEST	57
C REGULAR MAINTENANCE	58
I ENGINE OIL AND FILTER CHANGE	58
II ENGINE COOLANT REPLACEMENT	59
III AIR FILTER ELEMENT REPLACEMENT	63
IV SPARK PLUG REPLACEMENT	64
V AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT	66
5. REPAIR AND INSPECTION DETAILS	67
A ACCESSORY DRIVING BELT	67
B TIMING CHAIN	67
C CYLINDER HEAD	67
D VALVES	68
E CYLINDER HEAD VALVE SEATS	69
F ROCKER ARM AND SHAFTS	69
G HYDRAULIC LASH ADJUSTER	70
H CAMSHAFT	70
I PISTON AND PISTON RINGS	71
J CONNECTING RODS	72
K CRANKSHAFT	73
L CRANK CASE	74
M FUEL TANK	75
N CANISTER PURGE VALVE	75
O CANISTER	76
6. ENGINE SYSTEM	77
A AIR INTAKE SYSTEM	77
B BLOW BY SYSTEM	79
C LUBRICATION SYSTEM	80
D EXHAUST SYSTEM	84
E COOLING SYSTEM	86
F FUEL SYSTEM	89
7. ENGINE ON VEHICLE SERVICE PROCEDURE	92
A FUSE BOX SHIFTING PROCEDURE	92
B ENGINE REMOVAL AND INSTALLATION	93
C AIR FILTER ASSY	99
D FUEL RAIL AND INJECTOR	100
E SPARK PLUG	101
F EXHAUST SYSTEM	101
G FUEL SYSTEM	105
H COOLING SYSTEM	110
I COMPRESSOR AND ALTERNATOR BELT REMOVAL	114
J TIMING BELT REMOVAL	115
K WATER PUMP	118
L SOLENOID	119
M ELECTRONIC THROTTLE BODY	120
N STARTER MOTOR	120
O ALTERNATOR	121
P COMPRESSOR	121
8. ENGINE OVEHAULING (ON OVERHAUL STAND)	123
A ENGINE DIS-ASSEMBLY	123
I REMOVAL OF INTAKE MANIFOLD	123
II REMOVAL OF EXHAUST MANIFOLD	124
III REMOVAL OF OIL SUMP	126
IV REMOVAL OF SENSORS	126
V REMOVAL OF ACCESSORIES	127
VI REMOVAL OF TIMING CHAIN	130
VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT	132
VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES	133
IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES	134
B ENGINE ASSEMBLY	138
I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES	138
II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES	142
III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES	144
IV ASSEMBLY OF CYLINDER HEAD	145
V ASSEMBLY OF ENGINE TIMING CHAIN	147
VI ASSEMBLY OF ACCESSORIES DRIVING BELT	150
VII ASSEMBLY OF SENSORS AND PERIPHERALS	152
VIII ASSEMBLY OF OIL SUMP	153
IX ASSEMBLY OF EXHAUST MANIFOLD	153
X ASSEMBLY OF INTAKE MANIFOLD S	155
9. ENGINE MANAGEMENT SYSTEM	156
A ABBREVIATIONS	156
B AN OVERVIEW	157
C ELECTRONIC CONTROL UNIT	158
D SENSORS	163
I T-MAP SENSOR	164
II LAMBDA SENSOR	165
III CAMSHAFT POSITION SENSOR	167
IV KNOCK SENSOR	168
V CRANKSHAFT POSITION SENSOR	169
VI COOLANT TEMPERATURE SENSOR	170
E ACTUATOR	172
I IGNITION COIL	173
II PURGE CONTROL VALVE	174
III SOLENOID VALVE (OCV)	175
IV FUEL INJECTOR	176
V ELECTRONIC THROTTLE BODY	177
F SWITCH	179
I OIL PRESSURE SWITCH	179
II THROTTLE PEDAL SENSOR	180
III CLUTCH SWITCH	181
IV REVERSE LAMP SWITCH	181
V BRAKE SWITCH	182
VI VEHICLW SPEED SENSOR	183
TRANSAXLE MT (TA 65*, 5 SPEED)	184
1. TECHNICAL SPECIFICATIONS	187
2. PRECAUTIONS	187
3. GENERAL DESCRIPTION	188
4. TIGHTENING TORQUES	189
5. SPECIAL TOOLS LIST	190
6. DIAGNOSIS	194
7. CONSTRUCTIONAL DETAILS	195
8. CUT SECTION OF TRANSAXLE TA 65 STAR	196
9. CUT SECTION OF TOP COVER ASSEMBLY	197
10. EXPLODED VIEWS OF TRANSAXLE	198
A. TRANSAXLE HOUSING	198
B. TOP COVER ASSEMBLY	199
C. DIFFERENTIAL	201
D. SHIFTER FORK	202
E. GEAR SHIFT LINKAGE ASSEMBLY	203
F. LAY SHAFT AND INPUT SHAFT	204
11. FUSE BOX SHIFTING PROCEDURE	206
12. REMOVAL OF TRANSAXLE FROM VEHICLE	207
13. ON VEHICLE ASSEMBLY OF TRANSAXLE	210
14. TRANSAXLE TA65 STAR (ON BENCH) DISASSEMBLY	212
15. INPUT SHAFT DEEP GROOVE BEARING REMOVAL	217
16. INPUT SHAFT DEEP GROOVE BEARING ASSEMBLY	217
17. DISASSEMBLY OF LAY SHAFT	218
18. IDENTIFICATION OF COMPONENTS	220
A. ENGAGING GEARS	220
B. SHIFTER SHAFT SUB ASSEMBLY	221
C. SHIFTER FORKS	221
D. SHIFTER SHAFT	222
E. SHIFTER SLEEVE	222
F. SYNCHROCONE	222
G. SUB ASSEMBLIES	222
19. LAY SHAFT ASSEMBLY	224
20. DIFFERENTIAL ASSEMBLY	227
21. TRANSAXLE ASSEMBLY	229
22. DISASSEMBLY OF TOP COVER	234
23. ASSEMBLY OF TOP COVER	235
24. INSTRUCTION FOR ASSEMBLY / DISASSEMBLY OF CABLE AT GEAR BOX	237
25. REMOVAL OF GEAR SHIFTER AND SELECTOR CABLE	238
26. GEAR SHIFTER CABLE ASSEMBLY	239
CLUTCH MT (200MM)	240
1 GENERAL INFORMATION	242
2 TECHNICAL SPECIFICATIONS	243
A. CLUTCH DISC	243
B. CLUTCH PRESSURE PLATE	245
C. FLYWHEEL	247
3 TIGHTENING TORQUES	249
4 SPECIAL TOOLS	250
5 DIAGNOSIS OF CLUTCH	251
6 MAINTENANCE, TESTS AND FACTOR AFFECTING CLUTCH	254
A. INSPECTION OF COMPONENTS	254
B. TESTS	254
C. FACTORS AFFECTING CLUTCH	254
7 CONSTRUCTIONAL DETAILS	255
8 ON VEHICLE PROCEDURE	257
A. FUSE BOX SHIFTING PROCEDURE	257
B. CLUTCH CABLE REMOVAL AND INSPECTION	258
C. REMOVAL OF CLUTCH	259
D. FLYWHEEL REMOVAL	260
E. CLUTCH ADJUSTMENT PROCEDURE	261
DRIVESHAFT MT	262
1. INTRODUCTION	264
2. DRIVESHAFT	265
3. DRIVE SHAFT PARTS	266
4. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE	266
5. TESTING FOR NOISE	267
6. TIGHTENING TORQUES	268
7. SPECIAL TOOLS	268
8. ON VEHICLE REMOVAL OF DRIVE SHAFT (LH & RH SIDE	269
9. ON VEHICLE ASSEMBLY OF DRIVE SHAFT (LH & RH SIDE)	270
10. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT	271
11. ASSEMBLY PROCEDURE FOR DRIVESHAFT	272
12. PRECAUTION TO AVOID THE DAMAGE TO DRIVE SHAFT	273
13. DISASSEMBLY PROCEDURE FOR (TRIPOT JOINT)	274
14. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER)	277
15. DO’S AND DON’T’S FOR DRIVE SHAFT	281
TRANSAXLE AMT (TA 65*, 5 SPEED)	282
1 PRECAUTION	284
2 TRANSAXLE GENERAL INFORMATION	285
3 TECHNICAL SPECIFCICATIONS	286
4 TIGHTENING TORQUES	287
5 SPECIAL TOOLS	292
A. CLUTCH	292
B. TRANSAXLE	292
6 DIAGNOSIS OF TRANSAXLE	297
7 CUT SECTION OF TRANSAXLE	298
8 EXPLODED VIEWS OF TRANSAXLE	299
9 REMOVAL OF TRANSAXLE FROM VEHICLE	308
10 TRANSAXLE TA65 STAR AMT DISASSEMBLY (ON BENCH)	311
11 SUB ASSEMBLIES	317
12 TRANSAXLE TA65 STAR AMT ASSEMBLY	329
CLUTCH AMT (200MM)	332
1. GENERAL INFORMATION	334
2 TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES	334
3. DIAGNOSIS	338
4. CLUTCH	340
A. THEORY OF DIAPHRAGM SPRING CLUTCH	340
B. CONSTRUCTIONAL DETAILS	341
C. FACTOR AFFECTING CLUTCH WEAR	343
D. REMOVAL OF CLUTCH FROM THE CAR	343
E. INSTALLATION OF CLUTCH ON THE CAR	343
5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE	344
DRIVESHAFT AMT	345
1. DRIVESHAFT	347
2 GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE	348
3. TESTING FOR NOISE	348
4. DRIVE SHAFT PARTS	349
5. DISASSEMBLY PROCEDURE FOR TRIPOT JOINT	350
6. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER)	353
AMT KIT	358
1. AMT-KIT LOCATION ON VEHICLE(LAYTOUT)	360
2 NOMENCLATURE FOR AMT KIT	360
3. TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS	361
4. SPECIAL TOOLS	364
5. PRECAUTIONS	366
6. ON VEHICLE PROCEDURES	367
A. DEPRESSURIZATION OF AMT KIT	367
B. AMT KIT REMOVAL (FROM TOP)	370
7. ON BENCH PROCEDURES	372
A. OIL TANK REMOVAL AND RE-FITMENT	372
B. MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT	374
C. TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT	377
D. DC MOTOR REMOVAL AND RE-FITMENT	380
E. HYDRAULIC OIL ACCUMLATOR REMOVAL AND RE-FITMENT	381
F. CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT	381
G. POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH	382
AMT CONSOLE	383
1. AMT GEARBOX SHIFTER AND SHIFTING MECHANISM	385
2 DRIVING MODES	385
3. GEAR SHIFTER CENTER CONSOLE REMOVAL	387
4. GEAR SHIFTER PIN CONFIGURATION	389
SUSPENSION	390
1. GENERAL INFORMATION	392
2. TECHNICAL SPECIFICATION	396
3. TIGHTENING TORQUES	397
4. SPECIAL TOOLS	402
5. DIAGNOSIS	407
6. PRECAUTIONS	408
7. EXPLODED VIEWS FRONT SUSPENSION	410
8. EXPLODED VIEWS REAR SUSPENSION	414
9. ON VEHICLE REMOVAL AND ASSEMBLY PROCEDURE	417
9.1. ON VEHICLE FRONT STRUT REMOVAL AND ASSEMBLY	417
9.2. ON BENCH FRONT STRUT REMOVAL AND ASSEMBLY	418
9.3 ON VEHICLE WHEEL HUB REMOVAL AND ASSEMBLY	419
9.4 ON BENCH SUB ASSEMBLY OF KNUCKLE /WHEEL HUB	422
9.5 ON VEHICLE SUB FRAME REMOVAL	423
9.6 ON VEHICLE ANTI ROLL BAR REMOVAL AND ASSEMBLY	424
9.7 ON VEHICLE LOWER ARM BALL JOINT REMOVAL AND ASSEMBLY	425
9.8 ON BENCH LOWER ARM PIVOT BUSH REMOVAL AND ASSEMBLY	426
9.9 ON VEHICLE SUB FRAME ASSEMBLY	427
9.10 ON VEHICLE REAR SHOCK ABSORBER AND COIL SPRINGS REMOVAL	428
9.11 ON BENCH DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER	429
9.12 ON VEHICLE REAR SHOCK ABSORBER AND COIL SPRINGS ASSEMBLY	430
9.13 ON VEHICLE TORSION BEAM REMOVAL AND ASSEMBLY	431
10. SUSPENSION ECIE / PRE LOADING CONDITION	434
WHEELS & TYRES	435
1. GENERAL INFORMATION	437
2. CONSTRUCTION	437
3. TIGHTENING TORQUES	438
4. GENERAL SYMPTOMS & DIAGNOSIS	439
5. MAINTENANCE, INSPECTION AND TESTS	444
6. WHEEL AND TYRE REPLACEMENT	448
STEERING	450
1. GENERAL INFORMATION	452
2. SYSTEM LAYOUT	453
3. TIGHTENING TORQUES	454
4. SPECIAL TOOLS	457
5. MAINTAINANCE, INSPECTION AND TEST	458
6. ON VEHICLE REPAIRS	461
A.STEERING WHEEL REMOVAL	461
B. STEERING COLUMN REMOVAL	462
C. INTERMEDIATE SHAFT REMOVAL	465
D. ECU REMOVAL	466
E. MOTOR REMOVAL	467
F. RACK & PINION ASSEMBLY REMOVAL	468
G. OBJ REMOVAL	470
7. EXPLODED VIEWS OF STEERING RACK & PINION ASSEMBLY	473
8. OVERHAULING OF STEERING RACK & PINION ASSEMBLY	474
A. PRECAUTIONS	474
B.DISASSEMBLY OF RACK & PINION	474
C. INSPECTION OF DISMANTLED PARTS	475
D. ASSEMBLY OF RACK & PINION	475
E. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE	476
9. WHEEL ALIGNMENT	477
10. CAMBER ADJUSTMENT	478
11. TOE OUT ADJUSTMENT	478
12. TROUBLESHOOTING AND DIAGNOSIS	479
14. STEERING ANGLE CALIBRATION	484
15. TUNING DATA SELECTION	491
16. ELECTRIC POWER ASSISTED STEERING (EPAS) ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	492
BRAKE(ABS)	496
1 TECHNICAL SPECIFICATIONS	499
2 TIGHTENING TORQUES	501
3 SPECIAL TOOL	505
4 PRECAUTIONS	505
5 DIAGNOSIS	506
6 NESSECITY OF ABS WITH EBD	509
7 BRAKE HYDRAULIC LINES	510
8 VACUUM BRAKE BOOSTER	511
9 WORKING OF ANTI-LOCK BRAKING (ABS) SYSTEM	512
10 ABS COMPONENTS	516
A. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU)	517
B. HYDRAULIC CONTROL UNIT	518
C. WHEEL SPEED SENSOR: (MONITORS WHEEL SPEED)	518
D. ABS SYSTEM FAILURE WARNING LIGHT	519
11 MAINTENANCE, ADJUSTMENTS & TEST	520
A. FRONT BRAKE MAINTENANCE	520
B. REAR BRAKE MAINTENANCE	522
C. BRAKE TROUBLE SHOOTING	528
D. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO	529
E. STOP LIGHT SWITCH ADJUSTMENT	530
12 BRAKE PEDAL ASSEMBLY	531
13 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE	532
14 REPAIRS	533
A. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT	534
B. REMOVAL OF FRONT BRAKE DISC	541
C. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY	542
D. REAR BRAKE ASSEMBLY	544
E. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY	545
F. REMOVAL AND INSTALLATION OF PARKING BRAKE LEVER	551
G. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE	552
H. PARKING BRAKE CABLE ADJUSTMENT	553
I. REMOVAL AND REFITMENT OF ABS ECU / HCU	554
J. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR	555
K. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR	556
15 TROUBLE SHOOTING & DIAGNOSIS	557
16 ABS ECU CONNECTOR	559
HVAC	560
1 HVAC SYSTEM LAYOUT	563
2 TECHNICAL SPECIFICATIONS	564
3 TIGHTENING TORQUES	568
4 PRECAUTIONS	570
5 HVAC SYSTEM LAYOUT AND WORKING	571
6 ELECTRONIC TEMPERATURE CONTROLLER (ETC)	573
7 WORKING / FUNCTION OF ETC	574
A PROCEDURE OF AUTO LEARNING	574
B FAILURE INDICATION DURING NORMAL MODE	574
C MANUAL CALIBRATION OF DC MOTORS	574
D ENTER DIAGNOSTICS MODE	574
E BLINK CODES DISPLAY(FAULT CODE)	575
F CLEAR FAULT MEMORY	575
G EXIT FROM DIAGNOSTIC MODE	575
8 CONNECTOR DETAILS	576
9 HVAC UNIT COMPONENTS	577
A BLOWER MOTOR	577
B EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE)	577
C TXV (THERMOSTATIC EXPANSION VALVE)	577
D HEATER COIL	578
10 COMPRESSOR	578
11 CONDENSOR	579
12 RECEIVER DRIER (R.D)	579
13 TRINARY PRESSURE SENSOR	579
14 TROUBLESHOOTING	580
15 MAINTAINANCE	590
A PRELIMINARY INSPECTION	590
B REGULAR MAINTENANCE	592
16 ON VEHICLE REPAIR	596
A AC FILTER REMOVAL AND ASSEMBLY	596
B COMPRESSOR REMOVAL AND ASSEMBLY	596
C CONTROL PANEL REMOVAL AND ASSEMBLY	597
D BLOWER MOTOR REMOVAL AND ASSEMBLY	598
E FRONT HVAC UNIT REMOVAL AND ASSEMBLY	599
F CONDENSER REMOVAL AND ASSEMBLY	601
17 DO’S AND DONT’S FOR A/C SYSTEM	602
FATC	603
1 FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM	606
2 FATC LAYOUT	606
3 TECHNICAL SPECIFICATIONS	607
4 TIGHTENING TORQUES	611
5 PRECAUTIONS	614
6 HMI CLIMATE CONTRL DISPLAY	615
7 CONTROL PANEL	617
8 CONTROL PANEL MODULE CONNECTOR DETAILS	622
9 FATC UNIT	624
A BLOWER MOTOR	624
B EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE)	624
C HEATER COIL	624
10 FATC SENSOR AND ACTUATOR	625
A EVAPORATER SENSOR	625
B TRINARY PRESSURE SENSOR	626
C INCAR SENSOR	626
D MODE ACTUATOR	627
E TEMPERATURE ACTUATOR	627
F FRESH AIR / RECIRCULATION ACTUATOR	627
G BLOWER CONTROL MODULE	628
11 COMPRESSOR	628
12 CONDENSOR AND RECEIVER DRIER	629
13 TROUBLESHOOTING	630
14 MAINTAINANCE	641
A PRELIMINARY INSPECTION	641
B REGULAR MAINTENANCE	643
15 ON VEHICLE REPAIR	647
A AC FILTER REMOVAL AND ASSEMBLY	647
B CONTROL PANEL REMOVAL AND ASSEMBLY	647
C BLOWER MOTOR REMOVAL AND ASSEMBLY	648
D FRONT FATC UNIT REMOVAL AND ASSEMBLY	649
E REAR VENT REMOVAL AND ASSEMBLY	651
F COMPRESSOR REMOVAL AND ASEMBLY	652
G CONDENSER REMOVAL AND ASSEMBLY	652
16 DO’S AND DONT’S FOR A/C SYSTEM	654
BODY	655
1 LAYOUT	658
2 TIGHTENING TORQUES	659
3 SPECIAL TOOL	661
4 ON VEHICLE REPAIRS	662
1 BONNET	662
2 HOOD LATCH ASSEMBLY RTEMOVAL	662
3. BONNET LATCH RELEASE CABLE	663
4 FLOOR CONSOLE	663
5 DASHBOARD SKIN	665
6 COCKPIT REMOVAL (COMPLETE ASSY)	670
7 GLOVE BOX	674
8 SIDE AIR VENTS	675
9 FRONT BUMPER	675
10 REAR BUMPER	677
11 FRONT DOOR	678
12 FRONT DOOR TRIMS	679
13 DOOR INNER LOCK HANDLE	680
14 FRONT OUTER DOOR HANDLE	680
15 FRONT DOOR LATCH	681
16 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM	682
17 REAR DOOR	683
18 REAR DOOR TRIM	684
19 REAR OUTER DOOR HANDLE	685
20 DOOR LATCH REAR	686
21 TAIL GATE	687
22 INNER REAR VIEW MIRROR	689
23 ORVM	689
24 FRONT ROW SEAT	690
25 REAR ROW SEAT	691
26 ISOFIX REMOVAL	691
27 FRONT SCUFF PLATE	693
28 “A” PILLAR TRIM	693
29 “B” PILLAR TRIMS	694
30 “C” PILLAR TRIM	695
31 GRAB HANDLE	696
32 SUNVISOR	696
33 ROOF LINEAR	697
34 GEAR LEVER BOOT	697
35 BONNET INSULATION	697
36 PLENUM COVER	697
37 GLASS	698
38 FUEL FILLER ASSEMBLY	699
39 FRONT WHEEL ARC LINER	700
40 REAR WHEEL ARC LINER	701
41 FRONT FENDER	702
42 REAR WIPER MOTOR	704
43 FRONT WIPER MOTOR	705
ELECTRICAL	706
1 TECHNICAL SPECIFICATION	711
2 GENERAL PRECAUTIONS	713
3 BATTERY	717
4 ALTERNATOR	719
5 STARTER MOTOR	721
6 LIGHTING SYSTEM	728
A BULB SPECIFICATIONS	728
B FASTENERS TORQUE VALUE TABLE	728
C GENERAL SYMPTOMS AND DIAGNOSTICS	729
D HEAD LAMP	732
E DRL LAMP	735
F TAIL LAMP	737
G ROOF LAMP	739
H HIGH MOUNTED STOP LAMP	740
I FRONT FOG LAMP	741
J. REGISTRATION PLATE LAMP	742
7 HORN	743
8 POWER SOCKETS	745
9 FUEL GAUGE AND FUEL LEVEL METER	745
10 WIPER & WASHER SYSTEM	747
A FRONT AND REAR WIPER AND WAHSER SYSTEM LAYOUT	747
B FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY	748
C WIPER AND WIPER CARE	752
11 SWITCHES	754
A COMBI SWITCH	754
B FASCIA SWITCHES	760
C ENGINE START STOP OFF SWITCH	760
D STEERING CUM IGNITION SWITCH	763
E HAZARD SWITCH	764
F BUTTON PANEL	766
G MIRROR SWITCH	767
H WINDOW WINDING MODULE	768
I POWER WINDOW SWITCHES & INHIBIT SWITCH	769
J STEERING WHEEL SWITCH	772
K DOOR HANDLE SWITCH	775
L TAILGATE HANDLE SWITCH	776
12 INFOTAINMENT SYSTEM	777
A HMI DISPLAY 6.5 INCH (FOR HIGH VERSION)	777
B HMI DISPLAY 3.5 INCH (FOR MID VERSION)	779
C SILVER BOX (FOR HIGH VERSION)	781
D SILVER BOX (FOR MID VERSION)	783
E USB/AUX PORT	785
F SPEAKERS	786
G ANTENNA	787
H MICROPHONE (FOR HIGH VERSION)	787
I MICROPHONE (FOR LOW VERSION)	788
J TWEETER	789
13 INSTRUMENT CLUSTER	790
A FEATURES	790
B CIRCUIT DIAGRAM	791
C PIN DETAILS	792
D INSTRUMENT CLUSTER FEATURE MAPPING	793
F TELL TALES INFORMATION	794
F REMINDER FEATURES	797
G MAIN CONNECTOR PINOUTS	798
H FUEL GAUGE DETAILS	799
I TEMPRATURE BAR GRAPH DETAILS	800
J CHIME TABLES	800
K REMOVAL OF INSTRUMENT CLUSTER	801
14 IMMOBILIZER SYSTEM (IF APPLICABLE)	802
A TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB	804
B IMMOBILIZER SYSTEM STATUS IN EMS ECU	805
C IGNITION KEY LEARNING PROCEDURE	807
15 BODY CONTROL MODULE (BCM)	809
A CONNECTION DETAILS (PINOUT DETAILS)	810
B BCM SPECIFICATION	814
C BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX	815
D BCM FEATURES	820
E BCM FUNCTIONS	821
F BCM REPLACEMENT STRATEGY	823
16 RAIN LIGHT SENSOR (IF APPLICABLE)	824
A RAIN LIGHT SENSOR	824
B FUNCTIONAL DETAILS	827
C FAIL SAFE MODES OF RLS & BCM	828
17 FUSE AND RELAY BOX DETAILS	829
A FUSE AND RELAY BOX LAYOUT	831
B ENGINE FUSE AND RELAY BOX	832
C CABIN FUSE AND RELAY BOX	834
D FUSE AND RELAY REPLACEMENT	835
18 REVERSE PARK ASSIST SYSTEM	836
A SENSORS	840
B REVERSE PARK ASSIST WITH CAMERA (IF APPLICABLE)	844
C REAR VIEW CAMERA (IF APPLICABLE)	845
19 PASSIVE ENTRY PASSIVE START (PEPS)	849
A PEPS ECU	850
B START STOP SWITCH (IF APPLICABLE)	852
C ELCTRONIC STEERING COLUMN LOCK (ESCL)	853
D DOOR AND TAILGATE HANDLE SWITCHES	855
E LF ANTENNAS	856
20 TELEMATICS	858
SUPPLEMENTARYRESTRAINT SYSTEM(SRS)	861
1. WORKING OF RESTRAINTS	863
2. SYSTEM LAYOUT	865
3. SAFETY PRECAUTIONS	866
4. DISPOSAL OF FAULTY AIR BAG UNIT	868
5. SRS POST ACCIDENT PROCEDURE	870
6. TIGHTENING TORQUES	871
7. COMPONENTS	875
A. RESTRAINT WITHOUT AIRBAGS	875
B. RESTRAINT WITH AIRBAGS	875
1. ECU	875
2. FRONT IMPACT SENSOR (FIS)	879
3. AIRBAGS	881
4. RPDLL, APT & RPLL	883
5. CLOCK SPRING	886

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