| 1. GENERAL |
3 |
| 1.1. VEHICLE SPECIFICATION |
8 |
| 1.2. VEHICLE DIMENSIONS |
11 |
| 1.3. RECOMMENDATIONS |
12 |
| 1.3.1. REPAIRS AND REPLACEMENT |
12 |
| 1.4. GENERAL INFORMATION |
14 |
| 1.4.1. ABBREVIATIONS USED IN THIS MANUAL |
14 |
| 1.4.2. VEHICLE IDENTIFICATION NUMBER (VIN) |
14 |
| 1.5. VEHICLE JACKING AND LIFTING POINTS |
15 |
| 1.6. SPARE WHEEL REPLACEMENT |
16 |
| 1.7. EMERGENCY TOWING INFORMATION |
16 |
| 1.8. JUMP STARTING |
17 |
| 1.9. SERVICE AND MAINTENANCE SCHEDULE |
18 |
| 1.10. LUBRICANTS, FLUIDS AND CAPACITIES |
25 |
| 1.10.1. LUBRICANTS |
25 |
| 1.10.2. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
25 |
| 1.10.3. RECOMMENDED FUEL |
27 |
| 1.11. GENERAL FITTING REMINDERS |
27 |
| 1.11.1. WORKSHOP SAFETY |
27 |
| 1.11.2. PREPARATION |
27 |
| 1.11.3. DISMANTLING |
27 |
| 1.11.4. GENERAL INSPECTION |
28 |
| 1.11.5. JOINTS AND JOINT FACES |
28 |
| 1.11.6. FLEXIBLE HYDRAULIC PIPES, HOSES |
28 |
| 2. ENGINE 320Nm |
29 |
| 2.1. GENERAL INFORMATION |
37 |
| 2.1.1. ENGINE INTRODUCTION |
37 |
| 2.1.2. TECHNICAL SPECIFICATION |
38 |
| 2.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
39 |
| 2.1.4. SERVICE SCHEDULE |
40 |
| 2.1.5. ASSEMBLY CLEARANCES |
42 |
| 2.1.6. SPECIAL TOOLS |
43 |
| 2.2. GENERAL SYMPTOMS DIAGNOSIS |
44 |
| 2.3. CONSTRUCTIONAL AND SERVICE DETAILS |
47 |
| 2.3.1. ENGINE MOUNTING COMPONENTS |
47 |
| 2.3.2. CYLINDER HEAD AND COVER |
49 |
| 2.3.3. LUBRICATION SYSTEM COMPONENTS |
51 |
| 2.3.4. ENGINE |
53 |
| 2.3.5. OIL SUMP |
55 |
| 2.3.6. CYLINDER HEAD |
57 |
| 2.3.7. SPECIAL INSTALLATION |
59 |
| 2.3.8. EXHAUST SYSTEM COMPONENTS |
61 |
| 2.3.9. INTAKE SYSTEM COMPONENTS |
63 |
| 2.3.10. ENGINE SUSPENSION |
65 |
| 2.3.11. MOVING PARTS |
67 |
| 2.3.12. ENGINE TIMING |
69 |
| 2.3.13. FUEL INJECTION EQUIPMENT |
71 |
| 2.4. ENGINE TESTS AND MAINTENANCE |
73 |
| 2.4.1. PRELIMINARY INSPECTION |
73 |
| 2.4.2. ENGINE TESTS |
73 |
| 2.4.3. REGULAR MAINTENANCE |
76 |
| 2.4.3.1. ENGINE OIL REPLACEMENT |
76 |
| 2.4.3.2. OIL FILTER REPLACEMENT |
76 |
| 2.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
77 |
| 2.4.3.4. MAIN FUEL FILTER REPLACEMENT |
77 |
| 2.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR |
78 |
| 2.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT |
79 |
| 2.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT |
80 |
| 2.4.3.8. COOLANT REPLACEMENT |
84 |
| 2.5. REPAIR AND INSPECTION DETAILS |
85 |
| 2.5.1. TIMING BELT |
85 |
| 2.5.2. FUEL TANK |
85 |
| 2.5.3. CYLINDER HEAD |
86 |
| 2.5.4. VALVES |
87 |
| 2.5.5. VALVE SEATS |
88 |
| 2.5.6. CRANKCASE |
89 |
| 2.5.7. VALVE SEAT INSERT |
90 |
| 2.5.8. HYDRAULIC LASH ADJUSTER |
90 |
| 2.5.9. CYLINDER HEAD COVER |
90 |
| 2.5.10. VALVE GUIDES |
91 |
| 2.5.11. CAMSHAFT |
92 |
| 2.5.12. PISTON AND PISTON RINGS |
93 |
| 2.5.13. CONNECTING ROD |
94 |
| 2.5.14. CRANKSHAFT |
96 |
| 2.6. ENGINE SYSTEM |
98 |
| 2.6.1. AIR INTAKE SYSTEM |
98 |
| 2.6.2. BLOW BY SYSTEM |
100 |
| 2.6.3. VACUUM MANAGEMENT SYSTEM |
101 |
| 2.6.4. COOLING SYSTEM |
103 |
| 2.6.5. LUBRICATION SYSTEM |
106 |
| 2.6.6. FUEL SYSTEM |
110 |
| 2.6.7. EXHAUST SYSTEM |
119 |
| 2.6.8. EXHAUST GAS RECIRCULATION SYSTEM |
122 |
| 2.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
124 |
| 2.7.1. ENGINE REMOVAL |
124 |
| 2.7.2. AIR FILTER ASSEMBLY REMOVAL |
126 |
| 2.7.3. POWER STEERING PUMP BELT (STRETCH BELT) |
126 |
| 2.7.4. ALTERNATOR AND AC BELT |
127 |
| 2.7.5. INJECTOR REMOVAL |
128 |
| 2.7.6. TIMING BELT REMOVAL |
129 |
| 2.7.7. FITMENT OF TIMING BELT |
131 |
| 2.7.8. INTERCOOLER REMOVAL |
134 |
| 2.7.9. RADIATOR REMOVAL |
135 |
| 2.7.10. COOLANT TANK REMOVAL |
137 |
| 2.7.11. RADIATOR FAN SHROUD REMOVAL |
138 |
| 2.7.12. THERMOSTAT REMOVAL |
138 |
| 2.7.13. FUEL RAIL REMOVAL |
139 |
| 2.7.14. FUEL FILLER ASSEMBLY REMOVAL |
140 |
| 2.7.15. FUEL TANK |
141 |
| 2.7.16. TANK UNIT REMOVAL |
142 |
| 2.7.17. FUEL LEVEL SENSOR REMOVAL |
144 |
| 2.7.18. TANK PRESSURE VALVE REMOVAL |
145 |
| 2.7.19. FUEL TANK PURGING PROCEDURE |
146 |
| 2.7.20. POST SILENCER AND INTERMEDIATE PIPE |
147 |
| 2.7.21. PRE-SILENCER AND MAIN SILENCER |
147 |
| 2.7.22. FRONT EXHAUST PIPE |
148 |
| 2.7.23. CLOSE COUPLED CATALYTIC CONVERTER |
148 |
| 2.7.24. EGR COOLER MODULE |
149 |
| 2.7.25. TURBOCHARGER |
151 |
| 2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
154 |
| 2.8.1. ENGINE DIS-ASSEMBLY |
155 |
| 2.8.1.1. REMOVAL OF INTAKE MANIFOLD |
155 |
| 2.8.1.2. REMOVAL OF EXHAUST MANIFOLD |
160 |
| 2.8.1.3. REMOVAL OF OIL SUMP |
163 |
| 2.8.1.4. REMOVAL OF TIMING BELT |
164 |
| 2.8.1.5. REMOVAL OF CYLINDER HEAD |
166 |
| 2.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
168 |
| 2.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
171 |
| 2.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY |
172 |
| 2.8.2. ENGINE ASSEMBLY |
179 |
| 2.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
179 |
| 2.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
180 |
| 2.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
181 |
| 2.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
182 |
| 2.8.2.5. FITMENT OFTIMING BELT |
183 |
| 2.8.2.6. FITMENT OF OIL SUMP |
185 |
| 2.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
186 |
| 2.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
189 |
| 2.8.2.9. ON ENGINE SUPPORT STAND |
194 |
| 2.9. ENGINE MANAGEMENT SYSTEM (EMS) |
196 |
| 2.9.1. SYSTEM OVERVIEW |
197 |
| 2.9.2. BLOCK DIAGRAM |
198 |
| 2.9.3. CONNECTOR PIN ASSIGNMENT |
199 |
| 2.9.4. ANTI-CRANKING FUNCTION |
204 |
| 2.9.5. SENSORS AND ACTUATORS DETAILS |
205 |
| 2.9.5.1. CRANK ANGLE SENSOR |
205 |
| 2.9.5.2. CAM SENSOR |
206 |
| 2.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) |
208 |
| 2.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) |
209 |
| 2.9.5.5. COOLANT TEMPERATURE SENSOR |
211 |
| 2.9.5.6. FUEL TEMPERATURE SENSOR (FTS) |
212 |
| 2.9.5.7. INLET METERING VALVE (IMV) |
213 |
| 2.9.5.8. VENTURI |
213 |
| 2.9.5.9. RAIL PRESSURE SENSOR |
213 |
| 2.9.5.10. WATER IN FUEL SENSOR |
214 |
| 2.9.5.11. ACCELERATOR PEDAL SENSOR |
215 |
| 2.9.5.12. BRAKE SWITCH |
216 |
| 2.9.5.13. CLUTCH SWITCH |
218 |
| 2.9.5.14. GLOW PLUGS |
219 |
| 2.9.5.15. VTT ACTUATOR |
220 |
| 2.9.5.16. EGR VALVE ACTUATOR |
222 |
| 2.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) |
224 |
| 2.9.5.18. INTAKE THROTTLE VALVE |
225 |
| 2.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS |
226 |
| 3. ENGINE - 400Nm AUTOMATIC TRANSMISSION |
227 |
| 3.1. GENERAL INFORMATION |
235 |
| 3.1.1. ENGINE INTRODUCTION |
235 |
| 3.1.2. TECHNICAL SPECIFICATION |
236 |
| 3.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
237 |
| 3.1.4. SERVICE SCHEDULE |
238 |
| 3.1.5. ASSEMBLY CLEARANCES |
240 |
| 3.1.6. SPECIAL TOOLS |
241 |
| 3.2. GENERAL SYMPTOMS DIAGNOSIS |
242 |
| 3.3. CONSTRUCTIONAL AND SERVICE DETAILS |
245 |
| 3.3.1. ENGINE MOUNTING COMPONENTS |
245 |
| 3.3.2. CYLINDER HEAD AND COVER |
247 |
| 3.3.3. LUBRICATION SYSTEM COMPONENTS |
249 |
| 3.3.4. ENGINE |
251 |
| 3.3.5. OIL SUMP |
253 |
| 3.3.6. CYLINDER HEAD |
255 |
| 3.3.7. SPECIAL INSTALLATION |
257 |
| 3.3.8. EXHAUST SYSTEM COMPONENTS |
259 |
| 3.3.9. INTAKE SYSTEM COMPONENTS |
261 |
| 3.3.10. ENGINE SUSPENSION |
263 |
| 3.3.11. MOVING PARTS |
265 |
| 3.3.12. ENGINE TIMING |
267 |
| 3.3.13. FUEL INJECTION EQUIPMENT |
269 |
| 3.4. ENGINE TESTS AND MAINTENANCE |
271 |
| 3.4.1. PRELIMINARY INSPECTION |
271 |
| 3.4.2. ENGINE TESTS |
271 |
| 3.4.3. REGULAR MAINTENANCE |
274 |
| 3.4.3.1. ENGINE OIL REPLACEMENT |
274 |
| 3.4.3.2. OIL FILTER REPLACEMENT |
274 |
| 3.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
275 |
| 3.4.3.4. MAIN FUEL FILTER REPLACEMENT |
275 |
| 3.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR |
276 |
| 3.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT |
277 |
| 3.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT |
278 |
| 3.4.3.8. COOLANT REPLACEMENT |
282 |
| 3.5. REPAIR AND INSPECTION DETAILS |
283 |
| 3.5.1. TIMING BELT |
283 |
| 3.5.2. FUEL TANK |
283 |
| 3.5.3. CYLINDER HEAD |
284 |
| 3.5.4. VALVES |
285 |
| 3.5.5. VALVE SEATS |
286 |
| 3.5.6. CRANKCASE |
287 |
| 3.5.7. VALVE SEAT INSERT |
288 |
| 3.5.8. HYDRAULIC LASH ADJUSTER |
288 |
| 3.5.9. CYLINDER HEAD COVER |
288 |
| 3.5.10. VALVE GUIDES |
289 |
| 3.5.11. CAMSHAFT |
290 |
| 3.5.12. PISTON AND PISTON RINGS |
291 |
| 3.5.13. CONNECTING ROD |
292 |
| 3.5.14. CRANKSHAFT |
294 |
| 3.6. ENGINE SYSTEM |
296 |
| 3.6.1. AIR INTAKE SYSTEM |
296 |
| 3.6.2. BLOW BY SYSTEM |
298 |
| 3.6.3. VACUUM MANAGEMENT SYSTEM |
299 |
| 3.6.4. COOLING SYSTEM |
301 |
| 3.6.5. LUBRICATION SYSTEM |
304 |
| 3.6.6. FUEL SYSTEM |
308 |
| 3.6.7. EXHAUST SYSTEM |
317 |
| 3.6.8. EXHAUST GAS RECIRCULATION SYSTEM |
320 |
| 3.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
322 |
| 3.7.1. ENGINE REMOVAL |
322 |
| 3.7.2. AIR FILTER ASSEMBLY REMOVAL |
324 |
| 3.7.3. POWER STEERING PUMP BELT (STRETCH BELT) |
324 |
| 3.7.4. ALTERNATOR AND AC BELT |
325 |
| 3.7.5. INJECTOR REMOVAL |
326 |
| 3.7.6. TIMING BELT REMOVAL |
327 |
| 3.7.7. FITMENT OF TIMING BELT |
329 |
| 3.7.8. INTERCOOLER REMOVAL |
332 |
| 3.7.9. RADIATOR REMOVAL |
333 |
| 3.7.10. COOLANT TANK REMOVAL |
335 |
| 3.7.11. RADIATOR FAN SHROUD REMOVAL |
336 |
| 3.7.12. THERMOSTAT REMOVAL |
336 |
| 3.7.13. FUEL RAIL REMOVAL |
337 |
| 3.7.14. FUEL FILLER ASSEMBLY REMOVAL |
338 |
| 3.7.15. FUEL TANK |
339 |
| 3.7.16. TANK UNIT REMOVAL |
340 |
| 3.7.17. FUEL LEVEL SENSOR REMOVAL |
342 |
| 3.7.18. TANK PRESSURE VALVE REMOVAL |
343 |
| 3.7.19. FUEL TANK PURGING PROCEDURE |
344 |
| 3.7.20. POST SILENCER AND INTERMEDIATE PIPE |
345 |
| 3.7.21. PRE-SILENCER AND MAIN SILENCER |
345 |
| 3.7.22. FRONT EXHAUST PIPE |
346 |
| 3.7.23. CLOSE COUPLED CATALYTIC CONVERTER |
346 |
| 3.7.24. EGR COOLER MODULE |
347 |
| 3.7.25. TURBOCHARGER |
349 |
| 3.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
352 |
| 3.8.1. ENGINE DIS-ASSEMBLY |
353 |
| 3.8.1.1. REMOVAL OF INTAKE MANIFOLD |
353 |
| 3.8.1.2. REMOVAL OF EXHAUST MANIFOLD |
358 |
| 3.8.1.3. REMOVAL OF OIL SUMP |
361 |
| 3.8.1.4. REMOVAL OF TIMING BELT |
362 |
| 3.8.1.5. REMOVAL OF CYLINDER HEAD |
364 |
| 3.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
366 |
| 3.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
369 |
| 3.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY |
370 |
| 3.8.2. ENGINE ASSEMBLY |
377 |
| 3.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
377 |
| 3.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
378 |
| 3.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
379 |
| 3.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
380 |
| 3.8.2.5. FITMENT OF TIMING BELT |
381 |
| 3.8.2.6. FITMENT OF OIL SUMP |
383 |
| 3.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
384 |
| 3.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
387 |
| 3.8.2.9. ON ENGINE SUPPORT STAND |
392 |
| 3.9. ENGINE MANAGEMENT SYSTEM (EMS) |
394 |
| 3.9.1. SYSTEM OVERVIEW |
395 |
| 3.9.2. BLOCK DIAGRAM |
396 |
| 3.9.3. CONNECTOR PIN ASSIGNMENT |
397 |
| 3.9.4. ANTI-CRANKING FUNCTION |
402 |
| 3.9.5. SENSORS AND ACTUATORS DETAILS |
403 |
| 3.9.5.1. CRANK ANGLE SENSOR |
403 |
| 3.9.5.2. CAM SENSOR |
404 |
| 3.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) |
406 |
| 3.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) |
407 |
| 3.9.5.5. COOLANT TEMPERATURE SENSOR |
409 |
| 3.9.5.6. FUEL TEMPERATURE SENSOR (FTS) |
410 |
| 3.9.5.7. INLET METERING VALVE (IMV) |
411 |
| 3.9.5.8. VENTURI |
411 |
| 3.9.5.9. RAIL PRESSURE SENSOR |
411 |
| 3.9.5.10. WATER IN FUEL SENSOR |
412 |
| 3.9.5.11. ACCELERATOR PEDAL SENSOR |
413 |
| 3.9.5.12. BRAKE SWITCH |
414 |
| 3.9.5.13. CLUTCH SWITCH |
416 |
| 3.9.5.14. GLOW PLUGS |
417 |
| 3.9.5.15. VTT ACTUATOR |
418 |
| 3.9.5.16. EGR VALVE ACTUATOR |
420 |
| 3.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) |
422 |
| 3.9.5.18. INTAKE THROTTLE VALVE |
423 |
| 3.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS |
424 |
| 4. ENGINE - 400Nm MANUAL TRANSMISSION |
425 |
| 4.1. GENERAL INFORMATION |
433 |
| 4.1.1. ENGINE INTRODUCTION |
433 |
| 4.1.2. TECHNICAL SPECIFICATION |
434 |
| 4.1.3. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES |
435 |
| 4.1.4. SERVICE SCHEDULE |
436 |
| 4.1.5. ASSEMBLY CLEARANCES |
438 |
| 4.1.6. SPECIAL TOOLS |
439 |
| 4.2. GENERAL SYMPTOMS DIAGNOSIS |
440 |
| 4.3. CONSTRUCTIONAL AND SERVICE DETAILS |
443 |
| 4.3.1. ENGINE MOUNTING COMPONENTS |
443 |
| 4.3.2. CYLINDER HEAD AND COVER |
445 |
| 4.3.3. LUBRICATION SYSTEM COMPONENTS |
447 |
| 4.3.4. ENGINE |
449 |
| 4.3.5. OIL SUMP |
451 |
| 4.3.6. CYLINDER HEAD |
453 |
| 4.3.7. SPECIAL INSTALLATION |
455 |
| 4.3.8. EXHAUST SYSTEM COMPONENTS |
457 |
| 4.3.9. INTAKE SYSTEM COMPONENTS |
459 |
| 4.3.10. ENGINE SUSPENSION |
461 |
| 4.3.11. MOVING PARTS |
463 |
| 4.3.12. ENGINE TIMING |
465 |
| 4.3.13. FUEL INJECTION EQUIPMENT |
467 |
| 4.4. ENGINE TESTS AND MAINTENANCE |
469 |
| 4.4.1. PRELIMINARY INSPECTION |
469 |
| 4.4.2. ENGINE TESTS |
469 |
| 4.4.3. REGULAR MAINTENANCE |
472 |
| 4.4.3.1. ENGINE OIL REPLACEMENT |
472 |
| 4.4.3.2. OIL FILTER REPLACEMENT |
472 |
| 4.4.3.3. AIR FILTER ELEMENT CLEANING AND REPLACEMENT |
473 |
| 4.4.3.4. MAIN FUEL FILTER REPLACEMENT |
473 |
| 4.4.3.5. DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR |
474 |
| 4.4.3.6. PRE-FILTER CUM SEDIMENTOR REPLACEMENT |
475 |
| 4.4.3.7. PRE-FILTER CARTRIDGE REPLACEMENT |
476 |
| 4.4.3.8. COOLANT REPLACEMENT |
480 |
| 4.5. REPAIR AND INSPECTION DETAILS |
481 |
| 4.5.1. TIMING BELT |
481 |
| 4.5.2. FUEL TANK |
481 |
| 4.5.3. CYLINDER HEAD |
482 |
| 4.5.4. VALVES |
483 |
| 4.5.5. VALVE SEATS |
484 |
| 4.5.6. CRANKCASE |
485 |
| 4.5.7. VALVE SEAT INSERT |
486 |
| 4.5.8. HYDRAULIC LASH ADJUSTER |
486 |
| 4.5.9. CYLINDER HEAD COVER |
486 |
| 4.5.10. VALVE GUIDES |
487 |
| 4.5.11. CAMSHAFT |
488 |
| 4.5.12. PISTON AND PISTON RINGS |
489 |
| 4.5.13. CONNECTING ROD |
490 |
| 4.5.14. CRANKSHAFT |
492 |
| 4.6. ENGINE SYSTEM |
494 |
| 4.6.1. AIR INTAKE SYSTEM |
494 |
| 4.6.2. BLOW BY SYSTEM |
496 |
| 4.6.3. VACUUM MANAGEMENT SYSTEM |
497 |
| 4.6.4. COOLING SYSTEM |
499 |
| 4.6.5. LUBRICATION SYSTEM |
502 |
| 4.6.6. FUEL SYSTEM |
506 |
| 4.6.7. EXHAUST SYSTEM |
515 |
| 4.6.8. EXHAUST GAS RECIRCULATION SYSTEM |
518 |
| 4.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
520 |
| 4.7.1. ENGINE REMOVAL |
520 |
| 4.7.2. AIR FILTER ASSEMBLY REMOVAL |
522 |
| 4.7.3. POWER STEERING PUMP BELT (STRETCH BELT) |
522 |
| 4.7.4. ALTERNATOR AND AC BELT |
523 |
| 4.7.5. INJECTOR REMOVAL |
524 |
| 4.7.6. TIMING BELT REMOVAL |
525 |
| 4.7.7. FITMENT OF TIMING BELT |
527 |
| 4.7.8. INTERCOOLER REMOVAL |
530 |
| 4.7.9. RADIATOR REMOVAL |
531 |
| 4.7.10. COOLANT TANK REMOVAL |
533 |
| 4.7.11. RADIATOR FAN SHROUD REMOVAL |
534 |
| 4.7.12. THERMOSTAT REMOVAL |
534 |
| 4.7.13. FUEL RAIL REMOVAL |
535 |
| 4.7.14. FUEL FILLER ASSEMBLY REMOVAL |
536 |
| 4.7.15. FUEL TANK |
537 |
| 4.7.16. TANK UNIT REMOVAL |
538 |
| 4.7.17. FUEL LEVEL SENSOR REMOVAL |
540 |
| 4.7.18. TANK PRESSURE VALVE REMOVAL |
541 |
| 4.7.19. FUEL TANK PURGING PROCEDURE |
542 |
| 4.7.20. POST SILENCER AND INTERMEDIATE PIPE |
543 |
| 4.7.21. PRE-SILENCER AND MAIN SILENCER |
543 |
| 4.7.22. FRONT EXHAUST PIPE |
544 |
| 4.7.23. CLOSE COUPLED CATALYTIC CONVERTER |
544 |
| 4.7.24. EGR COOLER MODULE |
545 |
| 4.7.25. TURBOCHARGER |
547 |
| 4.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
550 |
| 4.8.1. ENGINE DIS-ASSEMBLY |
551 |
| 4.8.1.1. REMOVAL OF INTAKE MANIFOLD |
551 |
| 4.8.1.2. REMOVAL OF EXHAUST MANIFOLD |
556 |
| 4.8.1.3. REMOVAL OF OIL SUMP |
559 |
| 4.8.1.4. REMOVAL OF TIMING BELT |
560 |
| 4.8.1.5. REMOVAL OF CYLINDER HEAD |
562 |
| 4.8.1.6. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
564 |
| 4.8.1.7. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
567 |
| 4.8.1.8. PISTON CONNECTING ROD DIS-ASSEMBLY |
568 |
| 4.8.2. ENGINE ASSEMBLY |
575 |
| 4.8.2.1. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
575 |
| 4.8.2.2. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
576 |
| 4.8.2.3. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
577 |
| 4.8.2.4. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
578 |
| 4.8.2.5. FITMENT OFTIMING BELT |
579 |
| 4.8.2.6. FITMENT OF OIL SUMP |
581 |
| 4.8.2.7. FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS |
582 |
| 4.8.2.8. FITMENT OF INTAKE MANIFOLD AND PERIPHERALS |
585 |
| 4.8.2.9. ON ENGINE SUPPORT STAND |
590 |
| 4.9. ENGINE MANAGEMENT SYSTEM (EMS) |
592 |
| 4.9.1. SYSTEM OVERVIEW |
593 |
| 4.9.2. BLOCK DIAGRAM |
594 |
| 4.9.3. CONNECTOR PIN ASSIGNMENT |
595 |
| 4.9.4. ANTI-CRANKING FUNCTION |
600 |
| 4.9.5. SENSORS AND ACTUATORS DETAILS |
601 |
| 4.9.5.1. CRANK ANGLE SENSOR |
601 |
| 4.9.5.2. CAM SENSOR |
602 |
| 4.9.5.3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) |
604 |
| 4.9.5.4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) |
605 |
| 4.9.5.5. COOLANT TEMPERATURE SENSOR |
607 |
| 4.9.5.6. FUEL TEMPERATURE SENSOR (FTS) |
608 |
| 4.9.5.7. INLET METERING VALVE (IMV) |
609 |
| 4.9.5.8. VENTURI |
609 |
| 4.9.5.9. RAIL PRESSURE SENSOR |
609 |
| 4.9.5.10. WATER IN FUEL SENSOR |
610 |
| 4.9.5.11. ACCELERATOR PEDAL SENSOR |
611 |
| 4.9.5.12. BRAKE SWITCH |
612 |
| 4.9.5.13. CLUTCH SWITCH |
614 |
| 4.9.5.14. GLOW PLUGS |
615 |
| 4.9.5.15. VTT ACTUATOR |
616 |
| 4.9.5.16. EGR VALVE ACTUATOR |
618 |
| 4.9.5.17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) |
620 |
| 4.9.5.18. INTAKE THROTTLE VALVE |
621 |
| 4.9.5.19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS |
622 |
| 5. CLUTCH - 320Nm |
623 |
| 5.1. GENERAL INFORMATION |
629 |
| 5.1.1. SPECIFICATIONS |
629 |
| 5.1.1.1. CLUTCH DISC ASSEMBLY |
629 |
| 5.1.1.2. SELF ADJUSTING CLUTCH COVER ASSEMBLY |
630 |
| 5.1.1.3. SINGLE MASS FLYWHEEL |
631 |
| 5.1.2. CLUTCH SYSTEM LAYOUT |
632 |
| 5.1.2.1. CLUTCH MASTER CYLINDER |
633 |
| 5.1.2.2. CONCENTRIC SLAVE CYLINDER |
633 |
| 5.1.2.3. PEAK TORQUE LIMITER |
633 |
| 5.1.2.4. HYDRAULIC ADAPTER |
634 |
| 5.1.2.5. SINGLE MASS FLYWHEEL |
634 |
| 5.1.2.6. SELF ADJUSTING CLUTCH |
634 |
| 5.1.3. TIGHTENING TORQUES |
635 |
| 5.1.4. SPECIAL TOOLS |
639 |
| 5.1.5. GENERAL SYMPTOMS DIAGNOSIS |
640 |
| 5.2. MAINTENANCE, INSPECTION AND TESTS |
642 |
| 5.2.1. PRELIMINARY INSPECTION |
642 |
| 5.2.2. REGULAR MAINTENANCE |
643 |
| 5.2.2.1. CLUTCH SWITCH ADJUSTMENT |
643 |
| 5.2.2.2. CLUTCH BLEEDING PROCEDURE |
643 |
| 5.2.2.3. CLUTCH FLUID DRAINING PROCEDURE |
644 |
| 5.2.3. REPAIRS |
645 |
| 5.2.3.1. CLUTCH PEDAL ASSEMBLY |
645 |
| 5.2.3.2. SELF ADJUSTING CLUTCH ASSEMBLY |
650 |
| 5.2.3.3. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
655 |
| 5.2.3.4. SINGLE MASS FLYWHEEL (ON VEHICLE) |
660 |
| 6. CLUTCH - 400Nm |
661 |
| 6.1. GENERAL INFORMATION |
667 |
| 6.1.1. SPECIFICATIONS |
667 |
| 6.1.1.1. CLUTCH DISC ASSEMBLY |
667 |
| 6.1.1.2. SELF ADJUSTING CLUTCH COVER ASSEMBLY |
668 |
| 6.1.1.3. SINGLE MASS FLYWHEEL |
669 |
| 6.1.2. CLUTCH SYSTEM LAYOUT |
670 |
| 6.1.2.1. CLUTCH MASTER CYLINDER |
671 |
| 6.1.2.2. CONCENTRIC SLAVE CYLINDER |
671 |
| 6.1.2.3. PEAK TORQUE LIMITER |
671 |
| 6.1.2.4. HYDRAULIC ADAPTER |
672 |
| 6.1.2.5. SINGLE MASS FLYWHEEL |
672 |
| 6.1.2.6. SELF ADJUSTING CLUTCH |
672 |
| 6.1.3. TIGHTENING TORQUES |
673 |
| 6.1.4. SPECIAL TOOLS |
677 |
| 6.1.5. GENERAL SYMPTOMS DIAGNOSIS |
678 |
| 6.2. MAINTENANCE, INSPECTION AND TESTS |
680 |
| 6.2.1. PRELIMINARY INSPECTION |
680 |
| 6.2.2. REGULAR MAINTENANCE |
681 |
| 6.2.2.1. CLUTCH SWITCH ADJUSTMENT |
681 |
| 6.2.2.2. CLUTCH BLEEDING PROCEDURE |
681 |
| 6.2.2.3. CLUTCH FLUID DRAINING PROCEDURE |
682 |
| 6.2.3. REPAIRS |
683 |
| 6.2.3.1. CLUTCH PEDAL ASSEMBLY |
683 |
| 6.2.3.2. SELF ADJUSTING CLUTCH ASSEMBLY |
688 |
| 6.2.3.3. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
693 |
| 6.2.3.4. SINGLE MASS FLYWHEEL (ON VEHICLE) |
698 |
| 7. GEAR BOX GBS-76 |
699 |
| 7.1. GENERAL INFORMATION |
706 |
| 7.1.1. SPECIFICATIONS |
706 |
| 7.1.2. TIGHTENING TORQUES |
707 |
| 7.1.3. SPECIAL TOOLS |
711 |
| 7.1.4. GENERAL SYMPTOMS DIAGNOSIS |
715 |
| 7.2. MAINTENANCE, INSPECTION AND TEST |
716 |
| 7.2.1. PRELIMINARY INSPECTION |
716 |
| 7.2.2. REGULAR MAINTENANCE |
716 |
| 7.2.3. ON VEHICLE PROCEDURES |
717 |
| 7.2.3.1. GEARBOX REMOVAL |
717 |
| 7.3. OVERHAULING |
719 |
| 7.3.1. INFORMATION FOR OVERHAULING |
719 |
| 7.3.1.1. COMPONENT INDENTIFICATION |
719 |
| 7.3.1.2. PRECAUTIONS |
722 |
| 7.3.1.3. CONSTRUCTIONAL DETAILS |
723 |
| 7.3.2. GEARBOX DISMANTLING (ON BENCH) |
726 |
| 7.3.3. DISMANTLING OF SUB-ASSEMBLIES |
733 |
| 7.3.3.1. MAIN SHAFT |
733 |
| 7.3.3.2. DRIVE SHAFT |
744 |
| 7.3.3.3. REVERSE IDLER SHAFT |
745 |
| 7.3.3.4. COUNTER SHAFT |
747 |
| 7.3.3.5. FRONT COVER |
750 |
| 7.3.3.6. TOP COVER |
751 |
| 7.3.3.7. REAR COVER (4X2) |
752 |
| 7.3.3.8. ADAPTOR (4X4) |
753 |
| 7.3.3.9. SHIFTER SHAFTS & FORKS |
754 |
| 7.3.3.10. NON-ADJUSTABLE SHIFTER LINKAGE |
756 |
| 7.3.4. GEAR BOX ASSEMBLY |
759 |
| 8. GEAR BOX G-6450 |
768 |
| 8.1. GENERAL INFORMATION |
769 |
| 8.1.1. SPECIFICATIONS |
769 |
| 8.1.2. TIGHTENING TORQUE |
770 |
| 8.1.3. SPECIAL TOOLS |
775 |
| 8.1.4. GENERAL SYMPTOMS DIAGNOSIS |
779 |
| 8.2. MAINTENANCE, INSPECTION, AND TEST |
780 |
| 8.2.1. PRELIMINARY INSPECTION |
780 |
| 8.2.2. REGULAR MAINTENANCE |
780 |
| 8.2.3. ON VEHICLE PROCEDURE |
781 |
| 8.2.3.1. GEARBOX REMOVAL |
781 |
| 8.2.4. CONSTRUCTION OF GEAR BOX |
783 |
| 8.3. OVERHAULING |
785 |
| 8.3.1. INFORMATION FOR OVERHAULING |
785 |
| 8.3.1.1. COMPONENT INDENTIFICATION |
785 |
| 8.3.2. GEAR BOX DISMANTLING ON BENCH PROCEDURE |
788 |
| 8.3.3. INSPECTION |
798 |
| 8.3.4. GEAR BOX ASSEMBLY ON BENCH PROCEDURE |
800 |
| 9. AUTOMATIC TRANSMISSION |
816 |
| 9.1. TRANSMISSION BASE SPECIFICATION |
820 |
| 9.2. TRANSMISSION SYSTEM OVERVIEW |
821 |
| 9.3. EXPLANATION OF THE SELECTOR LEVER POSITIONS |
822 |
| 9.4. PRINCIPLE OF OPERATIONS |
824 |
| 9.5. EXPLODED VIEW OF TRANSMISSION |
831 |
| 9.6. MAINTENANCE AND SERVICE / FREQUENCY |
833 |
| 9.7. FLUID DRAIN AND OIL PAN REMOVING PROCEDURE |
834 |
| 9.8. OIL PAN INSTALLATION PROCEDURE |
835 |
| 9.9. TRANSMISSION FLUID FILL TUBE REMOVING AND INSTALLATION PROCEDURE |
835 |
| 9.10. TRANSMISSION FLUID LEVEL AFTER REPAIRS PROCEDURE |
836 |
| 9.11. TRANSMISSION FLUID LEVEL CHECKING PROCEDURE |
837 |
| 9.12. ESD (ELECTROSTATIC DISCHARGE) NOTICE |
838 |
| 9.13. REAR WHEEL DRIVE TRANSMISSION REMOVING PROCEDURE |
839 |
| 9.14. REAR WHEEL DRIVE TRANSMISSION INSTALLING PROCEDURE |
844 |
| 9.15. ALL-WHEEL DRIVE TRANSMISSION REMOVING PROCEDURE |
850 |
| 9.16. ALL-WHEEL DRIVE TRANSMISSION INSTALLING PROCEDURE |
857 |
| 9.17. TORQUE CONVERTER REMOVING PROCEDURE |
863 |
| 9.18. TORQUE CONVERTER INSTALLING PROCEDURE |
864 |
| 9.19. OIL FILTER-LIP SEAL REMOVING & INSTALLING PROCEDURE |
865 |
| 9.20. MECHATRONIC REMOVING PROCEDURE |
866 |
| 9.21. MECHATRONIC INSTALLING PROCEDURE |
868 |
| 9.22. SELECTOR SHAFT & LIP SEAL REMOVING PROCEDURE |
870 |
| 9.23. SELECTOR SHAFT & LIP SEAL INSTALLING PROCEDURE |
871 |
| 9.24. SHIFT LINKAGE ADJUSTMENT PROCEDURE |
872 |
| 9.25. TRANSMISSION AIR OIL COOLER REMOVAL WITHOUT HOSES AND TUBES |
874 |
| 9.26. TRANSMISSION WATER OIL COOLER REMOVAL PROCEDURE |
877 |
| 10. TORQUE ON DEMAND (TOD) |
879 |
| 10.1. GENERAL INFORMATION |
881 |
| 10.1.1. SPECIFICATIONS |
881 |
| 10.1.2. LAYOUT |
882 |
| 10.2. COMPONENTS OF TOD |
883 |
| 10.2.1. ECU |
883 |
| 10.2.1.1. GENERAL |
883 |
| 10.2.1.2. LOCATION |
883 |
| 10.2.1.3. ECU INPUT/ OUTPUT BLOCK DIAGRAM |
884 |
| 10.2.1.4. PINOUT |
885 |
| 10.2.2. MOMENTARY SWITCH |
886 |
| 10.2.3. WARNING LAMP |
886 |
| 10.2.4. CLUTCH COIL |
887 |
| 10.3. WORKING OF TOD |
887 |
| 10.4. TIGHTENING TORQUES |
892 |
| 10.5. SPECIAL TOOLS |
894 |
| 10.6. GENERAL SYMPTOMS AND DIAGNOSIS |
897 |
| 10.7. MAINTENANCE |
898 |
| 10.8. ON VEHICLE REPAIRS |
899 |
| 10.8.1. TRANSFER CASE |
899 |
| 10.8.2. TOD ELECTRONIC CONTROL UNIT (ECU) |
900 |
| 10.9. OVERHAULING |
901 |
| 10.9.1. DISMANTLING |
901 |
| 10.9.1.1. REAR YOKE |
901 |
| 10.9.1.2. REAR COVER ASSEMBLY |
901 |
| 10.9.1.3. CLUTCH PACK ASSEMBLY |
903 |
| 10.9.1.4. CHAIN DRIVE |
905 |
| 10.9.1.5. GEROTOR PUMP |
906 |
| 10.9.1.6. FRONT OUTPUT SHAFT AND YOKE |
908 |
| 10.9.1.7. ADAPTER, INPUT SHAFT AND CARRIER ASSEMBLY |
909 |
| 10.10. INSPECTION AND CLEANING |
910 |
| 10.10.1. ASSEMBLY |
910 |
| 10.10.1.1. ADAPTER AND INPUT SHAFT |
910 |
| 10.10.1.2. FRONT OUTPUT SHAggFT AND YOKE |
911 |
| 10.10.1.3. ASSEMBLY OF OUTPUT SHAFT AND GEROTOR PUMP |
912 |
| 10.10.1.4. CHAIN DRIVE |
914 |
| 10.10.1.5. CLUTCH PACK |
915 |
| 10.10.1.6. COVER ASSEMBLY |
919 |
| 10.10.1.7. REAR OUTPUT YOKE |
921 |
| 11. FRONT SUSPENSION |
922 |
| 11.1. GENERAL INFORMATION |
928 |
| 11.1.1. SPECIFICATIONS |
928 |
| 11.1.2. CONSTRUCTION |
929 |
| 11.1.3. TIGHTENING TORQUES |
930 |
| 11.1.4. SPECIAL TOOLS |
935 |
| 11.2. GENERAL SYMPTOMS AND DIAGNOSIS |
939 |
| 11.3. MAINTENANCE |
940 |
| 11.3.1. PRELIMINARY INSPECTION |
940 |
| 11.3.2. REGULAR MAINTENANCE |
940 |
| 11.4. ON VEHICLE REPAIRS |
942 |
| 11.4.1. ANTI ROLL BAR (ARB) REMOVAL |
942 |
| 11.4.2. FRONT STRUT ASSEMBLY REMOVAL |
943 |
| 11.4.3. LOWER WISHBONE REMOVAL |
944 |
| 11.4.4. UPPER WISHBONE REMOVAL |
945 |
| 11.4.5. BUMP STOPPER |
946 |
| 11.5. OVERHAULING |
947 |
| 11.5.1. PRECAUTIONS |
947 |
| 11.5.2. DISMANTLING, INSPECTION AND ASSEMBLY |
947 |
| 11.5.2.1. FRONT STRUT DISMANTLING./ DAMPER REPLACEMENT |
947 |
| 11.5.2.2. FRONT DAMPER BOTTOM BUSH |
950 |
| 11.5.2.3. UPPER WISHBONE BUSH |
950 |
| 11.5.2.4. UPPER WISHBONE BALL JOINT |
952 |
| 11.5.2.5. LOWER WISHBONE BALL JOINT REMOVAL |
952 |
| 12. REAR SUSPENSION |
953 |
| 12.1. GENERAL INFORMATION |
957 |
| 12.1.1. SPECIFICATIONS |
957 |
| 12.1.2. CONSTRUCTION |
958 |
| 12.1.3. TIGHTENING TORQUES |
959 |
| 12.1.4. SPECIAL TOOLS |
962 |
| 12.2. MAINTENANCE |
966 |
| 12.2.1. ON VEHICLE REPAIRS |
966 |
| 12.2.1.1. ANTIROLL BAR |
966 |
| 12.2.1.2. REAR SUSPENSION LINKS TIGHTENING PROCEDURE |
967 |
| 12.2.1.3. UPPER LINK REMOVAL |
968 |
| 12.2.1.4. LOWER LINK REMOVAL |
968 |
| 12.2.1.5. PAN HARD ROD REMOVAL |
969 |
| 12.2.1.6. REAR SHOCK ABSORBER REMOVAL |
969 |
| 12.2.1.7. REAR COIL SPRING REMOVAL |
970 |
| 12.3. OVERHAULING |
971 |
| 12.3.1. PRECAUTIONS |
971 |
| 12.3.2. DISMANTLING, INSPECTION AND ASSEMBLY |
971 |
| 12.3.2.1. UPPER LINK BUSH REMOVAL |
971 |
| 12.3.2.2. LOWER LINK BUSH REMOVAL |
972 |
| 12.3.2.3. PAN HARD ROD BUSH REMOVAL |
973 |
| 12.3.2.4. SHOCK ABSORBER BOTTOM BUSH REMOVAL |
975 |
| 12.3.2.5. SHOCK ABSORBER TOP REPLACEMENT |
976 |
| 13. FRONT AXLE 4X2 |
977 |
| 13.1. GENERAL INFORMATION |
983 |
| 13.1.1. TECHNICAL SPECIFICATION |
983 |
| 13.1.2. CONSTRUCTION AND LAYOUT |
983 |
| 13.1.3. TIGHTENING TORQUES |
984 |
| 13.1.4. SPECIAL TOOLS |
985 |
| 13.2. MAINTENANCE |
986 |
| 13.2.1. ON VEHICLE PROCEUDRE |
986 |
| 13.2.1.1. FRONT STUB AXLE ASSEMBLY |
986 |
| 13.2.1.2. HUB REPLACEMENT |
989 |
| 13.2.1.3. TONER RING REPLACEMENT |
991 |
| 14. FRONT AXLE 4X4 |
993 |
| 14.1. GENERAL INFORMATION |
999 |
| 14.1.1. SPECIFICATION |
999 |
| 14.1.2. CONSTRUCTION |
1000 |
| 14.1.3. TIGHTENING TORQUES |
1001 |
| 14.1.4. SPECIAL TOOLS |
1005 |
| 14.2. GENERAL SYMPTOMS AND DIAGNOSIS |
1010 |
| 14.3. MAINTENANCE |
1011 |
| 14.3.1. PRELIMINARY INSPECTION |
1011 |
| 14.3.2. REGULAR MAINTENANCE |
1011 |
| 14.4. ON VEHICLE REPAIRS |
1012 |
| 14.4.1. FRONT AXLE ASSEMBLY |
1012 |
| 14.4.2. ELECTRICAL DISCONNECT ASSEMBLY |
1015 |
| 14.4.3. TONER RING |
1016 |
| 14.5. OVERHAULING |
1018 |
| 14.5.1. PRECAUTIONS |
1018 |
| 14.5.2. DISMANTLING INSPECTION AND ASSEMBLY |
1018 |
| 14.5.2.1. DIFFERENTIAL CASING |
1018 |
| 14.5.2.2. PINION POSITION SHIM SELECTION |
1023 |
| 14.5.2.3. WHEEL END ASSEMBLY |
1031 |
| 14.5.2.4. FRONT AXLE DISCONNECT (FAD) |
1035 |
| 14.5.2.5. CONSTANT VELOCITY SHAFT |
1040 |
| 15. REAR AXLE |
1044 |
| 15.1. GENERAL INFORMATION |
1050 |
| 15.1.1. SPECIFICATION |
1050 |
| 15.1.2. SYSTEM LAYOUT |
1051 |
| 15.1.3. TIGHTENING TORQUE |
1052 |
| 15.1.4. SPECIAL TOOLS |
1055 |
| 15.2. GENERAL SYMPTOMS AND DIAGNOSIS |
1059 |
| 15.3. MAINTENANCE |
1061 |
| 15.3.1. PRELIMINARY INSPECTION |
1061 |
| 15.3.2. REGULAR MAINTENANCE |
1061 |
| 15.4. ON VEHICLE REPAIRS |
1062 |
| 15.4.1. REAR AXLE |
1062 |
| 15.4.2. AXLE SHAFT |
1064 |
| 15.4.3. DIFFERENTIAL CASE |
1065 |
| 15.5. OVERHAULING |
1067 |
| 15.5.1. PRECAUTIONS |
1067 |
| 15.5.2. DISMANTLING INSPECTION AND ASSEMBLY |
1067 |
| 15.5.2.1. AXLE SHAFT |
1067 |
| 15.5.2.2. DIFFERENTIAL CASING |
1070 |
| 15.5.2.3. PINION POSITION SHIM SELECTION |
1077 |
| 15.5.2.4. DIFFERENTIAL SHIM SELECTION |
1080 |
| 15.5.2.5. LIMITED SLIP DIFFERENTIAL |
1085 |
| 16. WHEELS AND TYRES |
1090 |
| 16.1. GENERAL INFORMATION |
1093 |
| 16.1.1. SPECIFICATIONS |
1093 |
| 16.1.2. CONSTRUCTION |
1094 |
| 16.1.3. TIGHTENING TORQUES |
1096 |
| 16.2. GENERAL SYMPTOMS DIAGNOSIS |
1097 |
| 16.2.1. DIAGNOSIS CHART |
1097 |
| 16.2.2. TYRE WEAR PATTERN |
1100 |
| 16.2.3. WEAR CAUSES |
1102 |
| 16.2.4. TYRE VIBRATION DIAGNOSIS |
1104 |
| 16.3. MAINTENANCE, INSPECTION AND TESTS |
1105 |
| 16.3.1. PRELIMINARY INSPECTION |
1105 |
| 16.3.2. REGULAR MAINTENANCE |
1106 |
| 16.3.2.1. INFLATION |
1106 |
| 16.3.2.2. WHEEL BALANCING |
1106 |
| 16.3.2.3. TYRE ROTATION |
1107 |
| 16.3.2.4. WHEEL RUN OUT |
1108 |
| 16.3.2.5. DO'S AND DON’TS |
1109 |
| 16.4. WHEEL AND TYRE REPLACEMENT |
1110 |
| 16.4.1. PRECAUTIONS DURING TYRE REPLACEMENT |
1110 |
| 16.4.2. TYRE REPLACEMENT |
1111 |
| 16.4.3. WHEEL ASSEMBLY REPLACEMENT |
1111 |
| 17. PROPELLER SHAFT |
1112 |
| 17.1. GENERAL INFORMATION |
1118 |
| 17.1.1. ADJUSTMENT / REPAIR DATA |
1118 |
| 17.2. SYSTEM DESCRIPTION |
1119 |
| 17.2.1. FOR 4X2 DRIVE |
1119 |
| 17.2.2. FOR 4X4 DRIVE |
1120 |
| 17.3. TIGHTENING TORQUE |
1121 |
| 17.4. SPECIAL TOOLS |
1122 |
| 17.5. GENERAL SYMPTOMS DIAGNOSIS |
1123 |
| 17.6. MAINTENANCE, INSPECTION AND TESTS |
1124 |
| 17.7. REGULAR MAINTENANCET |
1124 |
| 17.8. ON VEHICLE REPAIRS |
1125 |
| 17.8.1. PROPELLER SHAFT 4X2 |
1126 |
| 17.8.2. PROPELLER SHAFT 4X4 |
1127 |
| 17.9. OVERHAULING |
1128 |
| 18. BRAKES |
1133 |
| 18.1. GENERAL INFORMATION |
1138 |
| 18.1.1. SPECIFICATIONS |
1138 |
| 18.1.2. SYSTEM SCHEMATICS |
1139 |
| 18.1.3. SYSTEM LAYOUT |
1140 |
| 18.1.4. TIGHTENING TORQUES |
1141 |
| 18.2. GENERAL SYMTOMS DIAGNOSIS |
1143 |
| 18.3. MAINTENANCE, INSPECTION AND TEST |
1144 |
| 18.3.1. PRELIMINARY INSPECTION |
1145 |
| 18.3.1.1. FRONT BRAKE AND REAR BRAKE |
1145 |
| 18.3.1.2. PARKING BRAKE |
1145 |
| 18.3.1.3. BRAKE HOSES AND LINES |
1145 |
| 18.3.1.4. ROAD TEST |
1145 |
| 18.3.2. REGULAR MAINTAENANCE |
1146 |
| 18.3.2.1. BRAKE BLEEDING PROCEDURE |
1146 |
| 18.3.2.2. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) |
1147 |
| 18.3.2.3. CALIPER PAD REPLACEMENT |
1152 |
| 18.3.2.4. PARKING BRAKE ADJUSTMENT |
1153 |
| 18.3.2.5. BRAKE FLUID DRAINING PROCEDURE |
1154 |
| 18.3.2.6. BRAKE LIGHT SWITCH ADJUSTMENT |
1155 |
| 18.3.2.7. BOOSTER FILTER REPLACEMENT |
1156 |
| 18.3.2.8. GREASING |
1157 |
| 18.3.2.9. DISC RUN-OUT MEASUREMENT PROCEDURE |
1158 |
| 18.3.3. ON VEHICLE REPAIRS |
1158 |
| 18.3.3.1. CALIPER ASSEMBLY WITH CARRIER |
1158 |
| 18.3.3.2. BRAKE DISC |
1159 |
| 18.3.3.3. PARKING BRAKE |
1162 |
| 18.3.3.4. BRAKE PEDAL |
1165 |
| 18.3.3.5. VACUUM TANK AND VACUUM LINES |
1168 |
| 18.3.3.6. BOOSTER ASSEMBLY |
1170 |
| 18.3.3.7. PARKING BRAKE (DRUM IN HAT) |
1174 |
| 18.4. OVERHAULING |
1176 |
| 18.4.1. PRECAUTIONS |
1176 |
| 18.4.2. DISMANTLING, INSPECTION AND ASSEMBLY |
1177 |
| 18.4.2.1. FRONT CALIPER ASSEMBLY |
1177 |
| 18.4.2.2. REAR CALIPER ASSEMBLY |
1181 |
| 19. ANTI-LOCK BRAKING SYSTEM (ABS) |
1185 |
| 19.1. GENERAL INFORMATION |
1191 |
| 19.1.1. NECCESITY OF ABS WITH EBD |
1191 |
| 19.1.2. TECHNICAL SPECIFICATIONS |
1192 |
| 19.1.3. TIGHTENING TORQUES |
1193 |
| 19.1.4. SCHEMATIC OF HYDRAULIC CIRCUIT |
1195 |
| 19.1.5. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
1196 |
| 19.2. COMPONENTS |
1200 |
| 19.2.1. ABS ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
1201 |
| 19.2.2. WHEEL SPEED SENSOR |
1204 |
| 19.2.3. ABS SYSTEM FAILURE WARNING LIGHT |
1205 |
| 19.3. REPAIRS |
1207 |
| 19.3.1. ABS ECU/HCU REMOVAL |
1207 |
| 19.3.2. FRONT WHEEL SPEED SENSOR |
1210 |
| 19.3.3. FRONT TONER RING |
1211 |
| 19.3.4. REAR WHEEL SPEED SENSOR |
1212 |
| 19.3.5. REAR TONER RING |
1213 |
| 19.4. TROUBLE SHOOTING AND DIAGNOSIS |
1214 |
| 19.4.1. ROAD TEST |
1214 |
| 19.4.2. TABLE OF ABS 8.1 - FALL-BACK LEVEL |
1214 |
| 19.5. ABS DIAGNOSTIC USER MANUAL |
1215 |
| 20. ELECTRONIC STABILITY PROGRAM (ESP) |
1228 |
| 20.1. GENERAL INFORMATION |
1234 |
| 20.1.1. NECESSITY OF ESP AND TCS |
1234 |
| 20.1.2. SPECIFICATIONS |
1235 |
| 20.1.3. TIGHTENING TORQUES |
1236 |
| 20.1.4. SYSTEM LAYOUT |
1237 |
| 20.2. WORKING OF ESP |
1238 |
| 20.3. COMPONENTS |
1240 |
| 20.3.1. ESP ECU AND HYDRAULIC UNIT |
1240 |
| 20.3.2. YAW RATE SENSOR (YRS) |
1242 |
| 20.3.3. STEERING ANGLE SENSOR (SAS) |
1243 |
| 20.3.4. ESP SYSTEM FAILURE WARNING LIGHT |
1244 |
| 20.4. ON VEHICLE REPAIRS |
1245 |
| 20.4.1. YAW RATE SENSOR REMOVAL |
1245 |
| 20.4.2. STEERING ANGLE SENSOR REMOVAL |
1246 |
| 20.4.3. STEERING ANGLE SENSOR CALIBRATION USING DIAGNOSTIC TOOL |
1248 |
| 20.5. TROUBLESHOOTING |
1256 |
| 21. STEERING |
1257 |
| 21.1. GENERAL INFORMATION |
1259 |
| 21.1.1. SPECIFICATIONS |
1259 |
| 21.1.2. SYSTEM LAYOUT |
1260 |
| 21.1.3. TIGHTENING TORQUES |
1261 |
| 21.1.4. SPECIAL TOOLS |
1265 |
| 21.2. GENERAL SYMPTOMS DIAGNOSIS |
1266 |
| 21.3. MAINTENANCE, INSPECTION AND TEST |
1273 |
| 21.3.1. PRELIMINARY INSPECTION |
1273 |
| 21.3.1.1. INSPECTION OF TYRE |
1273 |
| 21.3.1.2. STEERING WHEEL FREE PLAY |
1273 |
| 21.3.1.3. LEAKAGES IN THE HYDRAULIC SYSTEM |
1273 |
| 21.3.1.4. TEST DRIVE |
1273 |
| 21.3.1.5. ROAD TEST |
1273 |
| 21.3.2. REGULAR MAINTENANCE |
1274 |
| 21.3.2.1. POWER STEERING OIL REPLACEMENT |
1274 |
| 21.3.2.2. POWER STEERING RESERVOIR ASSY |
1275 |
| 21.3.2.3. HYDRAULIC SYSTEM AIR BLEEDING |
1276 |
| 21.3.2.4. TOE IN ADJSUTMENT |
1277 |
| 21.3.2.5. STEERING WHEEL ALIGNMENT/CENTRALISING |
1278 |
| 21.3.2.6. STEERING WHEEL PLAY |
1278 |
| 21.3.2.7. POWER STEERING OIL FLUSHING PROCEDURE |
1279 |
| 21.3.3. REPAIRS |
1280 |
| 21.3.3.1. STEERING WHEEL |
1280 |
| 21.3.3.2. STEERING COLUMN |
1283 |
| 21.3.3.3. STEERING RESERVOIR AND POWER STEERING PUMP |
1286 |
| 21.3.3.4. RACK AND PINION ASSEMBLY |
1288 |
| 21.4. OVERHAULING |
1289 |
| 21.4.1. PRECAUTIONS |
1289 |
| 21.4.2. RACK AND PINION ASSEMBLY |
1290 |
| 21.4.3. DISMANTLING, INSPECTION AND ASSEMBLY |
1291 |
| 21.4.3.1. OUTER BALL JOINT (OBJ) |
1291 |
| 21.4.3.2. BELLOW KIT |
1292 |
| 21.4.3.3. INNER BALL JOINT (IBJ) |
1293 |
| 21.4.3.4. FEED PIPE |
1294 |
| 21.4.3.5. DO’S & DON’TS |
1295 |
| 21.4.4. STEERING PUMP |
1298 |
| 21.4.4.1. PRESSURE PORT CONNECTOR |
1298 |
| 21.4.4.2. SUCTION PORT CONNETOR |
1300 |
| 22. ELECTRICAL |
1301 |
| 22.1. TECHNICAL SPECIFICATIONS |
1303 |
| 22.2. GENERAL ELECTRCIAL PRECAUTIONS |
1307 |
| 22.3. CHARGING & STARTING SYSTEM |
1310 |
| 22.3.1. BATTERY |
1310 |
| 22.3.2. ALTERNATOR |
1320 |
| 22.3.3. STARTER MOTOR |
1337 |
| 22.4. LIGHTING SYSTEM |
1354 |
| 22.4.1. BULB SPECIFICATIONS |
1354 |
| 22.4.2. TORQUE VALUE TABLE |
1355 |
| 22.4.3. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS |
1356 |
| 22.4.4. HEAD LAMP |
1360 |
| 22.4.5. FRONT FOG LAMP WITH DRL |
1365 |
| 22.4.6. FIRST and SECOND ROOF LAMP |
1366 |
| 22.4.7. THIRD ROOF LAMP |
1367 |
| 22.4.8. REGISTRATION PLATE LAMP |
1368 |
| 22.4.9. HIGH MOUNTED STOP LAMP |
1368 |
| 22.4.10. DOOR AJAR CUM PUDDLE LAMP |
1369 |
| 22.4.11. GLOVE BOX LAMP |
1370 |
| 22.4.12. LOAD AREA LAMP |
1371 |
| 22.4.13. TAIL LAMP |
1371 |
| 22.4.14. SUNVISOR MIRROR LAMP |
1374 |
| 22.4.15. MOOD LAMP |
1374 |
| 22.5. HORN |
1375 |
| 22.6. POWER SOCKET |
1380 |
| 22.7. WIPER AND WASHER SYSTEM |
1383 |
| 22.7.1. FRONT AND REAR WIPER AND WASHER SYSTEM COMPONENT LOCATIONS |
1383 |
| 22.7.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
1385 |
| 22.7.3. FRONT WIPER MOTOR |
1386 |
| 22.7.4. FRONT WIPER ARM AND BLADE |
1388 |
| 22.7.5. REAR WIPER ARM AND BLADE |
1390 |
| 22.7.6. REAR WIPER MOTOR |
1392 |
| 22.7.7. WIPER CARE |
1394 |
| 22.7.8. WASHER BOTTLE |
1395 |
| 22.7.9. WASHER PUMP |
1397 |
| 22.7.10. FRONT WASHER NOZZLE |
1398 |
| 22.7.11. REAR WASHER NOZZLE |
1399 |
| 22.7.12. FLOAT LEVEL SENSOR |
1400 |
| 22.7.13. DIAGNOSTIC INFORMATION AND PROCEDURES |
1401 |
| 22.8. ELECTRICAL SWITCHES |
1402 |
| 22.8.1. COMBINATION - SWITCH |
1402 |
| 22.8.2. IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION |
1415 |
| 22.8.3. MASTER LIGHT SWITCH |
1417 |
| 22.8.4. FASCIA SWITCH |
1423 |
| 22.8.5. WINDOW WINDING SWITCHES |
1427 |
| 22.8.6. STEERING WHEEL SWITCHES |
1433 |
| 22.8.7. BONNET SWITCH |
1437 |
| 22.8.8. TAILGATE SWITCH |
1438 |
| 22.8.9. DOOR SWITCHES (FRONT & REAR) |
1439 |
| 22.8.10. GLOVE BOX SWITCH |
1440 |
| 22.8.11. REVERSE LIGHT SWITCH |
1441 |
| 22.8.12. HAND BRAKE SWITCH |
1442 |
| 22.8.13. INERTIA SWITCH |
1443 |
| 22.8.14. DRIVE CONTROL SWITCH (DCS) |
1444 |
| 22.9. IN VEHICLE NETWORKING (IVN) |
1453 |
| 22.10. WINDOW WINDING CONTROLLER |
1461 |
| 22.11. BODY CONTROL MODULE (BCM) |
1469 |
| 22.11.1. BCM CONNECTOR PIN SIGNALS APLICABILITY MATRIX |
1471 |
| 22.11.2. BCM FUNCTIONS |
1488 |
| 22.11.2.1. EXTERIOR LIGHTS |
1489 |
| 22.11.2.2. INTERIOR LIGHTS |
1501 |
| 22.11.2.3. WIPER WASHER |
1507 |
| 22.11.2.4. VEHICLE POWER MODE |
1513 |
| 22.11.2.5. CENTRAL LOCKING & RKE |
1520 |
| 22.11.2.6. PERIMETRIC ALARM |
1526 |
| 22.11.2.7. USER CUSTOMIZATION SETTINGS |
1527 |
| 22.11.2.8. ORVM FOLD/UNFOLD |
1529 |
| 22.12. IMMOBILIZER SYSTEM |
1535 |
| 22.12.1. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
1301 |
| 22.12.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
1539 |
| 22.12.3. IGNITION SWITCH_AT WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION (XMA, XTA) |
1540 |
| 22.13. INSTRUMENT CLUSTER (XE VARIANT) |
1541 |
| 22.13.1. TACHOMETER |
1543 |
| 22.13.2. SPEEDOMETER |
1543 |
| 22.13.3. TEMPERATURE GAUGE |
1543 |
| 22.13.4. FUEL GAUGE |
1543 |
| 22.13.5. TELLTALES |
1544 |
| 22.13.6. DRIVER INFORMATION CENTER |
1548 |
| 22.13.7. FUEL COMPUTER |
1549 |
| 22.13.8. DIC SWITCH FUNCTIONS |
1551 |
| 22.13.9. CONNECTION BLOCK DIAGRAM |
1555 |
| 22.13.10. CONNECTOR DETAILS |
1557 |
| 22.13.11. DIAGNOSTICS BRIEF |
1559 |
| 22.14. INSTRUMENT CLUSTER - XM, XMA, XTA (4X2), XT (4X4) |
1565 |
| 22.14.1. TACHOMETER |
1567 |
| 22.14.2. FUEL GAUGE |
1567 |
| 22.14.3. SPEEDOMETER |
1568 |
| 22.14.4. TEMPERATURE GAUGE |
1568 |
| 22.14.5. DRIVER INFORMATION SYSTEM |
1569 |
| 22.14.6. XM, XT, XT (4X4) DRIVE MODE AND GEAR DISPLAY |
1578 |
| 22.14.7. XMA, XMA (4X4) DRIVE MODE AND GEAR DISPLAY |
1581 |
| 22.14.8. DISPLAY MESSAGES |
1583 |
| 22.14.9. WARNING LAMPS |
1587 |
| 22.14.10. CONNECTOR DETAILS OF XT, XM & XMA VARIANTS INSTRUMENT CLUSTER |
1590 |
| 22.15. ULTRASONIC PARK ASSIST SYSTEM |
1591 |
| 22.15.1. ULTRASONIC PARK ASSIST SYSTEM ARCHITECTURE |
1591 |
| 22.15.2. ULTRASONIC PARK ASSIST |
1592 |
| 22.15.3. ULTRASONIC PARK ASSIST OVERVIEW |
1592 |
| 22.15.4. ULTRASONIC PARK ASSIST ACTIVATION PROCEDURE |
1592 |
| 22.15.5. ULTRASONIC PARK ASSIST DEACTIVATION PROCEDURE |
1593 |
| 22.15.6. PARK ASSIST BUTTON LED INDICATIONS (IF EQUIPPED) |
1593 |
| 22.15.7. PARK ASSIST AUDIO SETTINGS |
1593 |
| 22.15.8. PARK ASSIST VOLUME |
1593 |
| 22.15.9. MIX WITH AUDIO |
1594 |
| 22.15.10. PARK ASSIST TONE |
1594 |
| 22.15.11. PARK ASSIST DELAY TIMER |
1594 |
| 22.15.12. ULTRA PARK ASSIST HMI INDICATIONS |
1594 |
| 22.15.13. ULTRASONIC PARK ASSIST SYSTEM LIMITATIONS |
1595 |
| 22.15.14. ULTRASONIC PARK ASSIST SYSTEM MAINTENANCE |
1595 |
| 22.15.15. PARK DISTANCE CONTROLLER LOCATION |
1595 |
| 22.15.16. PHYSICAL IMAGES |
1597 |
| 22.15.17. SENSOR FITMENT TO THE BUMPER |
1598 |
| 22.15.18. PARKING DISTANCE CONTROL WITH REAR VIEW CAMERA ( IF EQUIPPED ) |
1602 |
| 22.16. INFOTAINMENT SYSTEM: (If fitted) |
1608 |
| 22.16.1. USB/AUX PORT |
1612 |
| 22.16.2. SPEAKERS |
1613 |
| 22.16.3. TWEETER |
1616 |
| 22.16.4. AUDIO AMPLIFIER |
1618 |
| 22.16.5. MICROPHONE |
1620 |
| 22.16.6. ANTENNA |
1621 |
| 22.17. GENERAL ELECTRICAL INFORMATION |
1622 |
| 22.17.1. INTRODUCTION |
1623 |
| 22.17.2. FUSE & RELAY BOX DETAILS |
1627 |
| 22.18. CLUTCH PEDAL SENSOR |
1639 |
| 23A. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) - AUTOLIV |
1643 |
| 23A.1. TIGHTENING TORQUES |
1649 |
| 23A.2. WORKING OF RESTRAINTS |
1651 |
| A. RESTRAINTS WITHOUT AIRBAGS |
1651 |
| B. RESTRAINTS WITH AIRBAGS |
1651 |
| 23A.3. WORKING OF SRS |
1651 |
| 23A.4. SYSTEM LAYOUT |
1652 |
| A. RESTRAINT WITHOUT AIRBAG |
1652 |
| B. RESTRAINT WITH AIRBAG |
1652 |
| C. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT |
1654 |
| 23A.5. SAFETY PRECAUTIONS |
1655 |
| 23A.6. DISPOSAL OF FAULTY AIR BAG UNIT |
1657 |
| 23A.7. COMPONENTS |
1659 |
| A. RESTRAINT WITHOUT AIRBAGS |
1659 |
| I. SEAT BELT |
1659 |
| II. EMERGENCY LOCKING RETRACTOR (ELR) |
1659 |
| III. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP |
1659 |
| B. RESTRAINT WITH AIRBAGS |
1659 |
| I. ECU |
1659 |
| II. SENSORS |
1666 |
| III. AIR BAGS |
1668 |
| IV. RPLL BELTS |
1674 |
| V. CLOCK SPRING |
1676 |
| VI. SRS WARNING LAMP |
1679 |
| VII. PAB DECACTIVATION SWITCH |
1679 |
| VIII. PAB INDICATOR |
1681 |
| 23B. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) - BOSCH |
1685 |
| 23B.0. ABBREVIATIONS |
1692 |
| 23B.1. TIGHTENING TORQUES |
1693 |
| 23B.2. WORKING OF RESTRAINTS |
1695 |
| A. RESTRAINTSWITHOUT AIRBAGS |
1695 |
| B. RESTRAINTSWITH AIRBAGS |
1695 |
| 23B.3. WORKING OF SRS |
1695 |
| 23B.4. SYSTEM LAYOUT |
1696 |
| A. RESTRAINTWITHOUT AIRBAG |
1696 |
| B. RESTRAINTWITH AIRBAG |
1696 |
| C. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT |
1698 |
| 23B.5. SAFETY PRECAUTIONS |
1699 |
| 23B.6. DISPOSAL OF FAULTY AIR BAG UNIT |
1701 |
| 23B.7. COMPONENTS |
1703 |
| A. RESTRAINTWITHOUT AIRBAGS |
1703 |
| I. SEAT BELT |
1703 |
| II. EMERGENCY LOCKING RETRACTOR (ELR) |
1703 |
| III. MICROSWITCH / SEAT BELT REMINDER WARNING LAMP |
1703 |
| B. RESTRAINTWITH AIRBAGS |
1703 |
| I. ECU |
1703 |
| II. SENSORS |
1709 |
| III. AIR BAGS |
1711 |
| IV. RPLL BELTS |
1717 |
| V. CLOCK SPRING |
1719 |
| VI. SRS WARNING LAMP |
1722 |
| VII. PAB DECACTIVATION SWITCH |
1722 |
| VIII. PAB INDICATOR |
1722 |
| 24. BODY |
1728 |
| 24.1. GENERAL INFORMATION |
1737 |
| 24.1.1. SPECIFICATIONS |
1737 |
| 24.1.2. CONSTRUCTION |
1741 |
| 24.1.3. TIGHTENING TORQUES |
1742 |
| 24.2. ON VEHICLE REPAIRS |
1748 |
| 24.2.1. BONNET |
1748 |
| 24.2.2. FLOOR CONSOLE |
1752 |
| 24.2.3. AC DUCTS IN FLOOR CONSOLE |
1755 |
| 24.2.4. DASHBOARD |
1756 |
| 24.2.5. FRONT BUMPER |
1762 |
| 24.2.6. REAR BUMPER |
1765 |
| 24.2.7. DOOR |
1766 |
| 24.2.8. TAIL GATE |
1775 |
| 24.2.9. MIRROR |
1780 |
| 24.2.10. SEATS |
1781 |
| 24.2.11. TRIMS |
1787 |
| 24.2.12. LEAF SCREEN |
1792 |
| 24.2.13. PANEL ASSEMBLY |
1792 |
| 24.2.14. STONE GUARD |
1793 |
| 24.2.15. FRONT WHEEL ARCH LINER |
1793 |
| 24.2.16. FUEL FLAP MECHANISM |
1794 |
| 24.2.17. GLASS |
1795 |
| 24.2.18. ROOF LINER ASSEMBLY |
1798 |
| 24.2.19. FRONT FENDER |
1799 |
| 24.2.20. FRONT WHEEL ARCH COVER |
1799 |
| 24.2.21. VALANCE COVER |
1800 |
| 24.2.22. REAR DOOR CLADDING |
1800 |
| 24.2.23. REAR WHEEL ARCH COVER |
1801 |
| 24.2.24. LOAD FLOOR |
1802 |
| 24.2.25. ROOF RAIL ASSEMBLY |
1803 |
| 24.2.26. "D" PILLAR MOULDING |
1803 |
| 24.3. BODY REPAIR |
1804 |
| 25. HVAC |
1813 |
| 25.1. GENERAL INFORMATION |
1815 |
| 25.2. TIGHTENING TORQUES |
1817 |
| 25.3. PRECAUTIONS |
1820 |
| 25.4. HVAC SYSTEM LAYOUT AND WORKING |
1822 |
| 25.5. COMPONENTS OF HVAC |
1826 |
| 25.5.1. CONTROL PANEL |
1827 |
| 25.5.2. FRONT HVAC UNIT |
1831 |
| 25.5.3. REAR AC UNIT |
1834 |
| 25.5.4. COMPRESSOR |
1834 |
| 25.5.5. CONDENSER AND RECEIVER DRIER CONDENSER |
1836 |
| 25.5.6. THERMISTER OR THERMO SENSOR |
1836 |
| 25.5.7. TRINARY PRESSURE SWITCH |
1838 |
| 25.5.8. TEMPERATURE AND MODE ACTUATOR |
1839 |
| 25.5.9. AIR INLET ACTUATOR |
1840 |
| 25.5.10. REAR BLOWER CONTROLLER |
1842 |
| 25.6. TROUBLESHOOTING |
1844 |
| 25.7. MAINTENANCE |
1857 |
| 25.7.1. PRELIMINARY INSPECTION |
1857 |
| 25.7.2. REGULAR MAINTENANCE |
1859 |
| 25.8. ON VEHICLE REPAIRS |
1865 |
| 25.8.1. CONTROL PANEL ASSEMBLY |
1865 |
| 25.8.2. COMPRESSOR REMOVAL |
1865 |
| 25.8.3. FRONT HVAC UNIT |
1866 |
| 25.8.4. REAR AC UNIT |
1867 |
| 25.8.5. BLOWER (FRONT HVAC UNIT) |
1868 |
| 25.8.6. BLOWER RESISTER |
1868 |
| 25.8.7. LPM (LINEAR POWER MODULE) |
1869 |
| 25.8.8. WIRE MESH |
1869 |
| 25.8.9. TXV (THERMAL EVAPORATION VALVE) |
1870 |
| 25.8.10. PRESSURE SWITCH |
1870 |
| 25.8.11. CONDENSER |
1871 |
| 25.8.12. REFRIGERANT HOSES/PIPES |
1872 |
| 25.8.13. REAR AC DUCTING |
1874 |
| 25.8.14. CONDENSER SEALING DUCT |
1877 |
| 25.9. OVERHAULING |
1878 |
| 25.9.1. FRONT HVAC UNIT |
1878 |
| 25.9.2. REAR AC |
1882 |
| 25.9.3. COMPRESSOR |
1883 |
| 25.10. DIAGNOSTICS USING BLINK CODES |
1886 |
| 25.10.1. ACTIVATING DIAGNOSTICS MODE |
1886 |
| 25.10.2. DISPLAYING BLINK CODES |
1887 |
| 25.10.3. READING BLINK CODES |
1887 |
| 25.10.4. ERASING ACTIVE FAULTS |
1888 |
| 25.10.5. EXITING DIAGNOSTIC MODE |
1888 |
| 25.11. FULLY AUTOMATIC TEMPERATURE CONTROL (FATC) |
1889 |
| 25.11.1. INTRODUCTION |
1889 |
| 25.11.2. TECHNICAL SPECIFICATION |
1890 |
| 25.11.3. FATC CONTROL SCHEMATICS |
1892 |
| 25.12. COMPONENTS |
1893 |
| 25.12.1. FATC CONTROL PANEL DETAILS |
1893 |
| 25.12.2. CONTROLS |
1895 |
| 25.12.3. VF DISPLAY (VACUUM FLUORESCENT DISPLAY) |
1898 |
| 25.12.4. SOLAR LOAD SENSOR |
1900 |
| 25.12.5. INCAR TEMPERATURE SENSOR WITH INTEGRATED ASPIRATOR |
1901 |
| 25.12.6. OUTSIDE AIR TEMPERATURE SENSOR |
1904 |
| 25.12.7. LPM (LINEAR POWER MODULE) |
1905 |