| 1. GENERAL |
4 |
| 1.1 TECHNICAL SPECIFICATIONS |
6 |
| 1.2 CHASSIS TYPE AND SALES DESIGNATION |
12 |
| 1.3 LUBRICANTS AND COOLANT RECOMMENDATIONS |
13 |
| 1.4 SERVICE AND MAINTENANCE SCHEDULE |
15 |
| 1.5 ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS |
20 |
| 2. PRECAUTIONS |
21 |
| 2.1 GENERAL PRECAUTIONS |
23 |
| 2.2 SAFETY AGAINST PERSONAL INJURY |
24 |
| A. WORKING WITH VEHICLES FITTED WITH AIRBAG |
24 |
| B. WORKING WITH ENGINE 'ON' |
25 |
| 2.3 AVOIDING DAMAGE |
26 |
| 2.4 USED OIL HANDLING AND DISPOSAL |
26 |
| 2.5 FUEL HANDLING PRECAUTIONS |
27 |
| 2.6 HAZARDOUS MATERIAL |
28 |
| 3. ENGINE |
29 |
| 3.1 GENERAL INFORMATION |
33 |
| 3.1.1 SPECIFICATION |
33 |
| 3.1.2 TIGHTENING TORQUES |
34 |
| 3.1.3 SPECIAL TOOLS |
52 |
| 3.1.4 GENERAL SYMPTOMS DIAGNOSIS |
53 |
| 3.2 MAINTENANCE, INSPECTION AND TESTS |
56 |
| 3.2.1 PRELIMINARY INSPECTION |
56 |
| 3.2.2 REGULAR MAINTENANCE |
58 |
| A. ENGINE OIL REPLACEMENT |
58 |
| B. OIL FILTER REPLACEMENT |
59 |
| C. AIR FILTER CLEANING |
59 |
| D. FUEL FILTER REPLACEMENT |
60 |
| E. DRAINING WATER FROM PREFILTER CUM SEDIMENTOR |
61 |
| F. PREFILTER CUM SEDIMENTOR REPLACEMENT |
61 |
| G. PREFILTER CARTIRDGE REPLACEMENT |
62 |
| H. COOLANT REPLACEMENT |
66 |
| 3.2.3 ON VEHICLE PROCEDURES |
67 |
| A. ENGINE REMOVAL |
67 |
| B. AIR FILTER ASSEMBLY REMOVAL |
69 |
| C. POWER STEERING PUMP BELT (STRETCH BELT) |
69 |
| D. ALTERNATOR AND AC BELT |
70 |
| E. INJECTOR REMOVAL |
71 |
| F. TIMING BELT REMOVAL |
72 |
| G. TIMING BELT FITMENT |
74 |
| 3.3 OVERHAULING |
77 |
| 3.3.1 ENGINE DISMANTLING (ON STAND) |
77 |
| 3.3.2 CYLINDER HEAD |
84 |
| 3.3.3 TIMING SYSTEM |
96 |
| 3.3.4 ENGINE BLOCK |
99 |
| 3.3.5 ENGINE ASSEMBLY |
124 |
| 3.4 AIR INTAKE SYSTEM |
133 |
| 3.5 COOLING SYSTEM |
142 |
| 3.6 LUBRICATION SYSTEM |
149 |
| 3.7 FUEL SYSTEM |
155 |
| 3.8 EXHAUST SYSTEM |
171 |
| 3.9 ENGINE MANAGEMENT SYSTEM (EMS) |
189 |
| 3.10 DIAGNOSTIC USER MANUAL |
222 |
| 4. CLUTCH |
232 |
| 4.1 GENERAL INFORMATION |
235 |
| 4.1.1 SPECIFICATIONS |
235 |
| A. CLUTCH DISC ASSEMBLY |
235 |
| B. SELF ADJUSTING CLUTCH COVER ASSEMBLY |
236 |
| C. SINGLE MASS FLYWHEEL |
237 |
| 4.1.2 CLUTCH SYSTEM LAYOUT |
238 |
| A. CLUTCH MASTER CYLINDER |
239 |
| B. CONCENTRIC SLAVE CYLINDER |
239 |
| C. PEAK TORQUE LIMITER |
239 |
| D. HYDRAULIC ADAPTER |
240 |
| E. SINGLE MASS FLYWHEEL |
240 |
| F. SELF ADJUSTING CLUTCH |
240 |
| 4.1.3 TIGHTENING TORQUES |
241 |
| 4.1.4 SPECIAL TOOLS |
244 |
| 4.1.5 GENERAL SYMPTOMS DIAGNOSIS |
245 |
| 4.2 MAINTENANCE, INSPECTION AND TESTS |
247 |
| 4.2.1 PRELIMINARY INSPECTION |
247 |
| 4.2.2 REGULAR MAINTENANCE |
248 |
| A. CLUTCH SWITCH ADJUSTMENT |
248 |
| B. CLUTCH BLEEDING PROCEDURE |
248 |
| C. CLUTCH FLUID DRAINING PROCEDURE |
249 |
| 4.2.3 REPAIRS |
250 |
| A. CLUTCH PEDAL ASSEMBLY |
250 |
| B. SELF ADJUSTING CLUTCH ASSEMBLY |
255 |
| C. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
260 |
| D. SINGLE MASS FLYWHEEL (ON VEHICLE) |
265 |
| 5A. 5 SPEED GEARBOX- G 76 MK II |
266 |
| 5A.1 GENERAL INFORMATION |
270 |
| 5A.1.1 SPECIFICATIONS |
270 |
| 5A.1.2 TIGHTENING TORQUES |
271 |
| 5A.1.3 SPECIAL TOOLS |
275 |
| 5A.1.4 GENERAL SYMPTOMS DIAGNOSIS |
279 |
| 5A.2 MAINTENANCE, INSPECTION AND TEST |
280 |
| 5A.2.1 PRELIMINARY INSPECTION |
280 |
| 5A.2.2 REGULAR MAINTENANCE |
280 |
| 5A.2.3 ON VEHICLE PROCEDURES |
281 |
| A. GEARBOX REMOVAL |
281 |
| 5A.3 OVERHAULING |
283 |
| 5A.3.1 INFORMATION FOR OVERHAULING |
283 |
| A. COMPONENT INDENTIFICATION |
283 |
| B. PRECAUTIONS |
286 |
| C. CONSTRUCTIONAL DETAILS |
287 |
| 5A.3.2 GEARBOX DISMANTLING (ON BENCH) |
290 |
| 5A.3.3 DISMANTLING OF SUB-ASSEMBLIES |
297 |
| A. MAIN SHAFT |
297 |
| B. DRIVE SHAFT |
308 |
| C. REVERSE IDLER SHAFT |
309 |
| D. COUNTER SHAFT |
311 |
| E. FRONT COVER |
314 |
| F. TOP COVER |
315 |
| G. REAR COVER (4X2) |
317 |
| H. ADAPTOR (4X4) |
318 |
| I. SHIFTER SHAFTS & FORKS |
319 |
| J. NON-ADJUSTABLE SHIFTER LINKAGE |
321 |
| 5A.3.4 GEAR BOX ASSEMBLY |
325 |
| 5B. 6 SPEED GEARBOX - G 6450 |
334 |
| 5B.1 GENERAL INFORMATION |
338 |
| 5B.1.1 SPECIFICATIONS |
338 |
| 5B.1.2 TIGHTENING TORQUE |
339 |
| 5B.1.3 SPECIAL TOOLS |
344 |
| 5B.1.4 GENERAL SYMPTOMS DIAGNOSIS |
348 |
| 5B.2 MAINTENANCE, INSPECTION AND TEST |
349 |
| 5B.2.1 PRELIMINARY INSPECTION |
349 |
| 5B.2.2 REGULAR MAINTENANCE |
349 |
| 5B.2.3 ON VEHICLE PROCEDURE |
350 |
| A. GEARBOX REMOVAL |
350 |
| 5B.2.4A CONSTRUCTION OF GEAR BOX (4X2) |
352 |
| 5B.2.4B CONSTRUCTION OF GEAR BOX (4X4) |
353 |
| 5B.3 OVERHAULING |
354 |
| 5B.3.1 INFORMATION FOR OVERHAULING |
354 |
| A. COMPONENT INDENTIFICATION |
354 |
| B. PRECAUTIONS |
356 |
| 5B.3.2 GEAR BOX DISMANTLING ON BENCH PROCEDURE |
357 |
| 5B.3.3 INSPECTION |
367 |
| 5B.3.4 GEAR BOX ASSEMBLY ON BENCH PROCEDURE |
369 |
| 6. TRANSFER CASE |
385 |
| 6.1 GENERAL INFORMATION |
389 |
| 6.1.1 SPECIFICATIONS |
389 |
| 6.1.2 CONSTRUCTION |
390 |
| 6.1.3 COMPONENTS OF TRANSFER CASE |
392 |
| A. ECU |
392 |
| B. TRANSFER CASE SWITCH |
394 |
| C. WARNING LAMP |
394 |
| D. GEROTOR PUMP |
394 |
| 6.1.4 WORKING OF TRANSFER CASE |
395 |
| 6.1.5 TIGHTENING TORQUES |
399 |
| 6.1.6 SPECIAL TOOLS |
402 |
| 6.1.7 GENERAL SYMPTOMS & DIAGNOSIS |
405 |
| 6.2 MAINTENANCE |
406 |
| 6.2.1 PRELIMINARY INSPECTION |
406 |
| 6.2.2 REGULAR MAINTENANCE |
406 |
| A. CHANGING TRANSFER CASE OIL |
406 |
| B. TRANSFER CASE OIL CHECK |
406 |
| 6.2.3 ON VEHICLE REPAIRS |
407 |
| A. TRANSFER CASE |
407 |
| B. TRANSFER CASE ELECTRONIC CONTROL UNIT (ECU) |
408 |
| C TRANSFER CASE SWITCH |
409 |
| 6.3 OVERHAULING |
409 |
| 6.3.1 PRECAUTIONS |
409 |
| 6.3.2 DISMANTLING |
409 |
| A. REAR YOKE |
409 |
| B. REAR COVER ASSEMBLY |
410 |
| C. LOCKUP SHIFT PART |
412 |
| D. CHAIN DRIVE |
413 |
| E. GEROTOR PUMP |
413 |
| F. REDUCTION SHIFT PART |
414 |
| G. FRONT OUTPUT SHAFT AND YOKE |
415 |
| H. ADAPTER, INPUT SHAFT & CARRIER ASSEMBLY |
416 |
| 6.3.3 INSPECTION & CLEANING |
419 |
| 6.3.4 ASSEMBLY |
419 |
| A. ADAPTER & INPUT SHAFT |
419 |
| B. FRONT OUTPUT SHAFT & YOKE |
421 |
| C. ASSEMBLY OF REDUCTION SHIFT PART |
422 |
| D. ASSEMBLY OF OUTPUT SHAFT & GEROTOR PUMP |
423 |
| E. CHAIN DRIVE |
425 |
| F. ASSEMBLY OF LOCK UP SHIFT PART |
426 |
| G. REAR COVER ASSEMBLY |
426 |
| H. REAR OUTPUT YOKE |
429 |
| 6.4 DIAGNOSTIC OF ECU |
430 |
| 7. SUSPENSION |
433 |
| 7.1 FRONT SUSPENSION |
435 |
| 7.1.1 GENERAL INFORMATION |
438 |
| 7.1.1.1 SPECIFICATIONS |
438 |
| 7.1.1.2 CONSTRUCTION |
439 |
| 7.1.1.3 TIGHTENING TORQUES |
440 |
| 7.1.1.4 SPECIAL TOOLS |
445 |
| 7.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS |
448 |
| 7.1.2 MAINTENANCE |
449 |
| 7.1.2.1 PRELIMINARY INSPECTION |
449 |
| 7.1.2.2 REGULAR MAINTENANCE |
449 |
| A. WHEEL ALIGNMENT |
449 |
| B. ANTI ROLL BAR MOUNTING GREASING |
450 |
| 7.1.2.3 ON VEHICLE REPAIRS |
451 |
| A. ANTI ROLL BAR (ARB) |
451 |
| B. FRONT STRUT ASSEMBLY |
452 |
| C. LOWER WISHBONE |
453 |
| D. UPPER WISHBONE |
454 |
| E. BUMP STOPPER |
456 |
| 7.1.3 OVERHAULING |
456 |
| 7.1.3.1 PRECAUTIONS |
456 |
| 7.1.3.2 DISMANTLING, INSPECTION AND ASSEMBLY |
457 |
| A. FRONT STRUT |
457 |
| B. UPPER WISHBONE BUSH |
458 |
| C. UPPER WISHBONE BALL JOINT |
460 |
| D. LOWER WISHBONE BALL JOINT REMOVAL |
460 |
| 7.2 REAR SUSPENSION |
436 |
| 7.2.1 GENERAL INFORMATION |
461 |
| 7.2.1.1 SPECIFICATIONS |
461 |
| 7.2.1.2 CONSTRUCTION |
462 |
| 7.2.1.3 TIGHTENING TORQUES |
463 |
| 7.2.1.4 SPECIAL TOOLS |
466 |
| 7.2.2 MAINTENANCE |
469 |
| 7.2.2.1 ON VEHICLE REPAIRS |
469 |
| A. ANTIROLL BAR |
469 |
| B. UPPER LINK |
471 |
| C. LOWER LINK |
472 |
| D. PAN HARD ROD |
472 |
| E. REAR SHOCK ABSORBER |
473 |
| F. REAR COIL SPRING |
474 |
| 7.2.3 OVERHAULING |
475 |
| 7.2.3.1 PRECAUTIONS |
475 |
| 7.2.3.2 DISMANTLING, INSPECTION AND ASSEMBLY |
475 |
| A. UPPER LINK BUSH |
475 |
| B. LOWER LINK BUSH |
476 |
| C. PAN HARD ROD BUSH |
477 |
| 7.3 WHEELS AND TYRES |
437 |
| 7.3.1 GENERAL INFORMATION |
479 |
| 7.3.1.1 SPECIFICATIONS |
479 |
| 7.3.1.2 CONSTRUCTION |
480 |
| 7.3.1.3 TIGHTENING TORQUES |
481 |
| 7.3.1.4 GENERAL SYMPTOMS DIAGNOSIS |
482 |
| A. DIAGNOSIS CHART |
482 |
| B. TYRE WEAR PATTERN |
485 |
| C. WEAR CAUSES |
487 |
| D. TYRE VIBRATION DIAGNOSIS |
489 |
| 7.3.2 MAINTENANCE, INSPECTION AND TESTS |
490 |
| 7.3.2.1 PRELIMINARY INSPECTION |
490 |
| 7.3.2.2 REGULAR MAINTENANCE |
491 |
| A. INFLATION |
491 |
| B. WHEEL BALANCING |
491 |
| C. TYRE ROTATION |
492 |
| D WHEEL RUN OUT |
493 |
| E. DO'S AND DON’TS |
494 |
| 7.3.2.3 WHEEL AND TYRE REPLACEMENT |
495 |
| A. PRECAUTIONS DURING TYRE REPLACEMENT |
495 |
| B. TYRE REPLACEMENT |
496 |
| C. WHEEL ASSEMBLY REPLACEMENT |
496 |
| 8. FRONT AXLE |
497 |
| 8.1 FRONT AXLE (4X4) |
497 |
| 8.1.1 GENERAL INFORMATION |
500 |
| 8.1.1.1 SPECIFICATION |
500 |
| 8.1.1.2 SYSTEM LAYOUT 4X4 |
501 |
| 8.1.1.3 TIGHTENING TORQUES |
502 |
| 8.1.1.4 SPECIAL TOOLS |
506 |
| 8.1.1.5 GENERAL SYMPTOMS AND DIAGNOSIS |
511 |
| 8.1.2 MAINTENANCE |
512 |
| 8.1.2.1 PRELIMINARY INSPECTION |
512 |
| 8.1.2.2 REGULAR MAINTENANCE |
512 |
| 8.1.2.3 ON VEHICLE REPAIRS |
513 |
| A. FRONT AXLE ASSEMBLY |
513 |
| B. ELECTRICAL DISCONNECT ASSEMBLY |
517 |
| C. TONER RING |
518 |
| 8.1.3 OVERHAULING |
519 |
| 8.1.3.1 PRECAUTIONS |
519 |
| 8.1.3.2 CONSTRUCTIONAL DETAILS |
519 |
| 8.1.3.3 DISMANTLING INSPECTION AND ASSEMBLY |
523 |
| 8.2 FRONT AXLE (4X2) |
553 |
| 8.2.1 GENERAL INFORMATION |
556 |
| 8.2.1.1 TECHNICAL SPECIFICATIONS |
556 |
| 8.2.1.2 CONSTRUCTION AND LAYOUT |
556 |
| 8.2.1.3 TIGHTENING TORQUE |
557 |
| 8.2.1.4 SPECIAL TOOLS |
558 |
| 8.2.2 MAINTENANCE |
560 |
| 8.2.2.1 ON VEHICLE REPAIRS |
560 |
| 8.2.3 OVERHAULING |
564 |
| 8.2.3.1 FRONT AXLE EXPLODED VIEW |
564 |
| 8.2.3.2 HUB REPLACEMENT |
565 |
| 8.2.3.3 TONER RING REPLACEMENT |
567 |
| 8.2.3.4 HUB BEARING REPLACEMENT |
568 |
| 9. REAR AXLE 15” |
569 |
| 9.1 SECTION - 1 |
572 |
| 9.1.1 AXLE SPECIFICATION AND SERVICE DATA |
573 |
| 9.1.2 AXLE LUBRICATION |
574 |
| 9.1.3 AXLE IDENTIFICATION |
574 |
| 9.1.4 EXPLODED VIEW |
575 |
| 9.1.5 PARTS DESCRIPTIONS |
576 |
| 9.2 DISASSEMBLY OF AXLE |
577 |
| 9.2.1 AXLE SHAFT DISASSEMBLY / OIL SEAL REMOVAL |
577 |
| 9.2.2 REMOVAL OF CARRIER SECTION FROM BANJO |
578 |
| 9.3 CARRIER SECTION DISASSEMBLY |
578 |
| 9.3.1 DISASSEMBLY OF CARRIER SECTION & DIFFERENTIAL |
578 |
| 9.3.2 RING GEAR REMOVAL |
579 |
| 9.3.3 CASE DISASSEMBLY STD |
580 |
| 9.3.4 DRIVE PINION REMOVAL |
581 |
| 9.3.5 RING GEAR PINION ASSEMBLY THEORY |
582 |
| 9.3.6 ESTABLISHING PINION & GEAR DEPTH USING SERVICE TOOLS |
584 |
| 9.3.7 CASE REASSEMBLY (STANDARD DIFFCASE ASSEMBLY) |
586 |
| 9.3.8 ASSEMBLY OF DIFFERENTIAL IN CARRIER |
587 |
| 9.3.9 INTERPRETATION OF CONTACT PATTERN |
590 |
| 9.4 DIS-ASSEMBLY & REASSEMBLY OF LIMITED SLIP DIFFERENTIAL |
591 |
| 9.4.1 DIS-ASSEMBLY OF TRAC-LOK DIFFERENTIAL |
591 |
| 9.4.2 INSPECTION OF ALL THE PARTS FOR WEAR, SCORE, ETC |
593 |
| 9.4.3 RE ASSEMBLY |
593 |
| 9.5 AXLE SHAFT DIS-ASSEMBLY & RE-ASSEMBLY |
595 |
| 9.5.1 DIS-ASSEMBLY OF AXLE SHAFT ASSEMBLY |
595 |
| 9.5.2 ASSEMBLY OF AXLE SHAFT ASSEMBLY |
596 |
| 9.6 RE-ASSEMBLY OF AXLE |
597 |
| 9.6.1 INSTALL CARRIER SECTION ON BANJO BEAM |
597 |
| 9.6.2 INSTALL AXLE SHAFT ASSEMBLY ON BANJO BEAM |
597 |
| 9.7 TROUBLE SHOOTING |
599 |
| 10. PROPELLER SHAFT |
601 |
| 10.1 GENERAL INFORMATION |
604 |
| 10.1.1 ADJUSTMENT / REPAIR DATA |
604 |
| 10.1.2 SYSTEM LAYOUT |
605 |
| A. FOR 4X2 DRIVE |
605 |
| B. FOR 4X4 DRIVE |
606 |
| 10.1.3 TIGHTENING TORQUE |
607 |
| 10.1.4 SPECIAL TOOL |
608 |
| 10.1.5 GENERAL SYMPTOMS DIAGNOSIS |
609 |
| 10.2 MAINTENANCE, INSPECTION AND TESTS |
610 |
| 10.2.1 PRELIMINARY INSPECTION |
610 |
| 10.2.2 REGULAR MAINTENANCE |
610 |
| 10.2.3 ON VEHICLE REPAIRS |
611 |
| A. PROPELLER SHAFT (4X2) |
612 |
| B. PROPELLER SHAFT (4X4) |
613 |
| C. TVD (TORSIONAL VIBRATION DAMPERS) |
614 |
| 10.3 OVERHAULING |
615 |
| 10.3.1 CONSTRUCTIONAL DETAILS |
615 |
| A. PROPELLER SHAFT 4X2 DRIVE |
615 |
| B. PROPELLER SHAFT 4X4 DRIVE |
616 |
| 10.3.2 UNIVERSAL JOINT |
617 |
| 10.3.3 CENTRE BEARING |
620 |
| 11. BRAKES |
623 |
| 11.1 GENERAL INFORMATION |
627 |
| 11.1.1 SPECIFICATION |
627 |
| 11.1.2 SYSTEM DETAILS |
628 |
| 11.1.3 TIGHTENING TORQUES |
632 |
| 11.1.4 GENERAL SYMPTOMS DIAGNOSIS |
636 |
| 11.2 MAINTENANCE, INSPECTION AND TEST |
638 |
| 11.2.1 PRELIMINARY INSPECTION |
638 |
| A. FRONT BRAKE AND REAR BRAKE |
638 |
| B. PARKING BRAKE |
638 |
| C. BRAKE HOSES AND LINES |
638 |
| D. ROAD TEST |
638 |
| E. REAR DRUM BRAKES |
639 |
| F. WHEEL CYLINDER SERVICING |
645 |
| 11.2.2 REGULAR MAINTENANCE |
647 |
| A. BRAKE BLEEDING PROCEDURE |
647 |
| B. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) |
648 |
| C. CALIPER PAD REPLACEMENT |
653 |
| D. PARKING BRAKE ADJUSTMENT |
654 |
| E. BRAKE FLUID DRAINING PROCEDURE |
655 |
| F. BRAKE LIGHT SWITCH ADJUSTMENT |
656 |
| G. BOOSTER FILTER REPLACEMENT |
657 |
| H. GREASING |
658 |
| I. DISC RUN-OUT MEASUREMENT PROCEDURE |
659 |
| 11.2.3 ON VEHICLE REPAIRS |
659 |
| A. CALIPER ASSEMBLY WITH CARRIER |
659 |
| B. BRAKE DISC REMOVAL |
660 |
| C. PARKING BRAKE |
663 |
| D. BRAKE PEDAL |
667 |
| E. VACUUM LINES |
670 |
| F. BOOSTER ASSEMBLY |
671 |
| G. PARKING BRAKE (DRUM IN HAT) |
676 |
| 11.3 OVERHAULING |
678 |
| 11.3.1 PRECAUTIONS |
678 |
| 11.3.2 DISMANTLING, INSPECTION AND ASSEMBLY |
679 |
| A. FRONT CALIPER ASSEMBLY |
679 |
| B. REAR CALIPER ASSEMBLY |
684 |
| 11.4 LOAD SENSING PRESSURE VALVE (LSPV) (FOR NON ABS VEHICLE ONLY) |
688 |
| 12. ANTI-LOCK BRAKING SYSTEM (ABS) |
690 |
| 12.1 GENERAL INFORMATION |
693 |
| 12.1.1 NECESSITY OF ABS WITH EBD |
693 |
| 12.1.2 TECHNICAL SPECIFICATIONS |
694 |
| 12.1.3 TIGHTENING TORQUES |
695 |
| 12.1.4 SCHEMATIC OF HYDRAULIC CIRCUIT |
697 |
| 12.1.5 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
698 |
| 12.1.6 COMPONENTS |
702 |
| A. ABS ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
703 |
| B. WHEEL SPEED SENSOR (WSS) |
706 |
| C. ABS SYSTEM FAILURE WARNING LIGHT |
707 |
| 12.2 REPAIRS |
708 |
| A. ABS ECU / HCU |
708 |
| B. FRONT WHEEL SPEED SENSOR |
711 |
| C. FRONT TONER RING |
712 |
| D. REAR WHEEL SPEED SENSOR |
712 |
| E. REAR TONER RING |
713 |
| 12.3 TROUBLE SHOOTING AND DIAGNOSIS |
714 |
| A. ROAD TEST |
714 |
| B. TABLE OF ABS 8.1 - FALL-BACK LEVEL |
714 |
| 12.4 ABS DIAGNOSTIC USER MANUAL |
715 |
| 12.4.1 GENERAL |
715 |
| 12.4.2 OPERATING PROCEDURE |
716 |
| 13. STEERING |
726 |
| 13.1 GENERAL INFORMATION |
730 |
| 13.1.1 SPECIFICATIONS |
730 |
| 13.1.2 SYSTEM LAYOUT |
731 |
| 13.1.3 TIGHTENING TORQUES |
732 |
| 13.1.4 SPECIAL TOOLS |
738 |
| 13.1.5 GENERAL SYMPTOMS DIAGNOSIS |
739 |
| 13.2 MAINTENANCE, INSPECTION AND TEST |
746 |
| 13.2.1 PRELIMINARY INSPECTION |
746 |
| 13.2.2 REGULAR MAINTENANCE |
747 |
| A. POWER STEERING OIL REPLACEMENT |
747 |
| B. POWER STEERING RESERVOIR ASSY |
748 |
| C. HYDRAULIC SYSTEM AIR BLEEDING |
749 |
| D. TOE IN ADJSUTMENT |
750 |
| E. STEERING WHEEL ALIGNMENT/ CENTRALISING |
750 |
| F. STEERING WHEEL PLAY |
751 |
| G. POWER STEERING OIL FLUSHING PROCEDURE |
751 |
| 13.2.3 REPAIRS |
752 |
| 13.2.3.1 STEERING WHEEL |
752 |
| 13.2.3.2 SYSTEM LAYOUT |
757 |
| 13.2.3.3 STEERING RESERVOIR & POWER STEERING PUMP |
762 |
| A. STEERING RESERVOIR |
763 |
| B. POWER STEERING PUMP |
763 |
| 13.2.3.4 RACK AND PINION ASSEMBLY |
764 |
| 13.3 RACK & PINION UNIT OVERHAULING |
765 |
| 13.3.1 GENERAL INSTRUCTIONS |
765 |
| 13.3.2 RACK AND PINION ASSEMBLY |
766 |
| 13.3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
767 |
| 13.3.3.1 OUTER BALL JOINT (OBJ) |
767 |
| 13.3.3.2 BELLOW KIT |
768 |
| 13.3.3.3 INNER BALL JOINT (IBJ) |
769 |
| 13.3.3.4 FEED PIPE |
770 |
| 13.3.3.5 DO’S & DON’TS |
771 |
| 14. ELECTRICAL |
774 |
| 14.1 TECHNICAL SPECIFICATIONS |
779 |
| 14.2 GENERAL ELECTRCIAL PRECAUTIONS |
782 |
| 14.3 STARTING AND CHARGING SYSTEM |
785 |
| 14.3.1 BATTERY |
785 |
| 14.3.2 ALTERNATOR |
791 |
| 14.3.3 STARTER MOTOR |
804 |
| 14.4 LIGHTING SYSTEM |
818 |
| 14.4.1 BULB SPECIFICATIONS |
818 |
| 14.4.2 TORQUE VALUE TABLE |
818 |
| 14.4.3 DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALL LAMPS |
819 |
| 14.4.4 HEAD LAMP |
822 |
| 14.4.5 FRONT FOG LAMP |
828 |
| 14.4.6 FRONT ROOF LAMP |
829 |
| 14.4.7 SECOND AND THIRD ROW ROOF LAMP |
830 |
| 14.4.8 REGISTRATION PLATE LAMP |
831 |
| 14.4.9 CENTER HIGH MOUNTED STOP LAMP |
831 |
| 14.4.10 PUDDLE LAMP |
833 |
| 14.4.11 GLOVE BOX LAMP |
834 |
| 14.4.12 TAIL LAMP |
834 |
| 14.4.13 REAR FOG LAMP (IF FITTED) |
835 |
| 14.5 HORN |
837 |
| 14.6 POWER SOCKET |
839 |
| 14.7 CIGAR LIGHTER |
841 |
| 14.8 BUZZER |
842 |
| 14.9 WIPER & WASHER SYSTEM |
843 |
| 14.9.1 FRONT AND REAR WIPER AND WAHSER SYSTEM COMPONENT LOCATIONS |
843 |
| 14.9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
844 |
| 14.9.3 FRONT AND REAR WIPER SYSTEM COMPONENTS |
845 |
| 14.9.3.1 FRONT WIPER MOTOR |
845 |
| 14.9.3.2 FRONT WIPER ARM & BLADE |
848 |
| 14.9.3.3 REAR WIPER ARM & BLADE |
849 |
| 14.9.3.4 REAR WIPER MOTOR |
850 |
| 14.9.3.5 WIPER CARE |
852 |
| 14.9.4 WAHSER SYSTEM COMPONENT |
853 |
| 14.9.4.1 WAHSER BOTTLE |
853 |
| 14.9.4.2 WASHER PUMP |
853 |
| 14.9.4.3 FRONT WAHSER NOZZLE |
854 |
| 14.9.4.4 REAR WASHER NOZZLE |
855 |
| 14.9.5 DIAGNOSTIC INFORMATION AND PROCEDURES |
856 |
| 14.10 ELECTRICAL SWITCHES |
857 |
| 14.10.1 COMBINATION – SWITCH |
857 |
| 14.10.2 IGNITION SWITCH WITH IMMOBILIZER CAN VERSION PLUS KEY RING ILLUMINATION |
864 |
| 14.10.3 MASTER LIGHT SWITCH |
867 |
| 14.10.4 ORVM SWITCH |
870 |
| 14.10.5 WINDOW WINDING SWITCHES |
873 |
| 14.10.6 BONNET SWITCH |
879 |
| 14.10.7 HAZARD WARNING SWITCH |
880 |
| 14.10.8 TRANSFER CASE SWITCH |
881 |
| 14.10.9 GLOVE BOX SWITCH |
882 |
| 14.10.10 REVERSE LIGHT SWITCH |
883 |
| 14.10.11 HAND BRAKE SWITCH |
885 |
| 14.10.12 INERTIA SWITCH |
886 |
| 14.11 WINDOW WINDING CONTROLLER |
888 |
| 14.12 BODY CONTROL MODULE (BCM) |
905 |
| 14.13 IMMOBILIZER SYSTEM |
948 |
| 14.14 INSTRUMENT CLUSTER |
970 |
| 14.15 REVERSE PARKING SYSTEM WITH ULTRASONIC SENSOR (IF EQUIPPED) |
983 |
| 14.16 ENTERTAINMENT SYSTEM |
999 |
| 14.17 GENERAL ELECTRICAL INFORMATION |
1013 |
| 15. SUPPLEMENTARY RESTRAINT SYSTEM (SRS) |
1021 |
| 15.1 TIGHTENING TORQUES |
1026 |
| 15.2 WORKING OF RESTRAINTS |
1026 |
| A. RESTRAINTS WITHOUT AIRBAGS |
1026 |
| B. RESTRAINTS WITH AIRBAGS |
1026 |
| 15.3 SYSTEM LAYOUT |
1027 |
| A. RESTRAINTS WITHOUT AIRBAGS |
1027 |
| B. RESTRAINTS WITH AIRBAGS |
1027 |
| 15.4 SAFETY PRECAUTIONS |
1028 |
| 15.5 DISPOSAL OF FAULTY AIR BAG UNIT |
1030 |
| 15.6 COMPONENTS |
1031 |
| 15.6.1 RESTRAINT WITHOUT AIRBAGS |
1031 |
| A. SEAT BELT |
1031 |
| B. EMERGENCY LOCKING RETRACTOR (ELR) |
1031 |
| C. MICROSWITCH AND SEAT BELT REMINDER (SBR) WARNING LAMP |
1031 |
| 15.6.2 RESTRAINT WITH AIRBAGS |
1032 |
| A. ECU |
1032 |
| B. SENSORS |
1037 |
| C. AIR BAGS |
1039 |
| D. CLOCK SPRING |
1041 |
| E. RPLL BELTS |
1044 |
| F. SRS WARNING LAMP |
1046 |
| 15.7 DIAGNOSTIC USER MANUAL |
1047 |
| 15.8. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT |
1055 |
| 16. BODY |
1056 |
| 16.1 GENERAL INFORMATION |
1061 |
| 16.1.1 SPECIFICATIONS |
1061 |
| 16.1.2 LAYOUT |
1065 |
| 16.1.3 TIGHTENING TORQUES |
1066 |
| 16.1.4 SPECIAL TOOL |
1069 |
| 16.2 ON VEHICLE REPAIRS |
1070 |
| 16.2.1 BONNET |
1070 |
| 16.2.2 FLOOR CONSOLE |
1074 |
| 16.2.3 DASHBOARD |
1076 |
| 16.2.4 TOP UTILITY BIN |
1080 |
| 16.2.5 GLOVE BOX |
1080 |
| 16.2.6 SIDE AIR VENTS |
1081 |
| 16.2.7 CENTRAL FINISHER |
1083 |
| 16.2.8 FRONT BUMPER |
1084 |
| 16.2.9 REAR BUMPER |
1087 |
| 16.2.10 DOOR TRIMS |
1090 |
| 16.2.11 FRONT DOOR |
1093 |
| 16.2.12 DOOR LOCK HANDLE AND DOOR LATCH |
1096 |
| 16.2.13 FRONT OUTER DOOR LOCK BARREL AND HANDLE |
1097 |
| 16.2.14 FRONT DOOR LATCH |
1098 |
| 16.2.15 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
1100 |
| 16.2.16 REAR DOOR |
1102 |
| 16.2.17 REAR OUTER DOOR LOCK |
1104 |
| 16.2.18 DOOR LATCH REAR |
1106 |
| 16.2.19 TAILGATE TRIM |
1107 |
| 16.2.20 TAIL GATE |
1110 |
| 16.2.21 ORVM |
1115 |
| 16.2.22 INNER REAR VIEW MIRROR |
1116 |
| 16.2.23 FRONT ROW SEAT |
1116 |
| 16.2.24 SECOND ROW SEAT |
1117 |
| 16.2.25 THIRD ROW SEAT |
1118 |
| 16.2.26 SEAT BELTS |
1119 |
| 16.2.27 SECOND ROW SEAT BELT |
1121 |
| 16.2.28 “A” PILLAR TRIM |
1122 |
| 16.2.29 “B” PILLAR TRIMS |
1123 |
| 16.2.30 “C” PILLAR TRIM |
1124 |
| 16.2.31 “D” PILLAR TRIM |
1125 |
| 16.2.32 REAR QUARTER TRIM |
1126 |
| 16.2.33 GRAB HANDLES |
1126 |
| 16.2.34 SUNVISOR |
1127 |
| 16.2.35 PLENUM COVER ASSEMBLY |
1128 |
| 16.2.36 STONE GUARD |
1128 |
| 16.2.37 FRONT WHEEL ARCH LINER |
1128 |
| 16.2.38 GEAR LEVER BOOT |
1129 |
| 16.2.39 BONNET INSULATION |
1129 |
| 16.2.40 FUEL FILLER ASSEMBLY |
1130 |
| 16.2.41 GLASS |
1132 |
| 16.2.42 ROOF LINER ASSEMBLY |
1137 |
| 16.2.43 FRONT FENDER |
1138 |
| 16.2.44 FRONT WHEEL ARCH COVER |
1139 |
| 16.2.45 SILL FINISHER |
1139 |
| 16.2.46 REAR WHEEL ARCH LINER |
1140 |
| 16.2.47 SIDE FOOT STEP |
1141 |
| 16.2.48 SPOILER |
1142 |
| 16.3 BODY REPAIR |
1143 |
| 17. HVAC |
1155 |
| 17.1 GENERAL INFORMATION |
1159 |
| 17.1.1 SPECIFICATIONS |
1159 |
| 17.1.2 TIGHTENING TORQUES |
1161 |
| 17.1.3 PRECAUTIONS |
1166 |
| 17.1.4 HVAC SYSTEM LAYOUT AND WORKING |
1168 |
| 17.1.5 COMPONENTS OF HVAC |
1172 |
| 17.1.5.1 CONTROL PANEL |
1173 |
| 17.1.5.2 FRONT HVAC UNIT |
1176 |
| 17.1.5.3 ROOF AC UNIT (IF FITTED) |
1178 |
| 17.1.5.4 COMPRESSOR |
1180 |
| 17.1.5.5 CONDENSER |
1181 |
| 17.1.5.6 THERMISTER OR THERMO SENSOR |
1182 |
| 17.1.5.7 TRINARY PRESSURE SWITCH |
1184 |
| 17.1.5.8 ACTUATOR |
1185 |
| 17.1.5.9 AIR INLET ACTUATOR |
1189 |
| 17.1.5.10 REAR BLOWER SWITCH |
1189 |
| 17.1.6 TROUBLESHOOTING |
1191 |
| 17.2 MAINTENANCE |
1204 |
| 17.2.1 PRELIMINARY INSPECTION |
1204 |
| A. AC SYSTEM PERFORMANCE TEST |
1204 |
| B. LEAK DETECTION |
1206 |
| 17.2.2 REGULAR MAINTENANCE |
1206 |
| A. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
1206 |
| B. FLUSHING OF AC SYSTEM |
1208 |
| C. REPLENISHING COMPRESSOR OIL |
1209 |
| D. PRESSURE TEST USING MANIFOLD GAUGES |
1210 |
| 17.3 ON VEHICLE REPAIRS |
1212 |
| 17.3.1 CONTROL PANEL ASSEMBLY |
1212 |
| 17.3.2 COMPRESSOR |
1212 |
| 17.3.3 FRONT HVAC UNIT |
1213 |
| 17.3.4 ROOF AC UNIT |
1214 |
| 17.3.5 HEATER HOSE |
1215 |
| 17.3.6 BLOWER (FRONT HVAC UNIT) |
1216 |
| 17.3.7 BLOWER CONTROL MODULE |
1216 |
| 17.3.8 PRESSURE SWITCH |
1217 |
| 17.3.9 CONDENSER |
1217 |
| 17.3.10 REFRIGERANT HOSES/PIPES |
1218 |
| 17.3.11 FRONT AC DUCTING |
1219 |
| 17.3.12 CONDENSER SEALING DUCT |
1220 |
| 17.3.13 RECEIVER DRIER BOTTLE |
1220 |
| 17.4 OVERHAULING |
1221 |
| 17.4.1 BLOWER |
1221 |
| 17.4.2 FRONT HVAC UNIT |
1223 |
| 17.4.3 ROOF AC |
1230 |
| 17.4.4 COMPRESSOR |
1232 |
| 17.4.5 DO’S AND DONT’S FOR A/C SYSTEM |
1235 |