| 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 SPECIFICA |
367 |
| 3 TIGHTENING TORQUE |
368 |
| 4 SPECIAL TOOLS |
374 |
| 5 DIAGNOSIS |
377 |
| 6 PRECAUTIONS |
378 |
| 7 EXPLODED VIEWS OF FRONT SUSPENSION |
379 |
| 8 EXPLODED VIEWS REAR SUSPENSION |
384 |
| 9 ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY |
386 |
| 10 ON BENCH FRONT STRUT DISASSEMBLY |
389 |
| 11 ON BENCH FRONT STRUT ASSEMBLY |
390 |
| 12 REMOVAL AND ASSEMBLY OF WHEEL DISC& STUB AXLE |
392 |
| 13 ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB (GEN1 BEARING) |
394 |
| 14 ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB (GEN3 BEARING) |
395 |
| 15 REMOVAL OF SUBFRAME ASSEMBLY |
395 |
| 16 INSTALLATION OF SUBFRAME ASSEMBLY |
398 |
| 17 LCA REAR HYDRA-BUSH INSTALLATION |
398 |
| 18 REMOVAL OF ANTI ROLL BAR |
399 |
| 19 REMOVAL/ASSEMBLY OF REAR DAMPER ASSEMBLY & COIL SPRINGS(FOR DRUM BRAKE) |
400 |
| 20 REMOVAL/ASSEMBLY OF REAR DAMPER ASSEMBLY & COIL SPRINGS(FOR DISC BRAKE) |
401 |
| 21 ECIE CONDITION |
402 |
| 22 INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS |
402 |
| 23 REAR SUSPENSION DISMANTLING AND INSTALLATION (FOR DRUM BRAKE) |
403 |
| 24 REAR SUSPENSION DISMANTLING AND INSTALLATION (FOR DISC BRAKE) |
406 |
| 25 RTB BUSH INSTALLATION |
409 |
| 26 PAN HARD ROD BUSH INSTALLATION AND REMOVA |
409 |
| 27 INSTALLATION AND REMOVAL OF DAMPER BOTTOM BUSH |
411 |
| 28 SUSPENSION ECIE / PRE-LOADING CONDITION |
412 |
| BRAKES |
413 |
| 1. SPECIFICATION |
415 |
| 2. SYSTEM DETAILS |
416 |
| 3. TIGHTENING TORQUES |
418 |
| 4. GENERAL SYMPTOMS DIAGNOSIS |
422 |
| 5. NECESSITY OF ABS with EBD |
424 |
| 6. VACUUM BRAKE BOOSTER |
424 |
| 7. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
426 |
| 8. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
429 |
| 9. WHEEL SPEED SENSOR |
431 |
| 10. ABS SYSTEM FAILURE WARNING LIGHT |
432 |
| 11. MAINTENANCE, INSPECTION AND TEST |
433 |
| 12. REAR DRUM BRAKES |
434 |
| 13. REMOVAL OF SHOES |
437 |
| 14. REGULAR MAINTENANCE |
441 |
| 15. ON VEHICLE REPAIRS |
447 |
| 16. DISMANTLING, INSPECTION AND ASSEMBLY |
457 |
| BRAKE (EPB) |
462 |
| 1 TECHNICAL SPECIFICATION |
464 |
| 2 SYSTEM DETAILS |
465 |
| 3 TIGHTENING TORQUE |
467 |
| 4 GENERAL SYMPTOMS DIAGNOSIS |
471 |
| 5 NECESSITY OF ABS WITH EBD |
473 |
| 6 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
475 |
| 7 ESP 9.3CPI ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
478 |
| 8 WHEEL SPEED SENSOR (MONITORS WHEEL SPEED) |
480 |
| 9 ABS SYSTEM FAILURE WARNING LIGHTS |
481 |
| 10 MAINTAINANCE, INSPECTION AND TEST |
482 |
| 11 REGULAR MAINTENANCE |
483 |
| A BRAKE BLEEDING PROCEDURE |
483 |
| B ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) |
484 |
| C FRONT BRAKE CALIPER PAD REPLACEMENT |
485 |
| D BRAKE FLUID DRAINING PROCEDURE |
486 |
| E BRAKE LIGHT SWITCH ADJUSTMENT |
487 |
| F CALIPER GREASING |
487 |
| G DISC RUN-OUT MEASUREMENT PROCEDURE |
487 |
| 12 ON VEHICLE REPAIRS |
489 |
| A FRONT CALIPER ASSEMBLY WITH CARRIER |
489 |
| B BRAKE CALIPER ASSEMBLY DISMANTLING |
489 |
| C FRONT AND REAR BRAKE DISC REMOVAL |
492 |
| D REAR CALIPER ASSEMBLY WITH CARRIER |
492 |
| E REAR BRAKE CALIPER PAD REPLACEMENT FOR EPB CALIPER |
493 |
| F C667 CALIPER RECEPTACLE HOUSING WITH CPA |
495 |
| G VACCUM LINES |
496 |
| H BOOSTER ASSEMBLY |
497 |
| I TANDEM MASTER CYLINDER & BOOSTER ASSY |
499 |
| J BOOSTER NRV |
500 |
| K BOOSTER ASSEMBLY |
500 |
| 13 DISMANTLING, INSPECTION AND ASSEMBLY |
502 |
| A FRONT CALIPER ASSEMBLY |
502 |
| B REAR CALIPER ASSEMBLY |
504 |
| HVAC |
507 |
| 1. HVAC SYSTEM LAYOUT |
509 |
| 2. SPECIFICATIONS: HVAC UNIT |
510 |
| 3. TIGHTENING TORQUES |
516 |
| 4. PRECAUTIONS |
520 |
| 5. HVAC SYSTEM LAYOUT AND WORKING |
521 |
| 6. CONTROL PANEL |
524 |
| 7. FRONT HVAC UNIT |
526 |
| 8. TRINARY PRESSURE SWITCH |
528 |
| 9. MODE & TEMPRATURE CONTROL AC-TUATOR |
529 |
| 10. COMPRESSOR |
530 |
| 11. CONDENSER |
532 |
| 12. RECEIVER DRIER (R.D) |
532 |
| 13. INSPECTION OF MODE AND TEMPERATURE ACTUATOR |
533 |
| 14. TROUBLESHOOTING |
535 |
| 15. MAINTENANCE |
546 |
| 16. ON VEHICLE REPAIRS |
554 |
| 17. DO’S AND DONT’S FOR A/C SYSTEM |
563 |
| FATC |
564 |
| 1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM |
566 |
| 2. TECHNICAL SPECIFICATIONS |
568 |
| 3. TIGHTENING TORQUES |
574 |
| 4. PRECAUTIONS |
578 |
| 5. HMI CLIMATE CONTRL DISPLAY |
579 |
| 6. CONTROL PANEL |
580 |
| 7. CONTROL PANEL MODULE CONNECTOR DETAILS |
585 |
| 8. FATC UNIT |
587 |
| 9. FATC SENSOR & ACTUATOR |
589 |
| 10. COMPRESSOR |
595 |
| 11. CONDENSER |
596 |
| 12. RECEIVER DRIER (R.D) |
596 |
| 13. REMOVAL OF INFOTAINMENT SYSTEM |
597 |
| 14. TROUBLESHOOTING |
598 |
| 15. MAINTENANCE |
609 |
| 16. ON VEHICLE REPAIR |
617 |
| 17. DO’S AND DONT’S FOR A/C SYSTEM |
626 |
| BODY |
627 |
| 1.1 GENERAL INFORMATION |
630 |
| 1.2 TIGHTENING TORQUES |
631 |
| 1.3 SPECIAL TOOL |
634 |
| 1.4 ON VEHICLE REPAIRS |
635 |
| 1.4.1 BONNET |
635 |
| 1.4.2 ARM REST |
637 |
| 1.4.3 FLOOR CONSOLE |
638 |
| 1.4.4 DASHBOARD SKIN |
639 |
| 1.4.5 GLOVE BOX |
647 |
| 1.4.6 SIDE AIR VENTS |
647 |
| 1.4.7 FRONT BUMPER |
649 |
| 1.4.8 REAR BUMPER |
651 |
| 1.4.9 FRONT DOOR |
653 |
| 1.4.10 FRONT DOOR TRIMS |
654 |
| 1.4.11 DOOR INNER LOCK HANDLE |
655 |
| 1.4.12 FRONT OUTER DOOR LOCK |
656 |
| 1.4.13 FRONT DOOR LATCH |
657 |
| 1.4.14 FRONT DOOR GLASS AND WINDOW WINDING MECHANISM |
658 |
| 1.4.15 REAR DOOR |
659 |
| 1.4.16 REAR DOOR TRIM |
660 |
| 1.4.17 REAR OUTER DOOR LOCK |
661 |
| 1.4.18 DOOR LATCH REAR |
662 |
| 1.4.19 TAIL GATE |
663 |
| 1.4.20 TAIL GATE TRIM |
665 |
| 1.4.21 ORVM |
666 |
| 1.4.23 FRONT ROW SEAT |
667 |
| 1.4.24 REAR ROW SEAT |
668 |
| 1.4.25 FRONT SEAT BELT |
669 |
| 1.4.26 REAR SEAT BELT |
671 |
| 1.4.27 “A” PILLAR TRIM |
672 |
| 1.2.28. FRONT SCUFF PLATE |
672 |
| 1.4.29 “B” PILLAR TRIMS: |
673 |
| 1.2.30.REAR SCUFF PLATE |
673 |
| 1.4.31 REAR QUARTER TRIM |
674 |
| 1.4.32 “C” PILLAR TRIMS |
675 |
| 1.4.33 GRAB HANDLE: |
675 |
| 1.4.34 SUNVISOR |
676 |
| 1.4.35 ROOF LINEAR |
676 |
| 1.4.36 PLENUM COVER: |
677 |
| 1.4.37 GEAR LEVER BOOT |
677 |
| 1.4.38 BONNET INSULATION |
677 |
| 1.4.39 GLASS |
677 |
| 1.4.40 FUEL FILLER ASSEMBLY. |
679 |
| 1.4.41 FRONT WHEEL ARCH LINER |
680 |
| 1.4.42 REAR WHEEL ARCH LINER |
681 |
| 1.4.43 FRONT FENDER |
682 |
| 1.4.44 REAR WIPER MOTOR |
683 |
| 1.4.45 FRONT WIPER |
684 |
| 1.4.46 SUNROOF |
685 |
| 1.4.47 WIND DEFLECTOR |
686 |
| 1.4.48 FRONT GLASS PANEL |
687 |
| 1.4.50 SUNSHADE ROLLO ASSEMBLY |
689 |
| 1.4.51 MECHANISM ELECTRIC DRIVE ASSEMBLY |
690 |
| 1.4.52 ROLLO ELECTRIC DRIVE ASSEMBLYREMOVAL |
690 |
| 1.4.53 MECHANISM MAINTENANCE |
691 |
| 1.4.54 WATER CHANNEL MAINTENANCE |
694 |
| 1.4.55 SUNROOF RESET PROCEDURE - INITIALIZING THE POWER SUNROOF |
694 |
| 1.4.56 SUNROOF RESET PROCEDURE - SELF LEARNING THE POWER SUNROOF |
695 |
| ELECTRICAL |
696 |
| 1. INSTRUMENT CLUSTER |
699 |
| 1.1. BASIC FUNCTIONAL MATRIX |
701 |
| 1.2. TELL TALES INFORMATION |
702 |
| 1.3 GAUGES |
707 |
| 1.4 Driver Information System (For Q5 7" Instrument Cluster) |
713 |
| 1.5 Display Messages for TFT Screen |
722 |
| 1.6 DRIVER INFORMATION SYSTEM (For Q5 4" Instrument Cluster) |
727 |
| 1.7 DISPLAY MESSAGE ON LCD SCREEN |
731 |
| 1.8 REMINDER FEATURES |
732 |
| 2. MAIN CONNECTOR PIN-OUTS |
733 |
| 3. FUEL GAUGE DETAILS |
735 |
| 4. TEMPERATURE BAR GRAPH DETAILS |
736 |
| 5. Reminder Features (Audible) |
737 |
| 6. INSTRUMENT CLUSTER REMOVAL |
738 |
| 7. IMMOBILIZER SYSTEM (IF APPLICABLE) |
739 |
| 8 FUEL GAUGE DETAILS |
747 |
| 9. TEMPERATURE BAR GRAPH DETAILS |
748 |
| 10. CHIME TABLE |
749 |
| 11. DISPLAY SCREEN FLOW AND SETTINGS |
749 |
| 12. IGNITION KEY LEARNING PROCEDURE |
752 |
| 13. BODY CONTROL MODULE (BCM) |
755 |
| 13.1 REMOVAL OF BCM |
755 |
| 13.2 CONNECTION DETAILS |
756 |
| 13.3 BCM SPECIFICATION |
761 |
| 13.4 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
762 |
| 14. FUSE AND RELAY BOX DETAILS |
768 |
| 14.1 CHECKING FUSES |
768 |
| 14.2 CHECKING RELAYS |
768 |
| 14.3 FUSE AND RELAY BOX LAYOUT |
770 |
| 14.4 BATTERY MOUNTED FUSE BOX |
771 |
| 14.5 ENGINE FUSE AND RELAY BOX |
771 |
| 14.6 CABIN FUSE AND RELAY BOX |
774 |
| 15. REVERSE PARK ASSIST SYSTEM |
776 |
| 15.1 REAR VIEW CAMERA (If Applicable) |
780 |
| 15.2 BCM TO SENSOR ELECTRICAL INTERFACE |
783 |
| 15.3 REVERSE PARK ASSIST SYSTEM |
788 |
| 15.4 REAR VIEW CAMERA REMOVAL |
790 |
| 15.5 TROUBLESHOOTING |
791 |
| 16. PASSIVE ENTRY PASSIVE START (PEPS) |
792 |
| 16.1 PEPS ECU |
793 |
| 16.2 START STOP SWITCH |
795 |
| 16.3 ELECTRONIC STEERING COLUMN LOCK (ESCL) |
796 |
| 16.4 DOOR AND TAILGATE HANDLE SWITCHES WITH HARNESS |
798 |
| 16.5 LF ANTENNAS |
799 |