| TATA SAFARI - BSVI |
1 |
| KRYOTEC ENGINE |
6 |
| 1. GENERAL INFORMATION |
9 |
| A ENGINE INTRODUCTION |
9 |
| B TECHNICAL SPECIFICATION |
10 |
| C ASSEMBLY CLEARANCES |
11 |
| D LEAKAGE RATES |
14 |
| E SPECIAL TOOLS |
14 |
| F RECOMMENDED LUBRICANTS AND COOLANTS (REFER OWNER'S MANUAL) |
7 |
| 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 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 |
| H EXHAUST PIPE |
90 |
| 7 ENGINE ON VEHICLE SERVICE |
91 |
| A ENGINE REMOVAL |
91 |
| B ENGINE FITMENT |
96 |
| C CYLINDER HEAD |
98 |
| D CYLINDER HEAD COVER |
103 |
| 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 |
224 |
| 12 DIFFERENTIAL BEARING ASSEMLY |
224 |
| 13 DISASSEMBLY GEARSHIFT CONTROL CABLE |
225 |
| 14 ASSEMBLY GEARSHIFT CONTROL CABLE |
227 |
| 15 REMOVAL GEARSHIFT MECHANISM |
231 |
| 16 ASSEMBLY GEARSHIFT MECHANISM |
231 |
| 17 ASSEMBLY DIFFERENTIAL OIL SEAL |
233 |
| 18 INPUT SHAFT DISASSEMBLY |
234 |
| 19 INPUT SHAFT ASSEMBLY |
235 |
| 20 DISASSEMBLY OF OUTPUT SHAFT1 (1, 2 ,5 AND 6) |
237 |
| 21 ASSEMBLY OF OUTPUT SHAFT1 (1, 2 ,5 AND 6) |
239 |
| 22 DISASSEMBLY OF OUTPUT SHAFT2 (3, 4 AND REV.) |
243 |
| 23 ASSEMBLY OF OUTPUT SHAFT2 (3, 4 AND REV.) |
245 |
| 24 REMOVAL BACKUP (REVERSE) LAMP SWITCH |
248 |
| 25 ASSEMBLY BACKUP (REVERSE) LAMP SWITCH |
249 |
| DRIVESHAFT |
250 |
| 1. GENERAL INFORMATION |
252 |
| 2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
253 |
| 3. DRIVESHAFT PARTS |
254 |
| 4. TIGHTENING TORQUES |
255 |
| 5. SPECIAL TOOL |
257 |
| 6. ON BENCH PROCEDURE |
258 |
| A. TRIPOT JOINT DISASSEMBLY |
258 |
| B. TRIPOT JOINT ASSEMBLY |
259 |
| C. CV JOINT OUTER DISASSEMBLY |
259 |
| 7. ON VEHICLE PROCEDURE |
260 |
| A. LH DRIVE SHAFT |
260 |
| B. RH DRIVE SHAFT |
264 |
| 6F33 TRANSAXLE |
268 |
| 1 TECHNICAL SPECIFICATION |
270 |
| 2 TIGHTENING TORQUE |
274 |
| 3 SPECIAL TOOLS |
276 |
| 4 GENERAL INFORMATION |
277 |
| 5 COMPONENTS |
278 |
| 6 DETAIL OF A/T COMPONENTS |
280 |
| 7 EXPLODED VIEWS |
285 |
| 8 REMOVAL AND RE-FITMENT |
287 |
| 9 TOWING SERVICE |
294 |
| 10 AUTO TRANSAXLE FLUID CHECK AND CHANGE INTERVAL |
295 |
| 11 REMOVAL OF TRANSAXLE FROM VEHICLE |
297 |
| 12 ASSEMBLY OF TRANSAXLE ON VEHICLE |
300 |
| 13 REMOVAL OF GEAR SHIFTING CABLE ON VEHICLE |
303 |
| 14 ASSEMBLY GEARSHIFT CONTROL CABLE |
306 |
| 15 REMOVAL GEARSHIFT MECHANISM |
309 |
| 16 ASSEMBLY GEARSHIFT MECHANISM |
311 |
| 17 OIL COOLER HOSES REMOVAL |
312 |
| 18 OIL COOLER HOSES REFITMENT |
313 |
| 19 TCU (TRANSMISSION CONTROL UNIT) |
314 |
| DRIVESHAFT (AT) |
315 |
| 1 GENERAL INFORMATION |
317 |
| 2 GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
318 |
| 3 DRIVE SHAFT PARTS |
319 |
| 4 TIGHTENING TORQUES |
320 |
| 5 SPECIAL TOOL |
323 |
| 6 ON BENCH PROCEDURE |
324 |
| 7 ON VEHICLE PROCEDURE |
329 |
| CLUTCH |
338 |
| 1 GENERAL INFORMATION |
340 |
| 2 TECHNICAL SPECIFICATION |
340 |
| 3 LUBRICANT SPECIFICATION |
340 |
| 4 CLUTCH PRESSURE PLATE |
341 |
| 5 CLUTCH DISC ASSEMBLY |
341 |
| 6 EXPLODED VIEWS |
342 |
| 7 TIGHTENING TORQUES |
343 |
| 8 SPECIAL TOOLS |
343 |
| 9 GENERAL SYMPTOMS DIAGNOSIS |
344 |
| A. CLUTCH GRAB / CHATTER |
344 |
| B. CLUTCH SLIPS |
344 |
| C. CLUTCH PEDAL NOISE |
345 |
| 10 ON VEHICLE PROCEDURE |
346 |
| A. SPECIAL TOOL ASSEMBLY |
346 |
| B. DISASSEMBLY PROCEDURE |
346 |
| C. ASSEMBLY PROCEDURE |
348 |
| CLUTCH RELEASE SYSTEM |
349 |
| 1 CLUTCH SYSTEM LAYOUT |
351 |
| 2 CLUTCH SYSTEM COMPONENTS |
352 |
| 3 REGULAR MAINTENANCE |
353 |
| 4 CLUTCH PEDAL ASSEMBLY |
354 |
| 5 BRAKE PEDAL ASSEMBLY |
355 |
| 6 REMOVAL OF ACCELERATOR PEDAL |
356 |
| 7 REMOVAL OF CLUTCH CONTROL BRACKET |
357 |
| 8 ASSEMBLY OF CLUTCH CONTROL BRACKET |
359 |
| 9 BRAKE SWITCH INSTALLTION PROCEDURE |
361 |
| STEERING |
362 |
| 1 GENERAL INFORMATION |
364 |
| A SPECIFICATIONS |
364 |
| B SYSTEM LAYOUT |
365 |
| C TIGHTENING TORQUE |
366 |
| D SPECIAL TOOLS |
369 |
| 2 GENERAL SYMPTOMS DIAGNOSIS |
370 |
| 3 MAINTENANCE, INSPECTION AND TEST |
377 |
| A PRELIMINARY INSPECTION |
377 |
| B REGULAR MAINTENANCE |
378 |
| C REPAIRS |
383 |
| 4 OVERHAULING |
392 |
| A PRECAUTIONS |
392 |
| B RACK AND PINION ASSEMBLY |
392 |
| C FEED PIPE |
393 |
| D DO’S & DON’TS |
393 |
| E STEERING PUMP |
394 |
| SUSPENSION |
395 |
| 1 GENERAL INFORMATION |
397 |
| 2 TECHNICAL SPECIFICATIONS |
400 |
| 3 TIGHTENING TORQUE |
401 |
| 4 SPECIAL TOOLS |
406 |
| 5 DIAGNOSIS |
409 |
| 6 PRECAUTIONS |
410 |
| 7 EXPLODED VIEWS OF FRONT SUSPENSION |
411 |
| 8 EXPLODED VIEWS REAR SUSPENSION |
416 |
| 9 ON VEHICLE FRONT SUSPENSION REMOVAL AND ASSEMBLY |
417 |
| 10 ON BENCH FRONT STRUT DISASSEMBLY |
420 |
| 11 ON BENCH FRONT STRUT ASSEMBLY |
421 |
| 12 REMOVAL AND ASSEMBLY OF WHEEL DISC |
424 |
| 13 ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB (GEN1 BEARING) |
426 |
| 14 ON BENCH REMOVAL AND ASSEMBLY OF WHEEL HUB (GEN3 BEARING) |
427 |
| 15 REMOVAL OF SUBFRAME ASSEMBLY |
427 |
| 16 INSTALLATION OF SUBFRAME ASSEMBLY |
430 |
| 17 LCA REAR HYDRA-BUSH INSTALLATION |
430 |
| 18 REMOVAL OF ANTI ROLL BAR |
431 |
| 19 REMOVAL AND ASSEMBLY OF REAR DAMPER ASSEMBLY AND COIL SPRINGS |
432 |
| 20 ECIE / PRELOAD CONDITION |
433 |
| 21 INSTALLATION OF REAR DAMPER ASSEMBLY AND COIL SPRINGS |
433 |
| 22 REAR SUSPENSION DISMANTLING OR INSTALLATION |
434 |
| 23 RTB BUSH INSTALLATION |
437 |
| 24 PAN HARD ROD BUSH INSTALLATION AND REMOVAL |
437 |
| 25 INSTALLATION AND REMOVAL OF DAMPER BOTTOM BUSH |
439 |
| 26 SUSPENSION ECIE / PRE-LOADING CONDITION |
440 |
| WHEELS AND TYRES |
441 |
| 1 GENERAL INFORMATION |
443 |
| A. SPECIFICATIONS FOR XZ & XT VARIANTS |
443 |
| B. SPECIFICATIONS FOR XM & XE VARIANTS |
444 |
| C. TIGHTENING TORQUES |
445 |
| 2 GENERAL SYMPTOMS DIAGNOSIS |
446 |
| A. DIAGNOSIS CHART |
446 |
| B. TYRE WEAR PATTERN |
448 |
| C. WEAR CAUSES |
449 |
| D. TYRE VIBRATION DIAGNOSIS |
450 |
| 3 MAINTENANCE, INSPECTION AND TESTS |
451 |
| A. PRELIMINARY INSPECTION |
451 |
| B. REGULAR MAINTENANCE |
452 |
| I.INFLATION |
452 |
| II. WHEEL BALANCING |
452 |
| III. TYRE ROTATION |
453 |
| IV.WHEEL RUN OUT |
454 |
| V. DO'S AND DON’TS |
454 |
| 4 WHEEL AND TYRE REPLACEMENT |
455 |
| A. PRECAUTIONS DURING TYRE REPLACEMENT |
455 |
| B. TYRE REPLACEMENT |
456 |
| C. WHEEL ASSEMBLY REPLACEMENT |
456 |
| D. WHEEL REMOVAL |
456 |
| E. BALANCING WHEELS |
457 |
| F. TYRE CARE |
457 |
| BRAKE DISC-DISC(Non EPB) |
458 |
| 1 TECHNICAL SPECIFICATION |
461 |
| 2 SYSTEM DETAILS |
462 |
| 3 TIGHTENING TORQUE |
464 |
| 4 GENERAL SYMPTOMS DIAGNOSIS |
469 |
| 5 NECESSITY OF ABS WITH EBD |
471 |
| 6 VACCUM BRAKE BOOSTER |
471 |
| 7 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS |
473 |
| 8 ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULLIC CONTROL UNIT (ECU\HCU |
476 |
| 9 WHEEL SPEED SENSOR (MONITORS WHEEL SPEED) |
478 |
| 10 ABS SYSTEM FAILURE WARNING LIGHT |
479 |
| 11 MAINTAINANCE, INSPECTION AND TEST |
480 |
| 12 REGULAR MAINTENANCE |
481 |
| A BRAKE BLEEDING PROCEDURE |
481 |
| B ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL |
482 |
| C CALIPER PAD REPLACEMENT. |
483 |
| D PARKING BRAKE ADJUSTMENT |
484 |
| E BRAKE FLUID DRAINING PROCEDURE |
485 |
| F BRAKE LIGHT SWITCH ADJUSTMENT |
485 |
| G CALIPER GREASING |
485 |
| H DISC RUN-OUT MEASUREMENT PROCEDURE |
486 |
| 13 ON VEHICLE REPAIRS |
487 |
| A FRONT CALIPER ASSEMBLYWITH CARRIER |
487 |
| B BRAKE CALIPER ASSEMBLY DISMANTALING |
487 |
| C FRONT AND REAR DISC REMOVAL |
489 |
| D REAR CALIPER ASSEMBLYWITH CARRIER |
490 |
| E PARKING BRAKE |
492 |
| F PARKING BRAKE CABLE REMOVAL |
493 |
| G HAND BRAKE LEVER REMOVAL |
494 |
| H VACCUM LINES |
495 |
| I BOOSTER ASSEMBLY |
496 |
| J TANDEM MASTER CYLINDER (TMC) & BOOSTER ASSEMBLY |
498 |
| K BOOSTER NRV |
499 |
| L BOOSTER ASSEMBLY |
499 |
| 14 DISMANTLING, INSPECTION AND ASSEMBLY |
501 |
| A FRONT CALIPER ASSEMBLY |
501 |
| B REAR CALIPER ASSEMBLY |
502 |
| BRAKE DISC-DISC (EPB) |
504 |
| 1 TECHNICAL SPECIFICATION |
506 |
| 2 SYSTEM DETAILS |
507 |
| 3 TIGHTENING TORQUE |
509 |
| 4 GENERAL SYMPTOMS DIAGNOSIS |
513 |
| 5 NECESSITY OF ABS WITH EBD |
515 |
| 6 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
517 |
| 7 ESP 9.3CPI ELECTRONIC CONTROL UNIT / HYDRAULLIC CONTROL UNIT (ECU/HCU) |
520 |
| 8 WHEEL SPEED SENSOR (MONITORS WHEEL SPEED) |
522 |
| 9 ABS SYSTEM FAILURE WARNING LIGHT |
523 |
| 10 MAINTAINANCE, INSPECTION AND TEST |
524 |
| 11 REGULAR MAINTENANCE |
525 |
| A BRAKE BLEEDING PROCEDURE |
525 |
| B ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) |
526 |
| C FRONT BRAKE CALIPER PAD REPLACEMENT |
527 |
| D BRAKE FLUID DRAINING PROCEDURE |
528 |
| E BRAKE LIGHT SWITCH ADJUSTMENT |
528 |
| F CALIPER GREASING |
528 |
| G DISC RUN-OUT MEASUREMENT PROCEDURE |
529 |
| 12 ON VEHICLE REPAIRS |
530 |
| A FRONT CALIPER ASSEMBLY WITH CARRIER |
530 |
| B BRAKE CALIPER ASSEMBLY DISMANTLING |
530 |
| C FRONT AND REAR BRAKE DISC REMOVAL |
533 |
| D REAR CALIPER ASSEMBLY WITH CARRIER |
533 |
| E REAR BRAKE CALIPER PAD REPLACEMENT FOR EPB CALIPER |
534 |
| F C667 CALIPER RECEPTACLE HOUSING WITH CPA |
536 |
| G VACCUM LINES |
537 |
| H BOOSTER ASSEMBLY |
538 |
| I TANDEM MASTER CYLINDER & BOOSTER ASSY |
540 |
| J BOOSTER NRV |
541 |
| K BOOSTER ASSEMBLY |
541 |
| 13 DISMANTLING, INSPECTION AND ASSEMBLY |
543 |
| A FRONT CALIPER ASSEMBLY |
543 |
| B REAR CALIPER ASSEMBLY |
544 |
| HVAC |
547 |
| 1 HVAC SYSTEM LAYOUT |
549 |
| 2 SPECIFICATIONS HVAC UNIT |
550 |
| 3 SPECIAL TOOLS |
559 |
| 4 TIGHTENING TORQUES |
560 |
| 5 PRECAUTIONS |
564 |
| 6 HVAC SYSTEM LAYOUT AND WORKING |
565 |
| 7 CONTROL PANEL |
568 |
| 8 FRONT HVAC UNIT |
570 |
| 9 COMPRESSOR |
572 |
| 10 CONDENSER |
573 |
| 11 RECEIVER DRIER (R.D) |
573 |
| 12 EVAPORATER SENSOR POSITION |
573 |
| 13 TRINARY PRESSURE SWITCH |
574 |
| 14 MODE & TEMPRATURE CONTROL ACTUATOR |
575 |
| 15 INSPECTION OF MODE AND TEMPERATURE ACTUATOR |
577 |
| 16 TROUBLESHOOTING |
579 |
| 17 MAINTENANCE |
589 |
| 18 ON VEHICLE REPAIRS |
595 |
| 19 DO'S AND DON’T'S FOR A/C SYSTEM |
606 |
| FATC |
607 |
| 1 FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) |
610 |
| 2 TECHNICAL SPECIFICATIONS |
611 |
| 3 SPECIAL TOOLS |
622 |
| 4 TIGHTENING TORQUE |
623 |
| 5 HMI CLIMATE CONTROL DISPLAY |
628 |
| 6 CONTROL PANEL |
629 |
| 7 CONTROL PANEL MODULE CONNECTOR DETAILS |
634 |
| 8 FATC UNIT |
636 |
| A BLOWER |
636 |
| B APORATOR COIL AND TXV (THERMAL EX-PANSION VALVE) |
636 |
| C HEATER COIL |
637 |
| 9 FATC SENSOR & ACTUATOR |
638 |
| A EVAPORATER SENSOR |
638 |
| B TRINARY PRESSURE SWITCH |
639 |
| C SOLAR LOAD SENSOR |
640 |
| D OAT SENSOR |
641 |
| E INCAR SENSOR |
642 |
| F MODE ACTUATOR |
642 |
| G TEMPERATURE ACTUATOR |
643 |
| H MODE ACTUATOR (B-PILLAR SIDE) |
643 |
| I BLOWER CONTROL MODULE |
643 |
| 10 COMPRESSOR |
644 |
| 11 CONDENSER AND RECEIVER DRIER CONDENSER |
645 |
| 12 RECEIVER DRIER (R.D) |
645 |
| 13 TROUBLESHOOTING |
646 |
| 14 MAINTENANCE |
656 |
| A PRELIMINARY INSPECTION |
656 |
| B REGULAR MAINTENANCE |
658 |
| 15 ON VEHICLE REPAIR |
662 |
| A AC FILTER REMOVAL |
662 |
| B CONTROL PANEL REMOVAL |
662 |
| C BLOWER MOTOR REMOVAL |
663 |
| D FRONT HVAC UNIT REMOVAL |
665 |
| E B-PILLAR VENT |
666 |
| F COMPRESSOR |
667 |
| G HEATER HOSE |
668 |
| H PRESSURE SWITCH |
669 |
| I CONDENSER |
670 |
| J CONDENSER SEALING DUCT REMOVAL |
671 |
| K REAR AC DUCT |
671 |
| L REAR AC UNIT |
672 |
| 16 DO’S AND DONT’S FOR A/C SYSTEM |
674 |
| BODY |
675 |
| 1 GENERAL INFORMATION |
679 |
| 1.1 LAYOUT |
679 |
| 1.2 TIGHTENING TORQUES |
680 |
| 1.3 SPECIAL TOOL |
683 |
| 2 ON VEHICLE REPAIRS |
684 |
| 2.1 BONNET |
684 |
| 2.2 ARM REST |
686 |
| 2.3 FLOOR CONSOLE |
687 |
| 2.4 DASHBOARD SKIN |
688 |
| 2.5 GLOVE BOX |
696 |
| 2.6 SIDE AIR VENTS |
697 |
| 2.7 FRONT BUMPER |
698 |
| 2.8 REAR BUMPER |
701 |
| 2.9 FRONT DOOR |
703 |
| 2.10 FRONT DOOR TRIMS |
704 |
| 2.11 DOOR INNER LOCK HANDLE |
706 |
| 2.12 FRONT OUTER DOOR LOCK |
707 |
| 2.13 FRONT DOOR LATCH |
708 |
| 2.14 FRONT DOOR GLASS ANDWINDOWWINDINGMECHANISM |
709 |
| 2.15 REAR DOOR |
710 |
| 2.16 REAR DOOR TRIMS |
712 |
| 2.17 REAR OUTER DOOR LOCK |
713 |
| 2.18 DOOR LATCH REAR |
714 |
| 2.19 TAIL GATE |
715 |
| 2.20 TAILGATE TRIM |
717 |
| 2.21 ORVM |
718 |
| 2.22 INNER REAR VIEW MIRROR |
719 |
| 2.23 FRONT ROW SEAT |
720 |
| 2.24 REAR ROW SEAT |
721 |
| 2.25 REAR ROW CAPTAIN SEAT (IF APPLICABLE) |
722 |
| 2.26 THIRD ROW SEAT |
723 |
| 2.27 “A” PILLAR TRIM |
724 |
| 2.28 FRONT SCUFF PLATE |
725 |
| 2.29 “B” PILLAR TRIM |
725 |
| 2.30 REAR SCUFF PLATE |
726 |
| 2.31 REAR QUARTER TRIM |
727 |
| 2.32 “C” PILLAR TRIMS |
728 |
| 2.33 “D” PILLAR TRIMS |
729 |
| 2.34 GRAB HANDLE |
730 |
| 2.35 SUNVISOR |
730 |
| 2.36 ROOF CONSOLE BEZEL |
731 |
| 2.37 ROOF LINEAR |
731 |
| 2.38 ROOF RAIL |
732 |
| 2.39 PLENUM COVER |
733 |
| 2.40 GEAR LEVER BOOT |
733 |
| 2.41 BONNET INSULATION |
734 |
| 2.42 GLASS |
735 |
| 2.43 FUEL FILLER ASSEMBLY |
736 |
| 2.44 FRONTWHEEL ARCH LINER |
737 |
| 2.45 REARWHEEL ARCH LINER |
738 |
| 2.46 FRONT FENDER |
740 |
| 2.47 REARWIPER MOTOR |
741 |
| 2.48 FRONTWIPER |
742 |
| 2.49 SUNROOF |
743 |
| 2.50 WIND DEFLECTOR |
744 |
| 2.51 FRONT GLASS PANEL (MOVING PANEL) |
745 |
| 2.52 REAR GLASS PANEL (FIXED PANEL) |
746 |
| 2.53 SUNSHADE ROLLO ASSEMBLY (SUN BLIND) |
747 |
| 2.54 MECHANISM ELECTRIC DRIVE ASSEMBLY |
748 |
| 2.55 ROLLO ELECTRIC DRIVE ASSEMBLY |
748 |
| 2.56 MECHANISM MAINTENANCE |
749 |
| 2.57 WATER CHANNEL MAINTENANCE |
752 |
| 2.58 SUNROOF RESET PROCEDURE - INITIALIZING THE POWER SUNROOF |
752 |
| 2.59 SUNROOF RESET PROCEDURE - SELFLEARNING THE POWER SUNROOF |
753 |
| ELECTRICAL |
754 |
| 1 TECHNICAL SPECIFICATIONS |
758 |
| 2 GENERAL PRECAUTIONS |
761 |
| 3 FUSE BOX / RELAY LOCATIONS |
767 |
| 4 BATTERY |
768 |
| 5 ALTERNATOR |
770 |
| 6 STARTER MOTOR |
771 |
| 7 LIGHTING SYSTEM |
776 |
| A.BULB SPECIFICATION |
776 |
| B. TORQUE VALUE TABLE |
776 |
| C. GENERAL SYMPTOMS AND DIAGNOSTICS FOR ALL LAMPS |
777 |
| D. HEAD LAMP |
781 |
| E. DRL ASSEMBLY |
785 |
| F. SIDE REPEATER LAMP (LH/RH) |
786 |
| G. ROOF LAMP |
786 |
| H. HIGH MOUNTED STOP LAMP |
789 |
| I. TAIL LAMP |
790 |
| J. REAR FOG LAMP |
792 |
| K. FRONT FOG LAMP |
793 |
| L. REGISTRATION PLATE LAMP |
794 |
| 8 HORN |
795 |
| 9 WIPER & WASHER SYSTEM |
797 |
| A. FRONT WIPER AND WAHSER SYSTEM LAYOUT |
797 |
| B. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
798 |
| C. WIPER AND WIPER CARE |
801 |
| 10 POWER SOCKETS |
803 |
| 11 GLOW PLUG CONTROL UNIT |
804 |
| 12 FUEL GAUGE AND FUEL LEVEL METER |
806 |
| 13 COMBI-SWITCH |
808 |
| 14 STEERING LOCK CUM IGNITION SWITCH |
814 |
| 15 FASCIA SWITCHES |
817 |
| 16 MIRROR SWITCH |
823 |
| 17 INFOTAINMENT SYSTEM |
826 |
| A.USB/AUX PORT |
829 |
| B.SPEAKERS |
830 |
| C.ANTENNA |
833 |
| D.MICROPHONE |
834 |
| E.SILVER BOX |
835 |
| F.TWEETERS |
839 |
| G.AMPLIFIER |
841 |
| 18 WINDOW WINDING MODULE. |
842 |
| 19 POWERWINDOW SWITCHES & INHIBIT SWITCH |
845 |
| 20 STEERINGWHEEL SWITCHES |
849 |
| 21 DOOR HANDLE SWITCH |
852 |
| 22 TAILGATE HANDLE SWITCH |
853 |
| 23 IGNITION KEY |
854 |
| 24 INSTRUMENT CLUSTER |
860 |
| A. BASIC FUNCTIONAL MATRIX |
864 |
| B. TELL TALES MATRIX |
865 |
| C. REMINDER FEATURES |
873 |
| D. DRIVER INFORMATION SYSTEM |
874 |
| E. FUEL GAUGE DETAILS |
896 |
| F. TEMPERATURE BAR GRAPH DETAILS |
897 |
| G. CHIME TABLE |
898 |
| 25 IMMOBILIZER SYSTEM |
900 |
| A. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
904 |
| B. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
905 |
| C. IGNITION KEY LEARNING PROCEDURE |
907 |
| D. CHECKING PAIRING STATUS |
908 |
| 26 BODY CONTROL MODULE (BCM) |
910 |
| A. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
917 |
| B. BCM FEATURES |
923 |
| C. BCM REPLACEMENT STRATEGY |
925 |
| D. BCM FUNCTIONS |
927 |
| 27 RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE) |
928 |
| 28 FUSE AND RELAY BOX DETAILS |
933 |
| A. BATTERY MOUNTED FUSE BOX |
936 |
| B. ENGINE FUSE AND RELAY BOX |
936 |
| C. CABIN FUSE AND RELAY BOX |
939 |
| 29 REVERSE PARK ASSIST SYSTEM |
942 |
| 30 PASSIVE ENTRY PASSIVE START (PEPS) |
952 |
| A. PEPS ECU |
953 |
| B. START STOP SWITCH |
955 |
| C. ELECTRONIC STEERING COLUMN LOCK (ESCL) |
956 |
| D. DOOR AND TAILGATE HANDLE |
958 |
| E. LF ANTENNAS |
959 |
| 31 TELEMATICS |
961 |
| SUPPLEMENTARY RESTRAINTSYSTEM (SRS) |
965 |
| 1 WORKING OF RESTRAINTS |
967 |
| 2 SYSTEM LAYOUT |
969 |
| 3 SAFETY PRECAUTIONS |
970 |
| 4 DISPOSAL OF FAULTY AIR BAG UNIT |
972 |
| 5 SRS POST ACCIDENT PROCEDURE |
973 |
| 6 TIGHTENING TORQUES |
974 |
| 7 COMPONENTS |
979 |
| 1 RESTRAINTWITHOUT AIRBAGS |
979 |
| 2 RESTRAINTWITH AIRBAGS |
979 |
| 8 FRONT SEAT BELT |
990 |
| 9 SECOND ROW SEAT BELT |
991 |
| 10 THIRD ROW SEAT BELT |
992 |
| 11 CLOCK SPRING |
993 |
| TIRE PRESSURE MONITORING SYSTEM (TPMS) |
996 |
| 1. INTRODUCTION |
998 |
| 2. SYSTEM WORKING |
999 |
| 3. SYSTEM LAYOUT |
999 |
| 4. COMPONENTS |
1000 |
| A. TPMS ECU |
1000 |
| B. TIRE PRESSURE SENSOR |
1000 |
| 5. ON VEHICLE PROCEDURES |
1001 |
| A. TPMS ECU REPLACEMENT PROCEDURE |
1001 |
| B. ECU REPLACEMENT PROCEDURE PREREQUISITE |
1001 |
| C. TPMS ECU LEARNING PROCEDURE |
1003 |
| D. TPMS SENSOR REPLACEMENT PROCEDURE USING LF TOOL |
1005 |
| 6. TIRE REPLACEMENT |
1006 |
| 7. MOUNTING OF THE TIRE |
1007 |