| NEW NEXON SERVICE MANUAL |
1 |
| Petrol Engine Ph-2 (CAFÉ) |
5 |
| TABLE OF CONTENTS |
6 |
| 1. GENERAL INFORMATION |
10 |
| A. ENGINE INTRODUCTION |
10 |
| B. ELECTRONIC CONTROL UNIT |
11 |
| C. TECHNICAL SPECIFICATION |
12 |
| D. SPECIAL TOOLS |
13 |
| E. ASSEMBLY CLEARANCES |
16 |
| F. SEALANTS |
16 |
| G. LEAKAGE RATES |
16 |
| 2. TROUBLE SHOOTING |
17 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
25 |
| A. ENGINE LIFTING HOOKS |
25 |
| B. INTAKE MANIFOLD |
26 |
| C. CYLINDER HEAD COVER |
28 |
| D. CYLINDER HEAD-A |
30 |
| E. CYLINDER HEAD-B |
32 |
| F. CYLINDER BLOCK |
34 |
| G. LUBRICATION PUMP AND COMPONENTS |
36 |
| H. PISTON, CRANKSHAFT AND COMPONENTS |
39 |
| I. ENGINE TIMING |
41 |
| J. TURBOCHARGER, CATCON AND COMPONENTS |
43 |
| K. FUEL INJECTION EQUIPMENT |
46 |
| L. AIR FILTER, SNORKEL AND BLOW-BY PIPE |
48 |
| M. WATER PUMP, THERMOSTAT AND COMPONENTS |
51 |
| N. STARTER MOTOR AND ALTERNATOR |
53 |
| O. COMPRESSOR, AUTO-TENSIONER AND BELT |
54 |
| P. ENGINE SUSPENSION |
55 |
| Q. INTERCOOLER AND HOSES |
58 |
| 4. ENGINE TESTS AND MAINTENANCE |
61 |
| A. PRELIMINARY INSPECTION |
61 |
| B. ENGINE TESTS |
62 |
| C. REGULAR MAINTENANCE |
65 |
| I. ENGINE OIL AND FILTER CHANGE DESCRIPTION |
65 |
| II. ENGINE COOLANT REPLACEMENT DESCRIPTION |
67 |
| III. AIR FILTER ELEMENT REPLACEMENT DESCRIPTION |
68 |
| IV. SPARK PLUG REPLACEMENT DESCRIPTION |
69 |
| V. AIR CONDITIONER COMPRESSOR AND ALTERNATOR BELT REPLACEMENT |
72 |
| 5. REPAIR AND INSPECTION DETAILS |
73 |
| A. ACCESSORY DRIVING BELT |
73 |
| B. TIMING CHAIN |
73 |
| C. CYLINDER HEAD |
73 |
| D. VALVES |
74 |
| E. CYLINDER HEAD VALVE SEATS |
76 |
| F. ROLLER FINGER FOLLOWER |
77 |
| G. HYDRAULIC LASH ADJUSTER (HLA) |
77 |
| H. CAMSHAFTS (INTAKE & EXHAUST) |
78 |
| I. PISTON AND PISTON RINGS |
79 |
| J. CONNECTING RODS |
80 |
| K. CRANKSHAFT |
82 |
| L. CRANK CASE |
84 |
| M. FUEL TANK |
85 |
| N. CANISTER PURGE VALVE |
85 |
| O. CANISTER |
86 |
| 6. ENGINE SYSTEM |
87 |
| A. AIR INTAKE SYSTEM |
87 |
| B. BLOW BY SYSTEM |
90 |
| C. LUBRICATION SYSTEM |
91 |
| D. EXHAUST SYSTEM |
95 |
| E. COOLING SYSTEM |
98 |
| F. FUEL SYSTEM |
101 |
| 7. ENGINE ON VEHICLE SERVICE PROCEDURE |
104 |
| A. ENGINE REMOVAL AND REFITMENT |
104 |
| B. AIR FILTER ASSEMBLY |
111 |
| C. INJECTOR REMOVAL |
112 |
| D. SPARK PLUG REMOVAL |
113 |
| E. EXHAUST SYSTEM REMOVAL MAINTENANCEPRECAUTIONS |
114 |
| F. FUEL SYSTEM |
118 |
| G. COOLING SYSTEM |
124 |
| H. REMOVAL OF ACCESSORIES |
129 |
| 8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
131 |
| A. ENGINE DISASSEMBLY |
131 |
| I. REMOVAL OF INTAKE MANIFOLD |
131 |
| II. REMOVAL OF CLOSED COUPLED CATCON |
133 |
| III. REMOVAL OF OIL SUMP |
135 |
| IV. REMOVAL OF SENSORS |
136 |
| V. REMOVAL OF ACCESSORIES |
137 |
| VI. REMOVAL OF TIMING CHAIN |
140 |
| VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
142 |
| VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
144 |
| IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
146 |
| B. ENGINE ASSEMBLY |
150 |
| I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
150 |
| II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
155 |
| III. ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES |
157 |
| IV. ASSEMBLY OF CYLINDER HEAD |
159 |
| V. ASSEMBLY OF ENGINE TIMING CHAIN |
161 |
| VI. FITMENT OF CYLINDER HEAD COVER AND PERIPHERALS |
164 |
| VII. ASSEMBLY OF SENSORS |
167 |
| VIII. ASSEMBLY OF OIL SUMP |
168 |
| IX. ASSEMBLY OF EXHAUST MANIFOLD |
169 |
| X. ASSEMBLY OF INTAKE MANIFOLD |
172 |
| 9. ENGINE MANAGEMENT SYSTEM |
175 |
| A. ABBREVIATIONS |
175 |
| B. OVERVIEW |
176 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
177 |
| D. SENSORS |
185 |
| I. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) |
186 |
| II. LAMBDA SENSOR |
187 |
| III. CAMSHAFT POSITION SENSOR |
189 |
| IV. KNOCK SENSOR |
191 |
| V. CRANKSHAFT POSITION SENSOR |
192 |
| VI. COOLANT TEMPERATURE SENSOR |
194 |
| E. ACTUATORS |
195 |
| I. IGNITION COIL |
196 |
| II. PURGE CONTROL VALVE COMPONENT DETAILS |
197 |
| III. SOLENOID VALVE (OIL CONTROL VALVE) |
198 |
| IV. FUEL INJECTORS COMPONENT DETAILS |
199 |
| V. ELECTRONIC THROTTLE BODY COMPONENT DETAILS |
200 |
| F. SWITCH |
202 |
| I. OIL PRESSURE SWITCH |
202 |
| II. THROTTLE PEDAL SENSOR |
203 |
| III. CLUTCH SWITCH |
204 |
| IV. BRAKE SWITCH |
205 |
| V. WHEEL SPEED SENSOR |
206 |
| VI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
207 |
| VII. START STOP SWITCH |
208 |
| VIII. AC PRESSURE SENSOR |
209 |
| Diesel Engine Ph-2 (CAFÉ) |
211 |
| TABLE OF CONTENTS |
212 |
| 1. GENERAL INFORMATION |
216 |
| A. ENGINE INTRODUCTION |
216 |
| B. TECHNICAL SPECIFICATION |
217 |
| C. SPECIAL TOOLS |
218 |
| D. ASSEMBLY CLEARANCES |
223 |
| E. LEAKAGE RATES |
224 |
| 2. TROUBLESHOOTING |
225 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
229 |
| A. ENGINE LIFTING HOOK |
229 |
| B. INTAKE MANIFOLD AND FUEL INJECTION SYSTEM |
230 |
| C. LUBRICATION SYSTEM |
233 |
| D. AIR FILTER, SNORKEL, BLOW BY PIPE |
236 |
| E. STARTER MOTOR, COMPRESSOR AND ALTERNATOR |
239 |
| F. TIMING BELT, AUTO TENSIONER, WATER PUMP |
242 |
| G. EXHAUST MANIFOLD, CATCON, TURBOCHARGER |
245 |
| H. CYLINDER HEAD AND COMPONENTS |
248 |
| I. PISTON, CRANKSHAFT AND COMPONENTS |
251 |
| J. ENGINE SUSPENSION |
253 |
| K. INTERCOOLER, THERMOSTAT AND COMPONENTS |
256 |
| L. CRANKCASE AND COMPONENTS |
259 |
| 4. ENGINE TESTS AND MAINTENANCE |
261 |
| A. PRELIMINARY INSPECTION |
261 |
| B. ENGINE TESTS |
261 |
| C. REGULAR MAINTENANCE |
266 |
| I. ENGINE OIL AND FILTER CHANGE DESCRIPTION |
266 |
| II. ENGINE COOLANT REPLACEMENT |
268 |
| III. COOLANT FILLING (DE - AREATION PROCEDURE) |
269 |
| IV. AIR FILTER ELEMEMT REPLACEMENT DESCRIPTION |
273 |
| V. FUEL FILTER REPLACEMENT |
274 |
| VI. DRAINING WATER FROM FUEL FILTER |
275 |
| VII. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
276 |
| 5. REPAIR AND INSPECTION DETAILS |
280 |
| A. TIMING BELT |
280 |
| B. FUEL TANK |
280 |
| C. CYLINDER HEAD |
281 |
| D. VALVES |
281 |
| E. VALVE SEATS |
283 |
| F. CRANKCASE |
284 |
| G. VALVE SEAT INSERT |
285 |
| H. HYDRAULIC LASH ADJUSTER |
285 |
| I. VALVE GUIDES |
286 |
| J. CAMSHAFT |
287 |
| K. PISTON AND PISTON RINGS |
288 |
| L. CONNECTING ROD |
289 |
| M. CRANK SHAFT |
291 |
| 6. ENGINE SYSTEMS |
293 |
| A. AIR INTAKE SYSTEM |
293 |
| B. EXHAUST SYSTEM |
296 |
| C. COOLING SYSTEM |
300 |
| D. LUBRICATION SYSTEM |
303 |
| E. EXHAUST GAS RECIRCULATION SYSTEM (EGR) |
306 |
| F. BLOW-BY VENTILATION SYSTEM |
308 |
| G. VACUUM MANAGEMENT SYSTEM |
309 |
| H. FUEL SYSTEM |
310 |
| 7. ENGINE ON VEHICLE SERVICE PROCEDURE |
316 |
| A. ENGINE REMOVAL DESCRIPTION |
316 |
| B. ENGINE INSTALLATION |
322 |
| C. EXHAUST SYSTEM ON VEHICLE REPAIRS |
323 |
| D. COOLING SYSTEM ON VEHICLE REPAIRS |
327 |
| E. FUEL SYSTEM PRECAUTIONS |
332 |
| F. TURBOCHARGER REMOVAL AND REFITMENT |
340 |
| G. TIMING BELT REMOVAL AND REFITMENT |
342 |
| H. STARTER MOTOR REMOVAL AND FITMENT - NEED INFORMATION |
344 |
| I. ALTERNATOR REMOVAL |
345 |
| J. COMPRESSOR REMOVAL |
346 |
| K. HIGH PRESSURE PUMP REMOVAL |
348 |
| 8. ENGINE OVERHAULING |
352 |
| A. ENGINE DIS-ASSEMBLY |
352 |
| I. ON OVERHAUL STAND |
352 |
| II. REMOVAL OF INTAKE MANIFOLD |
357 |
| III. REMOVAL OF EXHAUST MANIFOLD |
359 |
| IV. REMOVAL OF VSV AND THERMOSTAT |
361 |
| V. REMOVAL OF OIL SUMP |
362 |
| VI. REMOVAL OF TIMING BELT |
363 |
| VII. REMOVAL OF LIFTING SUPPORT |
367 |
| VIII. REMOVAL OF CYLINDER HEAD |
367 |
| IX. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
369 |
| X. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
372 |
| XI. PISTON CONNECTING ROD DISASSEMBLY |
374 |
| B. ENGINE ASSEMBLY |
380 |
| I. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
380 |
| II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
381 |
| III. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
382 |
| IV. ITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
385 |
| V. FITMENT OF LIFTING SUPPORT |
387 |
| VI. FITMENT OF TIMING BELT |
387 |
| VII. FITMENT OF OIL SUMP |
391 |
| VIII. FITMENT OF VSV AND THERMOSTAT |
393 |
| IX. FITMENT OF EXHAUST MANIFOLD AND OTHER COMPONENTS |
394 |
| X. FITMENT OF INTAKE MANIFOLD |
396 |
| XI. ON OVERHAUL STAND |
399 |
| 9. ENGINE MANAGEMENT SYSTEM |
404 |
| A. ABBREVIATIONS |
404 |
| B. OVERVIEW |
405 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
406 |
| D. EMS SENSORS |
411 |
| I. CRANK POSITION SENSOR |
411 |
| II. WHEEL SPEED SENSOR |
412 |
| III. CAMSHAFT POSITION SENSOR |
413 |
| IV. AIR MASS FLOW SENSOR |
414 |
| V. VENTURI |
415 |
| VI. RAIL PRESSURE SENSOR |
416 |
| VII. THROTTLE PEDAL SENSOR |
417 |
| VIII. WATER IN FUEL SENSOR |
418 |
| IX. CLUTCH SWITCH |
418 |
| X. OIL PRESSURE SWITCH |
419 |
| XI. BRAKE SWITCH |
421 |
| XII. COOLANT TEMPERATURE SENSOR |
422 |
| XIII. GLOW PLUG |
423 |
| XIV. AIR TEMPRETURE SENSOR |
424 |
| XV. START STOP SWITCH |
425 |
| XVI. AC PRESSURE SENSOR |
426 |
| XVII. LAMBDA SENSOR |
427 |
| XVIII. DPF TEMPERATURE SENSOR |
428 |
| XIX. DPS SENSOR |
429 |
| TRANSAXLE (TA6300) |
430 |
| TABLE OF CONTENTS |
431 |
| 1. GENERAL INFORMATION |
432 |
| 2. TECHNICAL SPECIFICATIONS (5 SPEED / 6 SPEED) |
433 |
| 3. PRECAUTIONS |
434 |
| 4. TIGHTENING TORQUES |
435 |
| 5. SPECIAL TOOL |
440 |
| 6. DIAGNOSIS |
446 |
| 7. SECTION VIEWS |
447 |
| 8. EXPLODED VIEW |
451 |
| 9. REMOVAL OF TRANSAXLE FROM VEHICLE (PETROL) |
461 |
| 10. REMOVAL OF TRANSAXLE FROM VEHICLE (DIESEL) |
464 |
| 11. TRANSAXLE DISASSEMBLY ON BENCH |
467 |
| A. INPUT SHAFT ASSEMBLY 3rd / 4th SYNCHROPACK ASSEMBLY: |
475 |
| B. LAY SHAFT DISASSEMBLY |
479 |
| C. DIFFERENTIAL DISASSEMBLY |
483 |
| D. SHIFTER SHAFTS |
487 |
| E. IDENTIFICATION OF ENGAGING GEARS |
487 |
| 12. TRANSAXLE ASSEMBLY ON BENCH |
488 |
| 13. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE ON TRANSAXLE |
494 |
| 14. REMOVAL OF GEAR SHIFTER HOUSING,GEAR SHIFTER AND SELECTOR CABLE |
495 |
| DRIVESHAFT MT_AMT |
497 |
| TABLE OF CONTENTS |
498 |
| 1. GENERAL INFORMATION |
499 |
| 2. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
501 |
| 3. DRIVE SHAFT PARTS |
502 |
| 4. TIGHTENING TORQUES |
503 |
| 5. ON BENCH PROCEDURE |
505 |
| A. TRIPOT JOINT DISASSEMBLY |
505 |
| B. TRIPOT JOINT ASSEMBLY |
506 |
| C. CV JOINT OUTER DISASSEMBLY |
507 |
| 6. ON VEHICLE PROCEDURE |
508 |
| A. DRIVE SHAFT (LH / RH) REMOVAL (PETORL VEHICLE) |
508 |
| B. DRIVE SHAFT (LH / RH) REMOVAL (DIESEL VEHICLE) |
509 |
| CLUTCH_MT_AMT |
511 |
| TABLE OF CONTENTS |
512 |
| 1. GENERAL INFORMATION |
514 |
| A. CLUCTH MASTER CYLINDER |
515 |
| B. CONCENTRIC SLAVE CYLINDER (CSC) |
515 |
| C. PEAK TORQUE LIMITER |
515 |
| D. HYDRAULIC ADAPTER |
515 |
| E. SINGLE MASS FLYWHEEL |
516 |
| F. SELF ADJUSTING CLUTCH |
516 |
| 2. TECHNICAL SPECIFICATIONS |
517 |
| A. CLUTCH DISC ASSEMBLY |
517 |
| B. SELF ADJUSTING CLUTCH COVER ASSEMBLY |
518 |
| C. SINGLE MASS FLYWHEEL |
519 |
| I. FOR PETROL VERSION |
519 |
| II. FOR DIESEL VERSION |
520 |
| 3. TIGHTENING TORQUES |
521 |
| 4. SPECIAL TOOLS |
524 |
| 5. MAINTENANCE, INSPECTION AND TESTS |
525 |
| A. PRELIMINARY MAINTENANCE |
525 |
| B. REGULAR MAINTENANCE |
526 |
| I. CLUTCH SENSOR ADJUSTMENT |
526 |
| II. CLUTCH BLEEDING PROCEDURE |
526 |
| III. CLUTCH FLUID DRAINING PROCEDURE |
527 |
| 6. GENERAL SYMPTOMS DIAGNOSIS |
528 |
| 7. TROUBLESHOOTING FOR SAC ASSEMBLY |
531 |
| 8. PRECAUTION FOR SAC ASSEMBLY |
532 |
| 9. EXPLODED VIEWS |
535 |
| A. CLUTCH PEDAL ASSEMBLY |
535 |
| B. SELF ADJUSTING CLUTCH ASSEMBLY |
536 |
| C. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
537 |
| 10. ON VEHICLE PROCEDURES |
538 |
| A. CLUTCH PEDAL ASSEMBLY REMOVAL |
538 |
| B. CONTROL BRACKET ASSEMBLY REMOVAL |
540 |
| C. SELF ADJUSTING CLUTCH ASSEMBLY REMOVAL |
541 |
| D. CLUTCH MASTER CYLINDER REMOVAL |
542 |
| E. FLYWHEEL REMOVAL |
544 |
| Transaxle AMT |
545 |
| TABLE OF CONTENTS |
546 |
| 1. GENERAL INFORMATION |
547 |
| 2. TECHNICAL SPECIFICATIONS |
548 |
| 3. PRECAUTIONS |
549 |
| 4. TIGHTENING TORQUES |
550 |
| 5. SPECIAL TOOL |
555 |
| 6. DIAGNOSIS |
561 |
| 7. SECTION VIEWS |
562 |
| 8. EXPLODED VIEW TRANSAXLE |
564 |
| 9. REMOVAL OF TRANSAXLE FROM VEHICLE (FOR PETROL VERSION) |
578 |
| 10. REMOVAL OF TRANSAXLE FROM VEHICLE (FOR DIESEL VERSION) |
582 |
| 11. TRANSAXLE DISASSEMBLY ON BENCH |
586 |
| 12. TRANSAXLE ASSEMBLY ON BENCH |
607 |
| Petrol Engine Ph-2 (CAFÉ)_DCT |
613 |
| TABLE OF CONTENTS |
614 |
| 1. GENERAL INFORMATION |
618 |
| A. ENGINE INTRODUCTION |
618 |
| B. ELECTRONIC CONTROL UNIT |
619 |
| C. TECHNICAL SPECIFICATION |
620 |
| D. SPECIAL TOOLS |
621 |
| E. ASSEMBLY CLEARANCES |
625 |
| F. SEALANTS |
625 |
| G. LEAKAGE RATES |
625 |
| 2. TROUBLE SHOOTING |
626 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
634 |
| A. ENGINE LIFTING HOOKS |
634 |
| B. INTAKE MANIFOLD |
635 |
| C. CYLINDER HEAD COVER |
637 |
| D. CYLINDER HEAD-A |
639 |
| E. CYLINDER HEAD-B |
641 |
| F. CYLINDER BLOCK |
643 |
| G. LUBRICATION PUMP AND COMPONENTS |
645 |
| H. PISTON, CRANKSHAFT AND COMPONENTS |
648 |
| I. ENGINE TIMING |
650 |
| J. TURBOCHARGER, CATCON AND COMPONENTS |
652 |
| K. FUEL INJECTION EQUIPMENT |
655 |
| L. AIR FILTER, SNORKEL AND BLOW-BY PIPE |
657 |
| M. WATER PUMP, THERMOSTAT AND COMPONENTS |
660 |
| N. STARTER MOTOR AND ALTERNATOR |
662 |
| O. COMPRESSOR, AUTO-TENSIONER AND BELT |
663 |
| P. ENGINE SUSPENSION |
664 |
| Q. INTERCOOLER AND HOSES |
666 |
| 4. ENGINE TESTS AND MAINTENANCE |
669 |
| A. PRELIMINARY INSPECTION |
669 |
| B. ENGINE TESTS |
670 |
| C. REGULAR MAINTENANCE |
673 |
| I. ENGINE OIL AND FILTER CHANGE DESCRIPTION |
673 |
| II. ENGINE COOLANT REPLACEMENT DESCRIPTION |
675 |
| III. AIR FILTER ELEMENT REPLACEMENT DESCRIPTION |
676 |
| IV. SPARK PLUG REPLACEMENT |
677 |
| V. AIR CONDITIONER COMPRESSOR AND ALTERNATOR BELT REPLACEMENT |
680 |
| 5. REPAIR AND INSPECTION DETAILS |
681 |
| A. ACCESSORY DRIVING BELT |
681 |
| B. TIMING CHAIN |
681 |
| C. CYLINDER HEAD |
681 |
| D. VALVES |
682 |
| E. CYLINDER HEAD VALVE SEATS |
684 |
| F. ROLLER FINGER FOLLOWER |
685 |
| G. HYDRAULIC LASH ADJUSTER (HLA) |
685 |
| H. CAMSHAFTS (INTAKE & EXHAUST) |
686 |
| I. PISTON AND PISTON RINGS |
687 |
| J. CONNECTING RODS |
688 |
| K. CRANKSHAFT |
690 |
| L. CRANK CASE |
692 |
| M. FUEL TANK |
693 |
| N. CANISTER PURGE VALVE |
693 |
| O. CANISTER |
694 |
| 6. ENGINE SYSTEM |
695 |
| A. AIR INTAKE SYSTEM |
695 |
| B. BLOW BY SYSTEM |
698 |
| C. LUBRICATION SYSTEM |
699 |
| D. EXHAUST SYSTEM |
703 |
| E. COOLING SYSTEM |
706 |
| F. FUEL SYSTEM |
709 |
| 7. ENGINE ON VEHICLE SERVICE PROCEDURE |
712 |
| A. ENGINE REMOVAL AND REFITMENT |
712 |
| B. AIR FILTER ASSEMBLY REMOVAL |
719 |
| C. INJECTOR REMOVAL |
720 |
| D. SPARK PLUG REMOVAL |
721 |
| E. EXHAUST SYSTEM REMOVAL MAINTENANCE PRECAUTIONS |
722 |
| F. FUEL SYSTEM |
726 |
| G. COOLING SYSTEM |
732 |
| H. REMOVAL OF ACCESSORIES |
737 |
| 8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
739 |
| A. ENGINE DIS-ASSEMBLY |
739 |
| I. REMOVAL OF INTAKE MANIFOLD |
739 |
| II. REMOVAL OF CLOSED COUPLED CATCON |
741 |
| III. REMOVAL OF OIL SUMP |
743 |
| IV. REMOVAL OF SENSORS |
744 |
| V. REMOVAL OF ACCESSORIES |
745 |
| VI. REMOVAL OF TIMING CHAIN |
748 |
| VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
750 |
| VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
752 |
| IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
754 |
| B. ENGINE ASSEMBLY |
758 |
| I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
758 |
| II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
762 |
| III. ASSEMBLY OF CYLINDER HEAD SUB ASSEMBLIES |
764 |
| IV. ASSEMBLY OF CYLINDER HEAD |
766 |
| V. ASSEMBLY OF ENGINE TIMING CHAIN |
768 |
| VI. FITMENT OF CYLINDER HEAD COVER AND PERIPHERALS |
772 |
| VII. ASSEMBLY OF SENSORS |
775 |
| VIII. ASSEMBLY OF OIL SUMP |
776 |
| IX. ASSEMBLY OF EXHAUST MANIFOLD |
777 |
| X. ASSEMBLY OF INTAKE MANIFOLD |
779 |
| 9. ENGINE MANAGEMENT SYSTEM |
782 |
| A. ABBREVIATIONS |
782 |
| B. OVERVIEW |
783 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
784 |
| D. SENSORS |
792 |
| I. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) |
793 |
| II. LAMBDA SENSOR |
794 |
| III. CAMSHAFT POSITION SENSOR |
796 |
| IV. KNOCK SENSOR |
798 |
| V. CRANKSHAFT POSITION SENSOR |
799 |
| VI. COOLANT TEMPERATURE SENSOR |
801 |
| E. ACTUATORS |
802 |
| I. IGNITION COIL |
803 |
| II. PURGE CONTROL VALVE COMPONENT DETAILS |
804 |
| III. SOLENOID VALVE (OIL CONTROL VALVE) |
805 |
| IV. FUEL INJECTORS COMPONENT DETAILS |
806 |
| V. ELECTRONIC THROTTLE BODY COMPONENT DETAILS |
807 |
| F. SWITCH |
809 |
| I. OIL PRESSURE SWITCH |
809 |
| II. THROTTLE PEDAL SENSOR |
810 |
| III. CLUTCH SWITCH |
811 |
| IV. BRAKE SWITCH |
812 |
| V. WHEEL SPEED SENSOR |
813 |
| VI. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
814 |
| VII. START STOP SWITCH |
815 |
| VIII. AC PRESSURE SENSOR |
816 |
| Dual Clutch Transmission (DCT) |
818 |
| TABLE OF CONTENTS |
819 |
| 1. INTRODUCTION |
822 |
| 2. DRIVETRAIN LAYOUT, MOUNTING AND LOCATION |
823 |
| 3. TIGHTENING TORQUE |
824 |
| 4. SPECIAL TOOL |
831 |
| 5. EXPLODED VIEWS OF DCT |
833 |
| 6. GENERAL INTRODUCTION TO DCT |
836 |
| A. TRANSMISSION DIAGRAM AND TERMINOLOGY |
836 |
| B. BASIC PRINCIPLES OF THE DT1 DOUBLE CLUTCH TRANSMISSIONS |
836 |
| I. CLUTCH ACTUATION |
836 |
| II. GEAR ACTUATION |
837 |
| C. KEY COMPONENTS |
838 |
| I. TCU |
838 |
| II. FILTER |
839 |
| III. PUMP |
840 |
| IV. HYDRAULIC CONTROL UNIT |
841 |
| V. POWER SHIFT MODULE |
842 |
| VI. BLDC DRUM MOTOR |
842 |
| VII. GEARTRAIN |
843 |
| VIII. PARK LOCK |
844 |
| 7. SERVICE INFORMATION |
845 |
| A. TOWING OF THE VEHICLE |
845 |
| B. SERVICE INTERVALS |
845 |
| C. OIL SPECIFICATION |
845 |
| D. ENGAGING THE PARK GEAR |
845 |
| E. TRANSMISSION CIRCULAR CONNECTOR LAYOUT |
845 |
| F. TCU INTERFACES |
846 |
| G. CONNECTOR PIN ALLOCATION |
847 |
| H. CLUTCH ADAPTION |
850 |
| I. REQUIRED ACTIVITIES AFTER TCU AND/OR HCU REPLACEMENT |
853 |
| 8. SERVICE ON VEHICLE DCT COMPONENTS REMOVAL PROCEDURE |
855 |
| A. BATTERY REMOVAL |
855 |
| B. BATTERY TRAY REMOVAL |
856 |
| C. TCU REMOVAL |
856 |
| D. THREE SENSOR REMOVAL |
857 |
| E. ANGLE SENSOR REMOVAL |
857 |
| F. BUSH SEAL REPLACEMENT |
858 |
| G. O-RING REPLACEAMENT |
858 |
| H. BLDC MOTOR REMOVAL |
859 |
| I. OIL COOLER REMOVAL |
860 |
| J. DCT WIRING HARNESS REMOVAL |
860 |
| K. OIL DRAINING AND FILLING PROCEDURE |
861 |
| I. OIL DRAIN PROCEDURE |
861 |
| II. INITIAL OIL FILL PROCEDURE NEW TRANSMISSION |
861 |
| III. OIL REPLACEMENT PROCEDURE DURING RECOMMONDED SERVICE INTERVAL |
862 |
| IV. OIL LEVEL CHECK PROCEDURE |
862 |
| L. OIL FILTER REPLACEMENT PROCEDURE |
863 |
| 9. ON VEHICLE DCT UNIT REMOVAL |
865 |
| 10. SERVICE PARTS AND REPLACEMENT INSTRUCTIONS ON BENCH |
872 |
| A. RELATED DOCUMENTS |
872 |
| B. NON SERVICEABLE PARTS |
872 |
| C. DCT UNIT SERVICE INSTRUCTION ON BENCH |
873 |
| I. TCU AND TCU MOUNTING BRACKET REMOVAL |
873 |
| II. ANGLE SENSOR, LOCK BUSH AND DRUM SHAFT SEAL REMOVAL |
875 |
| III. OIL COOLER AND COOLER SEAL REMOVAL |
877 |
| IV. INPUT AND OUTPUT ROTARY SEALS |
879 |
| V. SPEED SENSORS |
880 |
| VI. EXTERNAL CABLE HARNESS REMOVAL |
881 |
| VII. OIL PAN AND HYDRAULIC CONTROL UNIT REMOVAL |
883 |
| VIII. DRUM ACTUATION MOTOR REMOVAL |
886 |
| 11. TROUBLE SHOOTING GUIDE |
888 |
| A. MECHANICAL TROUBLE SHOOTING GUIDE |
888 |
| 12. MONOSTABLE SHIFTER ASSEMBLY FOR AMT AND DCT TRANSMMISION |
889 |
| A. FUNCTIONALITY OF MONOSTABLE SHIFTER |
889 |
| I. PARK |
889 |
| II. REVERSE |
890 |
| III. NEUTRAL |
890 |
| IV. DRIVE |
890 |
| B. EXPLODED VIEW MONOSTABLE SHIFTER |
891 |
| C. MONOSTABLE SHIFTER SHIFT MAPPING |
891 |
| D. GSM WARNING MESSAGES |
892 |
| E. DO’S & DON’TS FOR MSS |
892 |
| F. CONNECTOR DETAILS |
893 |
| G. REMOVAL OF MONOSTABLE SHIFTER |
894 |
| 13. VEHICLE SCHEMATIC FOR DCT |
895 |
| 14. WARNING WRT DCT AND GEAR SHIFTER LEVER |
896 |
| 15. AUTO PARK LOCK FEATURE OF DCT |
898 |
| 16. ROUTINES FOR DCT |
899 |
| DRIVESHAFT DCT |
900 |
| TABLE OF CONTENTS |
901 |
| 1. INTRODUCTION |
902 |
| 2. DRIVESHAFT |
903 |
| 3. DRIVE SHAFT PARTS |
904 |
| 4. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE |
905 |
| 5. TESTING FOR NOISE |
906 |
| 6. TIGHTENING TORQUES |
908 |
| 7. SPECIAL TOOLS |
910 |
| 8. DRIVESHAFT VIEWS |
911 |
| 9. ON VEHICLE REMOVAL OF DRIVE SHAFT (LH & RH SIDE) |
912 |
| 10. ON VEHICLE ASSEMBLY OF DRIVE SHAFT (LH & RH SIDE) |
914 |
| 11. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT |
916 |
| 12. ASSEMBLY PROCEDURE FOR DRIVESHAFT |
918 |
| 13. PRECAUTION TO AVOID THE DAMAGE TO DRIVE SHAFT |
919 |
| 14. DISASSEMBLY PROCEDURE FOR (TRIPOT JOINT) |
920 |
| 15. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER) |
923 |
| 16. DO’S AND DON’T’S FOR DRIVE SHAFT |
927 |
| SUSPENSION_PETROL |
928 |
| TABLE OF CONTENTS |
929 |
| 1. GENERAL INFORMATION |
930 |
| 2. TECHNICAL SPECIFICATIONS |
934 |
| 3. TIGHTENING TORQUES |
935 |
| 4. SPECIAL TOOLS |
940 |
| 5. DIAGNOSIS |
945 |
| 6. PRECAUTIONS |
947 |
| 7. EXPLODED VIEWS FRONT SUSPENSION |
948 |
| 8. EXPLODED VIEWS REAR SUSPENSION |
952 |
| 9. ON VEHICLE PROCEDURE |
956 |
| A. REMOVAL OF FRONT STRUT ASSEMBLY |
956 |
| B. DISASSEMBLY OF FRONT STRUT |
957 |
| C. REMOVAL OF WHEEL HUB |
959 |
| D. REMOVAL OF SUBFRAME ASSEMBLY |
962 |
| E. REMOVAL OF REAR SHOCK ABSORBER AND COIL SPRINGS |
966 |
| F. REMOVAL OF TORSION BEAM |
969 |
| G. SUSPENSION PRE-LOADING CONDITION |
973 |
| SUSPENSION_DIESEL |
974 |
| TABLE OF CONTENTS |
975 |
| 1. GENERAL INFORMATION |
976 |
| 2. TECHNICAL SPECIFICATIONS |
980 |
| 3. TIGHTENING TORQUES |
981 |
| 4. SPECIAL TOOLS |
986 |
| A. FRONT SUSPENSION |
986 |
| B. REAR SUSPENSION |
988 |
| 5. DIAGNOSIS |
989 |
| 6. PRECAUTIONS |
991 |
| 7. EXPLODED VIEWS FRONT SUSPENSION |
992 |
| A. ASSEMBLY FRONT STRUT |
992 |
| B. ANTI ROLL BAR MOUNTING |
993 |
| C. LOWER LINK |
994 |
| D. FRONT AXLE ASSEMBLY |
995 |
| 8. EXPLODED VIEWS REAR SUSPENSION |
996 |
| A. REAR SHOCK ABSORBER AND SPRING |
996 |
| B. REAR HUB ASSEMBLY |
997 |
| C. PIVOT MOUNTING BRACKET AND BUSH |
998 |
| 9. ON VEHICLE PROCEDURE |
999 |
| A. FRONT STRUT ASSEMBLY |
999 |
| B. FRONT STRUT ON BENCH |
1000 |
| C. FRONT WHEEL HUB WITH GEN 3 BEARING ASSY REMOVAL |
1001 |
| D. SUBFRAME ASSEMBLY |
1004 |
| I. REMOVAL OF SUBFRAME ASSEMBLY |
1004 |
| II. REMOVAL OF ANTI ROLL BAR |
1005 |
| III. REMOVAL OF LOWER ARM BALL JOINT |
1006 |
| IV. REMOVAL OF LOWER ARM RUBBER BUSHES |
1007 |
| V. INSTALLATION OF SUBFRAME ASSEMBLY |
1008 |
| E. REAR SHOCK ABSORBER AND COIL SPRINGS |
1009 |
| I. REMOVAL OF REAR SHOCK ABSORBER AND COIL SPRINGS |
1009 |
| II. INSTALLATION OF REAR SHOCK ABSORBER AND COIL SPRINGS |
1010 |
| F. REMOVAL OF REAR GEN 3 BEARING |
1011 |
| G. TORSION BEAM |
1013 |
| 10. SUSPENSION PRE-LOADING CONDITION |
1017 |
| Wheels and Tyres |
1018 |
| TABLE OF CONTENTS |
1019 |
| 1. GENERAL INFORMATION |
1020 |
| A. SPECIFICATIONS |
1020 |
| B. TYRE PRESURE DETAILS |
1020 |
| C. CONSTRUCTION |
1020 |
| 2. TIGHTENING TORQUES |
1025 |
| 3. GENERAL SYMPTOMS DIAGNOSIS |
1026 |
| A. DIAGNOSIS CHART |
1026 |
| B. TYRE WEAR PATTERN |
1028 |
| C. WEAR CAUSES |
1029 |
| D. TYRE VIBRATION DIAGNOSIS |
1030 |
| 4. MAINTENANCE, INSPECTION AND TESTS |
1031 |
| A. PRELIMINARY INSPECTION |
1031 |
| I. VISUAL INSPECTION |
1031 |
| II. PRECAUTIONS |
1031 |
| B. REGULAR MAINTENANCE |
1032 |
| I. INFLATION |
1032 |
| II. WHEEL BALANCING |
1033 |
| III. TYRE ROTATION |
1034 |
| IV. WHEEL RUN OUT |
1034 |
| V. DO’S AND DON’TS |
1035 |
| 5. WHEEL AND TYRE REPLACEMENT |
1036 |
| A. PRECAUTIONS DURING TYRE REPLACEMENT |
1036 |
| B. TYRE REPLACEMENT |
1037 |
| C. DEFECTIVE WHEEL ASSEMBLY REPLACEMENT |
1037 |
| D. ALLOY WHEEL PLASTIC INSERT |
1037 |
| E. WHEEL REMOVAL |
1038 |
| STEERING_MANDO |
1039 |
| TABLE OF CONTENTS |
1040 |
| 1. GENERAL INFORMATION |
1041 |
| A. SPECIFICATIONS |
1041 |
| B. SYSTEM LAYOUT |
1041 |
| C. GENERAL DESCRIPTION |
1042 |
| D. EPAS SYSTEM FLOW DIAGRAM |
1042 |
| E. EPAS SYSTEM BLOCK DIAGRAM |
1042 |
| F. TIGHTENING TORQUES |
1043 |
| G. SPECIAL TOOLS |
1045 |
| 2. MAINTENANCE, INSPECTION AND TEST |
1046 |
| A. PRELIMINARY INSPECTION |
1046 |
| B. REGULAR MAINTENANCE |
1047 |
| C. ON VEHICLE REPAIRS |
1049 |
| I. STEERING WHEEL REMOVAL |
1049 |
| II. STEERING COLUMN REMOVAL |
1050 |
| III. INTERMEADIATE SHAFT REMOVAL |
1054 |
| IV. ECU REMOVAL |
1055 |
| V. MOTOR REMOVAL |
1056 |
| VI. RACK & PINION ASSEMBLY REMOVAL |
1056 |
| 3. OVERHAULING |
1059 |
| A. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
1059 |
| B. PRECAUTIONS |
1060 |
| C. DISMANTLING, INSPECTION & ASSEMBLY |
1060 |
| I. DISASSEMBLY OF RACK & PINON |
1060 |
| II. INSPECTION OF DISMANTLED PARTS |
1061 |
| III. ASSEMBLY OF RACK & PINON |
1061 |
| IV. OBJ ON-VEHICLE REMOVAL |
1063 |
| V. DO’S & DON’TS |
1063 |
| VI. WHEEL ALIGNMENT |
1065 |
| 4. TROUBLESHOOTING AND DIAGNOSIS |
1068 |
| 5. STEERING ANGLE CALIBRATION |
1073 |
| 6. TUNING DATA SELECTION |
1081 |
| 7. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
1082 |
| BRAKE_PETROL |
1086 |
| TABLE OF CONTENTS |
1087 |
| 1. PRECAUTIONS |
1089 |
| 2. TECHNICAL SPECIFICATIONS |
1090 |
| 3. TIGHTENING TORQUES |
1092 |
| 4. DIAGNOSIS |
1093 |
| 5. NESSECITY OF ABS WITH EBD |
1096 |
| 6. BRAKE HYDRAULIC LINES |
1097 |
| 7. VACUUM BRAKE BOOSTER |
1098 |
| 8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) |
1100 |
| 9. ABS COMPONENTS |
1104 |
| A. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) |
1105 |
| B. HYDRAULIC CONTROL UNIT |
1106 |
| C. WHEEL SPEED SENSOR: (MONITORS WHEEL SPEED) |
1107 |
| D. ABS SYSTEM FAILURE WARNING LIGHT |
1108 |
| 10. MAINTENANCE, ADJUSTMENTS & TEST |
1109 |
| A. FRONT BRAKE MAINTENANCE |
1109 |
| B. REAR BRAKE MAINTENANCE |
1111 |
| C. BRAKE TROUBLE SHOOTING |
1116 |
| D. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
1117 |
| 11. BRAKE PEDAL ASSEMBLY REMOVAL |
1120 |
| 12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE |
1122 |
| 13. REPAIRS |
1123 |
| A. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT |
1124 |
| B. REMOVAL OF FRONT BRAKE DISC |
1129 |
| C. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
1130 |
| D. REAR BRAKE ASSEMBLY |
1132 |
| E. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY |
1135 |
| F. REMOVAL OF PARKING BRAKE LEVER |
1141 |
| G. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE |
1142 |
| H. PARKING BRAKE CABLE ADJUSTMENT |
1144 |
| I. REMOVAL AND REFITMENT OF ABS ECU / HCU |
1144 |
| J. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR |
1146 |
| K. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR |
1147 |
| 14. TROUBLE SHOOTING & DIAGNOSIS |
1148 |
| 15. ABS ECU CONNECTOR (K2) |
1150 |
| BRAKE_DIESEL |
1152 |
| TABLE OF CONTENTS |
1153 |
| 1. PRECAUTIONS |
1155 |
| 2. TECHNICAL SPECIFICATIONS |
1156 |
| 3. TIGHTENING TORQUES |
1158 |
| 4. DIAGNOSIS |
1159 |
| 5. NESSECITY OF ABS WITH EBD |
1162 |
| 6. BRAKE HYDRAULIC LINES |
1163 |
| 7. VACUUM BRAKE BOOSTER |
1164 |
| 8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS): |
1166 |
| 9. ABS COMPONENTS |
1170 |
| A. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU): |
1171 |
| B. HYDRAULIC CONTROL UNIT |
1172 |
| C. WHEEL SPEED SENSOR: (MONITORS WHEEL SPEED) |
1173 |
| D. ABS SYSTEM FAILURE WARNING LIGHT |
1174 |
| 10. MAINTENANCE, ADJUSTMENTS & TEST |
1175 |
| A. FRONT BRAKE MAINTENANCE |
1175 |
| B. REAR BRAKE MAINTENANCE |
1177 |
| C. BRAKE TROUBLE SHOOTING |
1182 |
| D. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
1183 |
| 11. BRAKE PEDAL ASSEMBLY REMOVAL |
1186 |
| 12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE |
1188 |
| 13. REPAIRS |
1189 |
| A. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT |
1190 |
| B. REMOVAL OF FRONT BRAKE DISC |
1195 |
| C. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
1196 |
| D. REAR BRAKE ASSEMBLY |
1198 |
| E. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY |
1199 |
| F. REMOVAL OF PARKING BRAKE LEVER |
1206 |
| G. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE |
1207 |
| H. PARKING BRAKE CABLE ADJUSTMENT |
1209 |
| I. REMOVAL AND REFITMENT OF ABS ECU / HCU |
1209 |
| J. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR |
1211 |
| K. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR |
1212 |
| 14. TROUBLE SHOOTING & DIAGNOSIS |
1213 |
| 15. ABS ECU CONNECTOR (K2) |
1215 |
| ELECTRONIC STABILITY CONTROL INTEGRATED PROGRAM (ESCi) |
1217 |
| TABLE OF CONTENTS |
1218 |
| 1. ELECTRONIC STABILITY CONTROL INTEGRATED PROGRAM (ESCI) |
1219 |
| A. GENERAL INFORMATION |
1219 |
| I. NECESSITY OF ESCI AND TCS |
1219 |
| II. SPECIFICATIONS |
1220 |
| III. TIGHTENING TORQUES |
1221 |
| IV. SYSTEM LAYOUT |
1222 |
| B. WORKING OF ESCI |
1223 |
| C. COMPONENTS |
1225 |
| D. ON VEHICLE REPAIRS |
1231 |
| E. TROUBLESHOOTING |
1233 |
| Tire Pressure Monitoring System (TPMS) |
1235 |
| TABLE OF CONTENTS |
1236 |
| 1. GENERAL INFORMATION |
1237 |
| A. INTRODUCTION |
1237 |
| B. SYSTEM WORKING |
1238 |
| C. SYSTEM LAYOUT |
1238 |
| D. COMPONENTS |
1239 |
| I. TPMS ECU |
1239 |
| II. TIRE PRESSURE SENSOR |
1239 |
| E. ON VEHICLE PROCEDURE |
1240 |
| I. TPMS ECU REPLACEMENT PROCEDURE |
1240 |
| II. ECU REPLACEMENT PROCEDURE PREREQUISITE |
1240 |
| III. TPMS ECU LEARNING PROCEDURE |
1243 |
| IV. TPMS SENSOR REPLACEMENT PROCEDURE USING LF TOOL |
1245 |
| F. TIRE REPLACEMENT |
1246 |
| G. MOUNTING OF THE TIRE |
1247 |
| HVAC W/O ETC |
1249 |
| TABLE OF CONTENTS |
1250 |
| 1. TECHNICAL SPECIFICATIONS |
1251 |
| 2. TIGHTENING TORQUES |
1253 |
| 3. PRECAUTIONS |
1255 |
| 4. HVAC SYSTEM LAYOUT AND WORKING |
1257 |
| 5. COMPONENTS OF HVAC |
1260 |
| A. CONTROL PANEL |
1260 |
| B. HVAC UNIT |
1262 |
| C. COMPRESSOR |
1264 |
| D. CONDENSER AND RECEIVER DRIER |
1265 |
| E. ON VEHICLE INSPECTION (WITHOUT DISMANTLING HVAC UNIT) |
1265 |
| F. TRINARY PRESSURE SWITCH / PRESSURE SENSOR |
1266 |
| G. AIR INLET ACTUATOR |
1267 |
| 6. TROUBLESHOOTING |
1268 |
| 7. MAINTENANCE |
1282 |
| A. PRELIMINARY INSPECTION |
1282 |
| B. REGULAR MAINTENANCE |
1284 |
| 8. ON VEHICLE REPAIRS |
1289 |
| A. CONTROL PANEL ASSEMBLY |
1289 |
| B. COMPRESSOR REMOVAL AND ASSEMBLY |
1294 |
| C. BLOWER REMOVAL AND ASSEMBLY |
1294 |
| D. LPM REMOVAL AND ASSEMBLY |
1295 |
| E. AIR FILTER REMOVAL AND ASSEMBLY |
1295 |
| F. TXV |
1298 |
| G. PRESSURE SENSOR |
1299 |
| H. HVAC UNIT |
1299 |
| I. CONDENSER SEALING DUCT |
1300 |
| J. CONDENSER |
1301 |
| 9. REFRIGERANT HOSES/PIPES |
1302 |
| 10. DO’S & DONT’S |
1303 |
| HVAC WITH ETC |
1304 |
| TABLE OF CONTENTS |
1305 |
| 1. GENERAL INFORMATION |
1306 |
| 2. TECHNICAL SPECIFICATIONS |
1308 |
| 3. TIGHTENING TORQUES |
1310 |
| A. FOR PETROL VARIENT |
1310 |
| B. FOR DIESEL VARIENT |
1313 |
| 4. COMPONENTS OF HVAC UNIT |
1316 |
| A. HVAC UNIT |
1316 |
| B. COMPRESSOR |
1318 |
| C. CONDENSER AND RECEIVER DRIER |
1318 |
| D. HVAC WITH ETC CONTROL PANEL |
1319 |
| 5. HMI CLIMATE CONTRL DISPLAY |
1322 |
| 6. CONTROL PANEL DETAILS |
1324 |
| A. CONTROL PANEL CONNECTOR |
1324 |
| B. CONTROL PANEL REMOVAL AND ASSEMBLY |
1326 |
| 7. HVAC SENSOR & ACTUATOR |
1327 |
| A. OAT SENSOR |
1327 |
| B. INCAR SENSOR |
1328 |
| C. ACTUATORS |
1328 |
| D. BLOWER CONTROL MODULE |
1329 |
| 8. BLOWER UNIT REMOVAL AND ASSEMBLY |
1331 |
| 9. REAR DUCT REMOVAL AND ASSEMBLY |
1332 |
| FATC |
1333 |
| TABLE OF CONTENTS |
1334 |
| 1. GENERAL INFORMATION |
1335 |
| 2. TECHNICAL SPECIFICATIONS |
1337 |
| 3. TIGHTENING TORQUES |
1339 |
| A. FOR PETROL VARIENT |
1339 |
| B. FOR DIESEL VARIENT |
1342 |
| 4. COMPONENTS OF FATC UNIT |
1345 |
| A. FATC UNIT |
1345 |
| B. COMPRESSOR |
1347 |
| C. CONDENSER AND RECEIVER DRIER |
1347 |
| D. FATC CONTROL PANEL |
1348 |
| 5. XPRESS COOLING |
1351 |
| 6. HMI CLIMATE CONTRL DISPLAY |
1352 |
| 7. CONTROL PANEL DETAILS |
1354 |
| A. CONTROL PANEL CONNECTOR |
1354 |
| B. CONTROL PANEL REMOVAL AND ASSEMBLY |
1355 |
| 8. FATC SENSOR & ACTUATOR |
1356 |
| A. SOLAR LOAD SENSOR |
1356 |
| B. OAT SENSOR |
1357 |
| C. INCAR SENSOR |
1358 |
| D. EVAPORATOR SENSOR |
1358 |
| E. ACTUATORS |
1358 |
| F. BLOWER CONTROL MODULE |
1360 |
| 9. BLOWER UNIT REMOVAL AND ASSEMBLY |
1361 |
| 10. REAR DUCT REMOVAL AND ASSEMBLY |
1362 |
| BODY |
1363 |
| TABLE OF CONTENTS |
1364 |
| 1. GENERAL LAYOUT |
1366 |
| 2. TIGHTENING TORQUE |
1367 |
| 3. SPECIAL TOOL |
1370 |
| 4. ON VEHICLE PROCEDURES |
1371 |
| A. BONNET REMOVAL |
1371 |
| B. FLOOR CONSOLE REMOVAL |
1372 |
| C. ARM REST REMOVAL |
1375 |
| D. WIRELESS CHARGER MAT CLEANING |
1376 |
| E. DASHBOARD SKIN (TOP PANEL ASSEMBLY INCLUDING DUCT ASSEMBLY, PAB CHUTE, AIR VENT ASSEMBLY ETC.) |
1377 |
| F. GLOVE BOX REMOVAL |
1382 |
| G. SIDE AIR VENTS & CENTER AIR VENT REMOVAL |
1383 |
| H. FRONT BUMPER REMOVAL |
1385 |
| I. REAR BUMPER REMOVAL |
1386 |
| J. FRONT DOOR REMOVAL |
1387 |
| K. FRONT DOOR TRIMS |
1388 |
| L. DOOR INNER LOCK HANDLE REMOVAL |
1389 |
| M. FRONT OUTER DOOR LOCK REMOVAL |
1390 |
| N. FRONT DOOR LATCH REMOVAL |
1391 |
| O. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM REMOVAL |
1392 |
| P. REAR DOOR REMOVAL |
1393 |
| Q. REAR DOOR TRIM REMOVAL |
1394 |
| R. REAR OUTER DOOR LOCK REMOVAL |
1395 |
| S. DOOR LATCH REAR REMOVAL |
1396 |
| T. TAIL GATE REMOVAL |
1397 |
| U. TAIL GATE LATCH CABLE |
1399 |
| V. TAIL GATE TRIM REMOVAL |
1401 |
| W. ORVM REMOVAL |
1401 |
| X. INNER REAR VIEW MIRROR REMOVAL |
1402 |
| Y. FRONT ROW SEAT REMOVAL |
1403 |
| Z. VENTILATED SEAT (IF APPLICABLE) |
1404 |
| AA. FRONT SEAT BELT |
1413 |
| AB. FRONT SEAT BELT BUCKLE REMOVAL |
1415 |
| AC. REAR ROW SEAT REMOVAL |
1415 |
| AD. REAR SEAT BELT REMOVAL |
1417 |
| AE. REAR SEAT BELT BUCKLE REMOVAL |
1418 |
| AF. “A” PILLAR TRIM |
1418 |
| AG. FRONT SCUFF PLATE REMOVAL |
1419 |
| AH. “B” PILLAR TRIMS REMOVAL |
1420 |
| AI. “C” PILLAR TRIMS REMOVAL |
1421 |
| AJ. GRAB HANDLE |
1422 |
| AK. SUNVISOR REMOVAL |
1422 |
| AL. ROOF LINER REMOVAL |
1423 |
| AM. PLENUM COVER REMOVAL |
1423 |
| AN. BONNET INSULATION REMOVAL |
1424 |
| AO. GLASS |
1424 |
| AP. FRONT WHEEL ARCH LINER REMOVAL |
1426 |
| AQ. REAR WHEEL ARCH LINER REMOVAL |
1426 |
| AR. FRONT FENDER REMOVAL |
1427 |
| AS. REAR WIPER MOTOR REMOVAL |
1429 |
| AT. FRONT WIPER REMOVAL |
1430 |
| AU. SUNROOF |
1431 |
| I. SUNROOF DO’S AND DON’TS |
1431 |
| II. EXPLODED VIEW |
1432 |
| III. SUNROOF REMOVAL |
1434 |
| IV. SUNROOF FITMENT |
1436 |
| ELECLTRICAL |
1449 |
| TABLE OF CONTENTS |
1450 |
| 1. BATTERY |
1456 |
| 2. ALTERNATOR |
1459 |
| 3. STARTER MOTOR |
1462 |
| 4. LIGHTING SYSTEM |
1469 |
| A. BULB SPECIFICATIONS |
1469 |
| B. FASTENERS TORQUE VALUE TABLE |
1470 |
| C. GENERAL SYMPTOMS AND DIAGNOSTICS |
1471 |
| D. HEAD LAMP |
1474 |
| E. DRL LAMP |
1479 |
| F. TAIL LAMP |
1480 |
| G. ROOF LAMP |
1483 |
| H. GLOVE BOX LAMP |
1484 |
| I. FRONT FOG LAMP |
1484 |
| J. REGISTRATION PLATE LAMP |
1485 |
| K. LOAD AREA LAMP |
1485 |
| 5. HORN |
1486 |
| 6. WIPER & WASHER SYSTEM |
1488 |
| A. FRONT WIPER AND WAHSER SYSTEM LAYOUT |
1488 |
| B. REAR WIPER AND WAHSER SYSTEM LAYOUT (IF APPLICABLE) |
1489 |
| C. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
1490 |
| D. WIPER AND WIPER CARE |
1491 |
| 7. POWER SOCKETS |
1493 |
| 8. SWITCHES |
1495 |
| A. COMBI SWITCH |
1495 |
| B. FASCIA SWITCHES (IF APPLICABLE) |
1501 |
| C. ENGINE START STOP OFF SWITCH |
1503 |
| D. STEERING CUM IGNITION SWITCH |
1505 |
| E. PEDDAL SHIFTER SWITCH |
1507 |
| F. MIRROR SWITCH |
1509 |
| G. WINDOW WINDING MODULE |
1512 |
| H. POWER WINDOW SWITCHES & INHIBIT SWITCH |
1514 |
| I. STEERING WHEEL SWITCH |
1518 |
| J. DOOR HANDLE SWITCH |
1521 |
| K. TAILGATE HANDLE SWITCH |
1522 |
| L. I-CALL & B-CALL SWITCH |
1523 |
| M. SUNROOF SWITCH |
1525 |
| N. PAB SWITCH |
1526 |
| O. DRIVE MODE SWITCH |
1528 |
| P. MONOSTABLE SWITCH |
1529 |
| 9. INFOTAINMENT SYSTEM 7” |
1530 |
| A. SILVER BOX (7 INCH) |
1532 |
| B. SPEAKERS |
1534 |
| C. ANTENNA (IF APPLICABLE) |
1535 |
| D. MICROPHONE |
1536 |
| E. TWEETERS |
1537 |
| 10. INFOTAINMENT SYSTEM 7” |
1539 |
| A. SILVER BOX (7 INCH) |
1541 |
| B. SPEAKERS |
1543 |
| C. ANTENNA (IF APPLICABLE) |
1544 |
| D. MICROPHONE |
1545 |
| E. TWEETERS |
1546 |
| 11. INFOTAINMENT SYSTEM 10.25” |
1548 |
| A. INFOTAINMENT DISPLAY |
1548 |
| B. SPEAKERS |
1549 |
| C. ANTENNA (AM+FM+GPS) (IF APPLICABLE) |
1551 |
| D. MICROPHONE |
1552 |
| E. TWEETERS |
1553 |
| F. SILVER BOX (IF APPLICABLE) |
1555 |
| 12. INSTRUMENT CLUSTER 4” GEN 2 |
1559 |
| A. INSTRUMENT CLUSTER ARTWORK |
1559 |
| B. INSTRUMENT CLUSTER FEATURES |
1560 |
| I. SPEEDOMETER DISPLAY |
1560 |
| II. TACHOMETER GAUGE |
1560 |
| III. PETROL FUEL GAUGE |
1561 |
| IV. TEMPERATURE GAUGE |
1562 |
| V. DRIVER INFORMATION SYSTEM |
1563 |
| VI. REMINDER FEATURES |
1572 |
| C. TELL TALES INFORMATION |
1574 |
| D. DIS SCREEN FLOW FOR HIGH END INSTRUMENT CLUSTER |
1579 |
| I. DIS SCREEN FLOW |
1579 |
| II. DIS SETTINGS FOR DOMESTIC VARIANT (Illumination and Clock) |
1579 |
| E. CONNECTOR DETAILS |
1580 |
| F. REMOVAL OF INSTRUMENT CLUSTER |
1581 |
| 13. INSTRUMENT CLUSTER 4” GEN 3 |
1582 |
| A. INSTRUMENT CLUSTER ARTWORK |
1582 |
| B. INSTRUMENT CLUSTER FEATURES |
1583 |
| I. SPEEDOMETER DISPLAY |
1583 |
| II. TACHOMETER GAUGE |
1583 |
| III. PETROL FUEL GAUGE |
1584 |
| IV. TEMPERATURE GAUGE |
1585 |
| V. DRIVER INFORMATION SYSTEM |
1586 |
| VI. REMINDER FEATURES |
1598 |
| C. TELL TALES INFORMATION |
1600 |
| D. DIS SCREEN FLOW FOR HIGH END INSTRUMENT CLUSTER |
1606 |
| I. DIS SCREEN FLOW |
1606 |
| II. DIS SETTINGS FOR DOMESTIC VARIANT (Illumination) |
1606 |
| III. DIS SETTINGS FOR DOMESTIC VARIANT (CLOCK) |
1607 |
| E. CONNECTOR DETAILS |
1607 |
| F. REMOVAL OF INSTRUMENT CLUSTER |
1608 |
| 14. INSTRUMENT CLUSTER 7” GEN 3 |
1610 |
| A. INSTRUMENT CLUSTER ARTWORK |
1610 |
| B. INSTRUMENT CLUSTER FEATURE MAPPING |
1610 |
| C. INSTRUMENT CLUSTER FEATURES |
1611 |
| I. SPEEDOMETER GAUGE |
1611 |
| II. DIGITAL TACHOMETER GAUGE |
1611 |
| III. FUEL GAUGE |
1612 |
| IV. TEMPERATURE GAUGE |
1613 |
| V. DRIVER INFORMATION SYSTEM |
1615 |
| VI. TELL TALES INFORMATION |
1630 |
| VII. REMINDER FEATURES (AUDIBLE) |
1637 |
| D. CONNECTOR DETAILS |
1638 |
| E. REMOVAL OF INSTRUMENT CLUSTER |
1639 |
| 15. INSTRUMENT CLUSTER 10” |
1640 |
| A. INSTRUMENT CLUSTER ARTWORK |
1640 |
| B. INSTRUMENT CLUSTER FEATURE MAPPING |
1640 |
| C. INSTRUMENT CLUSTER FEATURES |
1642 |
| I. SPEEDOMETER GAUGE |
1642 |
| II. DIGITAL TACHOMETER GAUGE |
1642 |
| III. FUEL GAUGE |
1643 |
| IV. TEMPERATURE GAUGE |
1644 |
| V. DRIVER INFORMATION SYSTEM |
1645 |
| VI. TELL TALES INFORMATION |
1659 |
| D. CONNECTOR DETAILS |
1664 |
| E. REMOVAL OF INSTRUMENT CLUSTER |
1664 |
| 16. IGNITION KEY (IF APPLICABLE) |
1666 |
| 17. IMMOBILIZER SYSTEM (IF APPLICABLE) |
1673 |
| A. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
1676 |
| B. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
1677 |
| C. IGNITION KEY LEARNING PROCEDURE |
1680 |
| 18. BODY CONTROL MODULE (BCM) |
1682 |
| A. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
1688 |
| B. BCM FUNCTIONS |
1696 |
| 19. FUSE AND RELAY BOX DETAILS |
1697 |
| A. BATTERY MOUNTED FUSE BOX (BDU) |
1699 |
| B. ENGINE COMPARTMENT FUSE AND RELAY BOX (Petrol) |
1699 |
| C. ENGINE COMPARTMENT FUSE AND RELAY BOX (Diesel) |
1703 |
| D. CABIN FUSE AND RELAY BOX |
1705 |
| 20. FRONT AND REAR REVERSE PARK ASSIST SYSTEM (IF APPLICABLE) |
1707 |
| A. FRONT AND REVERSE PARK ASSIST SYSTEM DETAILS |
1707 |
| B. ECU TO SENSOR ELECTRICAL INTERFACE |
1711 |
| C. REVERSE PARK ASSIST WITH CAMERA (IF EQUIPPED) |
1718 |
| D. REAR VIEW CAMERA (VGA) (IF EQUIPPED) |
1719 |
| E. REAR VIEW CAMERA (HD) (IF EQUIPPED) |
1723 |
| F. TROUBLESHOOTING |
1727 |
| 21. RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE) |
1729 |
| A. RAIN LIGHT SENSOR |
1729 |
| B. FUNCTIONAL DETAILS |
1733 |
| C. FAIL SAFE MODES OF RLS & BCM AUTO LIGHT |
1735 |
| 22. PASSIVE ENTRY PASSIVE START (PEPS) |
1736 |
| A. PEPS ECU |
1736 |
| B. START STOP SWITCH |
1738 |
| C. ELECTRONIC STEERING COLUMN LOCK(ESCL) |
1739 |
| D. DOOR HANDLE SWITCHES WITH HARNESS |
1741 |
| E. LF ANTENNAS |
1741 |
| 23. RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE) |
1744 |
| A. RAIN LIGHT SENSOR |
1744 |
| B. FUNCTIONAL DETAILS |
1748 |
| C. FAIL SAFE MODES OF RLS & BCM AUTO LIGHT |
1750 |
| 24. ELECTRIC CHROMIC MIRROR (EC-IRVM) (IF EQUIPPED) |
1751 |
| 25. WIRELESS CHARGING (IF APPLICABLE) |
1753 |
| A. WIRELESS CHARGING COMPONENTS |
1753 |
| B. INTERFACE DIAGRAM |
1754 |
| C. CHARGING FUNCTION |
1754 |
| D. CHARGING STATUS DISPLAY FUNCTION |
1754 |
| E. CONDITIONS TO CHARGE PHONE PROPERLY |
1754 |
| F. CONNECTOR PIN & DETAILS |
1755 |
| G. WPC EPC TROUBLE SHOOTING PROCEDURE |
1755 |
| H. DO’S AND DON’T |
1758 |
| I. WPC ECU REPLACEMENT PROCEDURE |
1759 |
| 26. TELEMATICS |
1764 |
| A. TATA MOTORS CONNECTED CAR SYSTEM |
1764 |
| B. THE CONNECTED CAR MODULE RECORDS THE FOLLOWING INFORMATION |
1764 |
| C. TCM LOCATION |
1764 |
| D. PRE-CHECKS FOR INSTALLATION OF THE TELEMATICS CONTROL MODULE |
1764 |
| E. PRE-CHECKS / TASKS TO BE DONE BEFORE REPLACING THE TELEMATICS CONTROL MODULE |
1764 |
| F. I/P - O/P BLOCK DIAGRAMS |
1765 |
| G. LED INDICATION ON TCM |
1766 |
| H. CONNECTOR PIN & USB DETAILS |
1767 |
| I. TCM REMOVAL PROCEDURE |
1768 |
| 27. SURROUND VIEW SYSTEM (SVS) (IF EQUIPPED) |
1769 |
| A. SURROUND VIEW SYSTEM DETAILS |
1769 |
| I. SVS FUNCTION WORKING PROCEDURE |
1769 |
| II. CAMERA LOCATION |
1769 |
| III. ACTIVATION OF SVS |
1770 |
| IV. DEACTIVATION OF SVS |
1770 |
| V. SURROUND VIEW SYSTEM FEATURES |
1771 |
| VI. 2D VIEW |
1771 |
| VII. 3D VIEW |
1773 |
| VIII. FRONT CORNER VIEW |
1773 |
| IX. REAR CORNER VIEW |
1774 |
| X. FULL VIEW |
1774 |
| XI. SETTINGS |
1776 |
| XII. CANCEL ICON |
1778 |
| XIII. UNDERSTANDING GUIDELINES INDICATION |
1779 |
| XIV. PDC GUIDELINES SETTINGS |
1781 |
| XV. BLIND VIEW MONITOR |
1782 |
| XVI. ACTIVATION OF BLIND VIEW MONITOR |
1783 |
| XVII. DEACTIVATION OF BLIND VIEW MONITOR |
1784 |
| XVIII. UNDERSTANDING STATIC OVERLAYS INDICATION |
1784 |
| XIX. DO’S AND DON’TS |
1784 |
| XX. CLEANING CAMERA |
1784 |
| XXI. WARNING |
1785 |
| B. SVS INPUT OUTPUT BLOCK DIAGRAM |
1786 |
| C. SURROUND VIEW SYSTEM COMPONENTS REMOVAL |
1787 |
| I. FRONT BUMPER CAMERA |
1787 |
| II. TAILGATE CAMERA |
1788 |
| III. ORVM LH/RH CAMERA |
1789 |
| IV.ORVM CAMERA SERVICE SOP AND CARE |
1790 |
| D. TROUBLESHOOTING CHART |
1792 |
| E. TROUBLESHOOTING CHART |
1794 |
| F. CAMERAS CALIBRATION |
1795 |
| G. DO’S AND DON’TS WHILE PERFORMING CALIBRATION |
1796 |
| SRS |
1797 |
| TABLE OF CONTENTS |
1798 |
| 1. WORKING OF RESTRAINTS |
1799 |
| 2. SYSTEM LAYOUT |
1801 |
| 3. SAFETY PRECAUTIONS |
1803 |
| 4. DISPOSAL OF FAULTY AIR BAG UNIT |
1806 |
| 5. SRS POST ACCIDENT PROCEDURE |
1808 |
| 6. TIGHTENING TORQUES |
1809 |
| 7. COMPONENTS |
1813 |
| A. RESTRAINT WITHOUT AIRBAGS |
1813 |
| B. RESTRAINT WITH AIRBAGS |
1813 |
| I. ECU |
1813 |
| II. SENSORS |
1817 |
| III. AIR BAGS |
1819 |
| IV. RPLL BELTS |
1824 |
| V. CLOCK SPRING |
1828 |
| VI. PAB DEACTIVATION SWITCH |
1831 |
| VII. PAB INDICATOR |
1833 |