1 857

PUNCH.EV SERVICE MANUAL

PUNCH.EV SERVICE MANUAL 1
HIGH VOLTAGE ELECTRICALSYSTEM (HV) 5
TABLE OF CONTENTS 6
1. GENERAL INFORMATION 9
A. TOOLS 9
I. INSULATED TOOLS 9
II. GENERAL TOOLS 9
B. HAND GLOVES 10
C. PPES FOR HV 11
D. MEASURING TOOLS 15
E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM 16
F. DO’S AND DON’TS 17
G. SAFETY WHILE SERVICING 20
H. WASHING INSTRUCTIONS 24
I. ELECTRICAL COMPONENT INFORMATION 25
J. MOTOR COMPARTMENT 34
2. TYPES OF CHARGING 35
A. NORMAL / AC CHARGING 37
B. AC CHARGING (WALL MOUNT UNIT) 44
C. FAST CHARGING 46
3. TIGHTENING TORQUES 49
4. SPECIAL TOOL LIST 59
5. HV CONNECTOR CONNECTION AND LOCKING PROCESS 62
A. 3IN1 COMBO BOX TO MCU 62
B. 3IN1 COMBO BOX TO HV BATTERY 62
C. 3IN1 TO CCS PORT 63
D. 3IN1 TO E-COMPRESSOR 64
E. 3IN1 TO AC INPUT 65
F. 3IN1 TO PTC 65
G. 3IN1 COMBO BOX TO SIGNAL 66
6. HV COMPONENT IN UNDER BONNET COMPARTMENT 67
A. 3IN1 UNIT ASSY REMOVAL 67
B. 3 IN 1 SERVICEABILITY 69
C. VEHICLE CONTROL UNIT REMOVAL 71
D. VACCUM PUMP REMOVAL 72
E. E-DRIVE REMOVAL 73
F. CHARGING PORT HOUSING 77
G. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS 79
I. OIL LEVEL CHECK 79
II. DISCHARGE AND FILLING OF LUBRICATING OIL 79
7. TRACTION COOLING SYSTEM (TCS) 80
A. SYSTEM LAYOUT 80
B. CIRCUIT SCHEMATIC 80
C. TCS COOLANT DRAINING PROCEDURE 81
D. TCS COOLANT FILLING PROCEDURE 81
E. TCS COOLING PUMP REMOVAL 82
F. RADIATOR / RADIATOR FAN REMOVAL 83
G. CONDENSER REMOVAL 84
H. TCS AUX TANK RESERVIOR REMOVAL 86
8. HV BATTERY 87
A. SYSTEM LAYOUT 87
B. BATTERY PACK STORAGE GUIDELINES 88
C. HV BATTERY REMOVAL 88
D. REPLACMENT OF CONTACTORS 90
E. REPLACMENT OF FUSE 92
F. REPLACMENT OF PYRO SWITCH 94
G. REPLACMENT OF SMOKE SENSOR 96
H. REPLACMENT OF PRECHARGE 97
I. REPLACMENT OF CURRENT SENSOR 99
J. REPLACMENT OF HV CONNECTOR 100
K. REPLACMENT OF MODULE TO SLAVE HARNESS 101
L. REPLACMENT OF LV HARNESS 103
9. BATTERY COOLING SYSTEM (BCS) 107
A. SYSTEM LAYOUT 107
B. CIRCUIT SCHEMATIC 107
C. BCS COOLANT DRAINING PROCEDURE 108
D. BCS COOLANT FILLING PROCEDURE 108
E. COMPRESSOR 109
F. BATTERY COOLING PUMP REMOVAL 111
G. BCS COOLANT TANK REMOVAL 112
H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL 113
I. HV / LV CHARGER PORT & CABLE REMOVAL 114
10. CRADLE 116
A. CRADLE EXPLODED VIEW - LR 116
B. CRADLE REMOVAL - LR 118
C. CRADLE EXPLODED VIEW - MR 120
D. CRADLE REMOVAL - MR 122
LOW VOLTAGE ELECTRICALSYSTEM (LV) 124
TABLE OF CONTENTS 125
1. GENERAL PRECAUTIONS 129
2. BATTERY 133
3. LIGHTING SYSTEM 136
A. BULB & LED SPECIFICATION 136
B. FASTENERS TORQUE VALUE TABLE 137
C. GENERAL SYMPTOMS AND DIAGNOSTICS 138
D. HEAD LAMP 141
E. ROOF LAMP 148
F. HIGH MOUNTED STOP LAMP 149
G. TAIL LAMP 150
H. REAR FOG LAMP WITH REVERSE LAMP (IF APPLICABLE) 152
I. FRONT FOG LAMP 153
J. REGISTRATION PLATE LAMP 154
K. DRL LAMP 155
4. WIPER & WASHER SYSTEM 157
A. FRONT WIPER AND WASHER SYSTEM LAYOUT 157
B. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY 158
I. FRONT AND REAR WIPER SYSTEM 160
II. MOTOR SPECIFICATION 161
III. CIRCUIT DIAGRAM OF WIPER MOTOR 161
C. WIPER AND WIPER CARE 162
D. DIAGNOSTIC INFORMATION AND PROCEDURES 164
5. SWITCHES 165
A. COMBI-SWITCH (IF APPLICABLE) 165
B. FASCIA SWITCHES (IF APPLICABLE) 173
C. MIRROR SWITCH (IF APPLICABLE) 176
D. WINDOW WINDING MODULE 178
E. POWER WINDOW SWITCHES & INHIBIT SWITCH 179
F. STEERING WHEEL SWITCHES WITH PADDLE SHIFTER 182
G. DRIVE MODE KNOB 188
H. STEERING CUM IGNITION SWITCH (IF APPLICABLE) 192
I. PASSENGER AIRBAG (PAB) SWITCH 194
J. PASSENGER AIRBAG (PAB) INDICATOR SWITCH 195
K. E-CALL AND I-CALL SWITCH 197
L. SUNROOF SWITCH 199
6. HORN 201
7. POWER SOCKETS 203
8. INFOTAINMENT SYSTEM 204
A. USB/AUX PORT 207
B. SPEAKERS 209
C. TWEETER 210
D. ANTENNA 212
E. MICROPHONE 213
9. INSTRUMENT CLUSTER 4” DISPLAY 214
A. BASIC FUNCTIONAL MATRIX 216
B. INSTRUMENT CLUSTER 218
C. TELL TALES DETAILS 220
D. DRIVER INFORMATION SYSTEM 224
E. REMINDER FEATURES 233
F. WARNING ON TFT SCREEN 235
G. TEXT MESSAGE 239
H. FAULT LEVEL INDICATIONS ON INSTRUMENT CLUSTER 240
I. MAIN CONNECTOR PIN OUTS 242
J. TEMPERATURE BAR GRAPH DETAILS 243
K. CHIME TABLE 244
L. DISPLAY SCREEN FLOW AND SETTINGS 245
M. REMOVALOF INSTRUMENT CLUSTER 246
10. INSTRUMENT CLUSTER 7” DISPLAY 247
A. INSTRUMENT CLUSTER FEATURE MAPPING 248
B. TELL TALES INFORMATION 251
C. REMINDER FEATURES (AUDIO ALERTS) 256
D. TEXT MESSAGE 258
E. FAULT LEVEL INDICATIONS ON INSTRUMENT CLUSTER 259
F. CHIMES 261
G. WARNING ON TFT SCREEN 261
H. CONNECTOR DETAILS 266
I. REMOVAL OF INSTRUMENT CLUSTER 268
11. INSTRUMENT CLUSTER 10” DISPLAY 269
A. INSTRUMENT CLUSTER FEATURE MAPPING 270
B. TELL TALES INFORMATION 273
C. REMINDER FEATURES (AUDIO ALERTS) 278
D. TEXT MESSAGE 280
E. FAULT LEVEL INDICATIONS ON INSTRUMENT CLUSTER 281
F. CHIMES 283
G. WARNING ON TFT SCREEN 283
H. CONNECTOR DETAILS 288
I. REMOVAL OF INSTRUMENT CLUSTER 290
12. IMMOBILIZER 291
13. IGNITION KEY 296
A. IGNITION REMOTE KEY (IF APPLICABLE) 296
B. SMART KEY (IF APPLICABLE) 299
14. BODY CONTROL MODULE (BCM) 306
A. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 312
B. BCM FEATURES 319
C. BCM REPLACEMENT STRATEGY 320
D. BCM FUNCTIONS 321
15. FUSE AND RELAY BOX DETAILS 323
A. FUSE AND RELAY BOX LAYOUT 325
B. UNDER BONNET FUSE AND RELAY BOX 325
C. CABIN FUSE AND RELAY BOX 329
D. FUSE AND RELAY REPLACEMENT 331
16. REVERSE PARK ASSIST SYSTEM 332
A. SENSORS 336
B. REVERSE PARK ASSIST WITH CAMERA (IF APPLICABLE) 341
C. REAR VIEW CAMERA (IF APPLICABLE) 342
D. TROUBLESHOOTING 345
17. PASSIVE ENTRY PASSIVE START (PEPS) 346
A. PEPS ECU 347
B. START STOP SWITCH (IF APPLICABLE) 349
C. ELECTRONIC STEERING COLUMN LOCK (ESCL) 350
D. LF ANTENNAS 352
18. TELEMATICS (IF APPLICABLE) 354
A. TATA MOTORS CONNECTED CAR SYSTEM 354
B. THE CONNECTED CAR MODULE RECORDS THE FOLLOWING INFORMATION 354
C. TCM LOCATION 354
D. PRE-CHECKS FOR INSTALLATION OF THE TELEMATICS CONTROL MODULE 354
E. PRE-CHECKS / TASKS TO BE DONE BEFORE REPLACING THE TELEMATICS CONTROLMODULE 354
F. TCM REMOVAL PROCEDURE 355
G. CONNECTOR PIN & USB DETAILS 356
19. WIRELESS CHARGING (IF APPLICABLE) 357
20. SURROUND VIEW SYSTEM (IF APPLICABLE) 367
DRIVESHAFT 392
TABLE OF CONTENTS 393
1. INTRODUCTION 394
2. DRIVE SHAFT PARTS 395
3. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 396
4. TESTING FOR NOISE 397
5. TIGHTENING TORQUES 398
6. SPECIAL TOOLS 399
7. ON VEHICLE REMOVAL OF DRIVE SHAFT (LH & RH SIDE) 400
8. ON VEHICLE ASSEMBLY OF DRIVE SHAFT (LH & RH SIDE) 402
9. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT 404
10. ASSEMBLY PROCEDURE FOR DRIVESHAFT 406
11. PRECAUTION TO AVOID THE DAMAGE TO DRIVE SHAFT 407
12. DO’S AND DON’T’S FOR DRIVE SHAFT 408
SUSPENSION (LR) 409
TABLE OF CONTENTS 410
1. GENERAL INFORMATION 412
A. FRONT SUSPENSION 412
B. REAR SUSPENSION 413
C. SHOCK ABSORBER 415
2. TECHNICAL SPECIFICATIONS 416
3. TIGHTENING TORQUES 417
4. SPECIAL TOOLS 422
5. DIAGNOSIS 427
6. PRECAUTIONS 429
7. EXPLODED VIEWS FRONT SUSPENSION 430
A. FRONT STRUT ASSEMBLY 430
B. ANTI ROLL BAR MOUNTING EXPLODED VIEW 431
C. LOWER LINK EXPLODED VIEW 432
D. FRONT AXLE ASSEMBLY 433
8. EXPLODED VIEWS OF REAR SUSPENSION 434
A. REAR SHOCK ABSORBER AND SPRING 434
B. REAR HUB ASSEMBLY 435
C. REAR TWIST BEAM AND PIVOT BUSH 436
9. ON VEHICLE AND ON BENCH REMOVAL AND ASSEMBLY PROCEDURE 437
A. FRONT STRUT REMOVAL 437
B. OVERHAULING OF FRONT STRUT 438
C. WHEEL HUB REMOVAL 439
D. OVERHAULING OF KNUCKLE AND WHEEL HUB SUB ASSEMBLY 441
E. SUBFRAME ASSEMBLY REMOVAL & ASSEMBLY 442
F. ANTI ROLL BAR REMOVAL & ASSEMBLY 444
G. LOWER ARM BALL JOINT REMOVAL & ASSEMBLY 445
H. OVERHAULING OF LOWER ARM PIVOT BUSH 446
I. LOWER ARM FRONT PIVOT BUSH 446
II. LOWER ARM REAR PIVOT BUSH 446
I. SUBFRAME ASSEMBLY 447
J. REAR SHOCK ABSORBER AND COIL SPRING REMOVAL & ASSEMBLY 448
K. OVERHAULINGOF REAR SHOCK ABSORBER 450
L. REAR SHOCK ABSORBER AND COIL SPRING ASSEMBLY 450
M. TORSION BEAM REMOVAL 451
10. SUSPENSION ECIE / PRE-LOADING CONDITION 456
SUSPENSION (MR) 458
TABLE OF CONTENTS 459
1. GENERAL INFORMATION 461
A. FRONT SUSPENSION 461
B. REAR SUSPENSION 462
C. SHOCK ABSORBER 464
2. TECHNICAL SPECIFICATIONS 465
3. TIGHTENING TORQUES 466
4. SPECIAL TOOLS 471
5. DIAGNOSIS 477
6. PRECAUTIONS 479
7. EXPLODED VIEWS FRONT SUSPENSION 480
A. FRONT STRUT ASSEMBLY 480
B. ANTI ROLL BAR MOUNTING EXPLODED VIEW 481
C. LOWER LINK EXPLODED VIEW 482
D. FRONT AXLE ASSEMBLY 483
8. EXPLODED VIEWS OF REAR SUSPENSION 484
A. REAR SHOCK ABSORBER AND SPRING 484
B. REAR HUB ASSEMBLY 485
C. REAR TWIST BEAM AND PIVOT BUSH 486
9. ON VEHICLE AND ON BENCH REMOVAL AND ASSEMBLY PROCEDURE 487
A. FRONT STRUT REMOVAL 487
B. OVERHAULING OF FRONT STRUT 488
C. WHEEL HUB REMOVAL 490
D. OVERHAULING OF KNUCKLE AND WHEEL HUB SUB ASSEMBLY 492
E. SUBFRAME ASSEMBLY REMOVAL & ASSEMBLY 493
F. ANTI ROLL BAR REMOVAL & ASSEMBLY 495
G. LOWER ARM BALL JOINT REMOVAL & ASSEMBLY 495
H. OVERHAULING OF LOWER ARM PIVOT BUSH 496
I. LOWER ARM FRONT PIVOT BUSH 496
II. LOWER ARM REAR PIVOT BUSH 497
I. SUBFRAME ASSEMBLY 497
J. REAR SHOCK ABSORBER AND COIL SPRING REMOVAL & ASSEMBLY 499
K. OVERHAULINGOF REAR SHOCK ABSORBER 501
L. REAR SHOCK ABSORBER AND COIL SPRING ASSEMBLY 501
M. TORSION BEAM REMOVAL 502
10. SUSPENSION ECIE / PRE-LOADING CONDITION 507
WHEELS AND TYRES 509
TABLE OF CONTENTS 510
1. GENERAL INFORMATION 511
A. SPECIFICATIONS 511
B. TYRE PRESSURE DETAILS 511
C. CONSTRUCTION 513
D. TIGHTENING TORQUES 518
2. GENERAL SYMPTOMS DIAGNOSIS 519
A. DIAGNOSIS CHART 519
B. TYRE WEAR PATTERN 521
C. WEAR CAUSES 522
D. TYRE VIBRATION DIAGNOSIS 523
3. MAINTENANCE, INSPECTION AND TESTS 524
A. PRELIMINARY INSPECTION 524
I. VISUAL INSPECTION 524
II. PRECAUTIONS 524
B. REGULAR MAINTENANCE 524
I. INFLATION 524
II. WHEEL BALANCING 525
III. TYRE ROTATION 526
IV. WHEEL RUNOUT 527
V. DO’S AND DON’TS 527
4. WHEEL AND TYRE REPLACEMENT 528
A. PRECAUTIONS DURING TYRE REPLACEMENT 528
B. TYRE REPLACEMENT 528
C. WHEEL ASSEMBLY REPLACEMENT 529
D. WHEEL REMOVAL 530
E. TYRE CARE 532
STEERING 533
TABLE OF CONTENTS 534
1. GENERAL INFORMATION 536
A. TECHNICAL SPECIFICATION 536
B. INTRODUCTION 536
C. SYSTEM LAYOUT 538
2. TIGHTENING TORQUES 539
3. SPECIAL TOOLS 542
4. MAINTENANCE, INSPECTION AND TEST 543
A. PRELIMINARY INSPECTION 543
B. REGULAR MAINTENANCE 544
5. ON VEHICLE REPAIRS 547
A. STEERING WHEEL REMOVAL 547
B. STEERING COLUMN REMOVAL 548
C. INTERMEDIATE SHAFT REMOVAL 551
D. ECU REMOVAL 551
E. MOTOR REMOVAL 552
F. RACK & PINION ASSEMBLY REMOVAL 553
6. STEERING RACK AND PINION ASSEMBLY EXPLODED VIEW 555
7. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY 557
A. PRECAUTIONS 557
B. DISASSEMBLY OF RACK & PINON 557
C. INSPECTION OF DISMANTLED PARTS 558
D. ASSEMBLY OF RACK & PINON 558
E. OBJ ON-VEHICLE REMOVAL 559
F. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE 560
8. DO’S & DON’TS 561
9. WHEEL ALIGNMENT 564
10. TROUBLESHOOTING AND DIAGNOSIS 566
11. STEERING ANGLE CALIBRATION PROCESS 572
12. TUNING DATA SELECTION 579
13. ELECTRIC POWER ASSISTED STEERING (EPAS) ECU REPLACEMENT AND SOFTWAREUPDATE PROCEDURE IN FIELD 580
A. EPAS ECU REPLACEMENT – AUTOMATIC (IF FITTED) 581
B. EPAS ECU FIELD SOFTWARE UPGRADE/RE FLASH – MANUAL 582
C. EPAS ECU FIELD SOFTWARE UPGRADE/RE FLASH – AUTOMATIC (IF FITTED) 583
BRAKE (LR) 584
TABLE OF CONTENTS 585
1. TECHNICAL SPECIFICATIONS 587
2. SYSTEM COMPONENTS 588
3. I/O DIAGRAM OF BRAKE SYSTEM 589
4. TIGHTENING TORQUES 590
5. PRECAUTIONS 593
6. DIAGNOSIS 594
7. NESSECITY OF ABS WITH EBD 597
8. BRAKE HYDRAULIC LINES 598
9. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 599
A. BRAKING WITHOUT ABS IN OPERATION 599
B. BRAKING WITH EBD INTO OPERATION 599
C. BRAKING WITH ABS INTO OPERATION 599
D. FAIL-SAFE FUNCTION 600
10. MAINTENANCE, ADJUSTMENTS & TEST 601
A. FRONT BRAKE MAINTENANCE 601
B. REAR BRAKE MAINTENANCE 602
C. INSPECTION OF CALIPER 604
D. BLEEDING PROCEDURE 606
E. FRONT BRAKE MAINTENANCE 609
11. BRAKE PEDAL ASSEMBLY REMOVAL 610
12. REGENERATION SENSOR REMOVAL 612
13. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 613
14. EXPLODED VIEWS 614
A. TMC ASSEMBLY 614
B. FRONT CALIPER BRAKE ASSEMBLY 615
C. REAR CALIPER BRAKE ASSEMBLY 616
15. ON VEHICLE REMOVAL 618
A. BRAKE REMOVAL AND REFITMENT 618
B. FRONT BRAKE DISC REMOVAL 623
C. FRONT WHEEL SPEED SENSOR REMOVAL 624
D. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY 625
E. REAR BRAKE DISC REMOVAL 627
F. EPB MOTOR REMOVAL 629
G. REAR WHEEL SPEED SENSOR REMOVAL 630
16. TROUBLE SHOOTING & DIAGNOSIS 632
BRAKE (MR) 634
TABLE OF CONTENTS 635
1. TECHNICAL SPECIFICATIONS 637
2. TIGHTENING TORQUES 639
3. SPECIAL TOOL 643
4. PRECAUTIONS 644
5. DIAGNOSIS 645
6. NESSECITY OF ABS WITH EBD 648
7. BRAKE HYDRAULIC LINES 649
8. VACUUM BRAKE BOOSTER 650
9. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 652
A. BRAKING WITHOUT ABS IN OPERATION 652
B. BRAKING WITH EBD INTO OPERATION 652
C. BRAKING WITH ABS INTO OPERATION 653
D. FAIL-SAFE FUNCTION 654
10. ABS COMPONENTS 655
A. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU) 655
B. WHEEL SPEED SENSOR 657
C. ABS SYSTEM FAILURE WARNING LIGHT 657
11. MAINTENANCE, ADJUSTMENTS & TEST 659
A. FRONT BRAKE MAINTENANCE 659
I. INSPECTION OF PADS 659
II. INSPECTION OF CALIPER 660
III. DISC INSPECTION 660
B. REAR BRAKE MAINTAINANCE 661
C. BLEEDING OF HYDRAULIC SYSTEM 663
I. BRAKE BLEEDING PROCEDURE (WITHOUT DIAGNOSTIC TOOL) 663
II. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) 664
D. BRAKE TROUBLE SHOOTING 666
E. ROAD TESTING 667
12. STOP LIGHT SWITCH ADJUSTMENT 668
13. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO 669
14. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION 670
A. CHECK AIR TIGHTNESS 670
B. CHECK OPERATION 670
C. CHECK AIR TIGHTNESS UNDER LOAD 670
15. BRAKE PEDAL ASSEMBLY REMOVAL 671
16. REPAIRS 673
A. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT 674
I. REMOVAL OF CALIPER FROM CARRIER 674
II. ASSEMBLY OF CALIPER 676
III. BRAKE PAD 677
IV. CARRIER ASSEMBLY 679
B. REMOVAL OF FRONT BRAKE DISC 682
C. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY 683
D. REAR BRAKE ASSEMBLY 685
E. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY 686
F. REMOVAL OF PARKING BRAKE LEVER 692
G. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE 692
H. PARKING BRAKE CABLE ADJUSTMENT PROCEDURE 694
I. REMOVAL AND REFITMENT OF ABS ECU / HCU 695
J. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR 696
K. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR 697
17. TROUBLE SHOOTING & DIAGNOSIS 699
18. ABS ECU CONNECTOR 701
FATC 702
TABLE OF CONTENTS 703
1. TECHNICAL SPECIFICATIONS 705
2. TIGHENING TORQUE 707
3. FATC SYSTEM & LAYOUT 711
4. FATC UNIT AIR FLOW LAYOUT 712
5. PRECAUTIONS 713
6. BATTERY COOLING SYSTEM LAYOUT 715
7. SCHEMATICS OF HVAC & BATTERY COOLING SYSTEM (BCS) 716
8. HVAC UNIT ELECTRICAL CIRCUIT DIAGRAM 717
9. FATC 718
10. CONTROL PANEL CONNECTOR 723
11. FATC UNIT 724
12. COMPRESSOR 726
13. CHILLER UNIT 727
14. COOLANT PUMP 728
15. AC FILTER 729
16. FATC SENSORS AND ACTUATORS 730
A. LINEAR PRESSURE SENSOR 730
B. ON VEHICLE INSPECTION (WITHOUT DISMANTLING HVAC UNIT) 730
C. CONDENSER AND RECEIVER DRIER 730
D. SOLAR LOAD SENSOR 731
E. OAT SENSOR 733
F. THERMISTOR OR THERMO SENSOR 734
G. AIR INLET ACTUATOR 735
H. BLOWER CONTROLLER MODULE 737
I. PTC HEATER 738
17. DO’S AND DONT’S 739
18. PREACUTIONS 742
19. TROUBLESHOOTING 744
20. MAINTENANCE 756
A. PRELIMINARY INSPECTION 756
I. AC SYSTEM PERFORMANCE TEST 756
II. LEAK DETECTION 759
B. REGULAR MAINTENANCE 759
I. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 759
II. FLUSHING OF AC SYSTEM 760
III. REPLENISHING COMPRESSOR OIL 761
IV. PRESSURE TEST USING MANIFOLD GAUGES 762
21. ON VEHICLE REMOVAL PROCEDURE 764
A. CONTROL PANEL ASSEMBLY REMOVAL 764
B. COMPRESSOR REMOVAL 764
C. BLOWER REMOVAL 766
D. LPM REMOVAL 766
E. PTC HEATER REMOVAL 767
F. TXV 767
G. HVAC UNIT REMOVAL 768
H. CONDENSER SEALING DUCT REMOVAL 768
I. CONDENSER 769
J. CHILLER UNIT REMOVAL 769
K. SOLENOID VALVE REMOVAL 771
L. AIR PURIFIER (IF APPLICABLE) 771
I. CABIN AIR PURIFICATION 771
II. AIR QUALITY INDEX: (IF AVAILABLE) 771
III. PM2.5 SENSOR: (IF AVAILABLE) 772
IV. SERVICE SCHEDULE 772
V. PM2.5 SENSOR REMOVAL 772
BODY 773
TABLE OF CONTENTS 774
1. LAYOUT 776
2. TIGHTENING TORQUES 777
3. SPECIAL TOOLS 780
4. ON VEHICLE REPAIR 781
A. BONNET 781
B. HOOD LATCH ASSEMBLY REMOVAL 781
C. BONNET LATCH RELEASE CABLE 782
D. FLOOR CONSOLE REMOVAL 783
E. DASHBOARD SKIN 785
F. GLOVE BOX 791
G. SIDE AIR VENTS 792
H. FRONT BUMPER 792
I. REAR BUMPER 794
J. FRONT DOOR 796
K. FRONT DOOR TRIMS 797
L. DOOR INNER LOCK HANDLE 798
M. FRONT OUTER DOOR HANDLE 798
N. FRONT DOOR LATCH 799
O. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM 800
P. REAR DOOR REMOVAL 801
Q. REAR DOOR TRIM 802
R. REAR OUTER DOOR LOCK REMOVAL 803
S. DOOR LATCH REAR 804
T. TAIL GATE 805
I. TAIL GATE REMOVAL 805
II. TAIL GATE LATCH CABLE 806
III. TAIL GATE STRIKER 806
IV. TAIL GATE LOCK 806
V. TAIL GATE TRIM 807
U. INNER REAR VIEW MIRROR 807
V. ORVM 807
W. FRONT ROW SEAT 808
X. REAR ROW SEAT 809
Y. ISOFIX REMOVAL (IF APPLICABLE) 810
Z. FRONT SCUFF PLATE 811
AA. “A” PILLAR TRIM 812
AB. “B” PILLAR TRIMS 812
AC. “C” PILLAR TRIM 813
AD. GRAB HANDLE 814
AE. SUNVISOR REMOVAL 815
AF. ROOF LINEAR 815
AG. BONNET INSULATION 816
AH. PLENUM COVER 816
AI. GLASS 817
AJ. FRONT WHEEL ARCH LINER REMOVAL 818
AK. REAR WHEEL ARCH LINER REMOVAL 819
AL. FRONT FENDER REMOVAL 819
AM. REAR WIPER MOTOR REMOVAL 821
AN. FRONT WIPER REMOVAL 822
SRS 824
TABLE OF CONTENTS 825
1. WORKING OF RESTRAINTS 826
2. SYSTEM LAYOUT 828
3. SAFETY PRECAUTIONS 830
4. DISPOSAL OF FAULTY AIR BAG UNIT 832
5. SRS POST ACCIDENT PROCEDURE 834
6. TIGHTENING TORQUES 835
7. SRS COMPONENTS 839
A. RESTRAINT WITHOUT AIRBAGS 839
B. RESTRAINT WITH AIRBAGS 839
I. ECU 839
II. FRONT IMPACT SENSOR (FIS) 844
III. SIDE IMPACT SENSOR 845
IV. AIR BAGS 847
V. FRONT SEAT (DRIVER) BELT BUCKLE 851
VI. RPLL BELTS 851
VII. CLOCK SPRING 854

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