| 1.2L REVOTRON NGNA ENGINE |
6 |
| 1. GENERAL INFORMATION |
12 |
| A. ENGINE INTRODUCTION |
12 |
| B. ELECTRONIC FUEL INJECTION CONTROL |
13 |
| C. TECHNICAL SPECIFICATION |
14 |
| D. SPECIAL TOOLS |
15 |
| E. ASSEMBLY CLEARANCES |
18 |
| F. SEALANTS |
18 |
| G. LEAKAGE RATES |
18 |
| 2. TROUBLESHOOTING |
19 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
25 |
| A. ENGINE LIFTING |
25 |
| B. INTAKE MANIFOLD |
26 |
| C. CYLINDER HEAD AND COVER |
28 |
| D. CYLINDER HEAD-A |
30 |
| E. CYLINDER HEAD-B |
32 |
| F. CYLINDER BLOCK |
33 |
| G. OIL SUMP |
35 |
| H. MOVING PARTS |
36 |
| I. ENGINE TIMING |
38 |
| J. EXHAUST MANIFOLD |
40 |
| K. FUEL INJECTION EQUIPMENT |
41 |
| L. LUBRICATION PUMP AND COMPONENTS |
42 |
| M. AIR INTAKE SYSTEM |
44 |
| N. SPECIAL INSTALLATION |
46 |
| O. ENGINE SUSPENSION |
49 |
| 4. ENGINE TESTS AND MAINTENANCE |
51 |
| A. PRELIMINARY INSPECTION |
51 |
| B. ENGINE TESTS |
52 |
| I. ENGINE COMPRESSION TEST |
52 |
| II. ENGINE OIL CONSUMPTION TEST |
53 |
| III. ENGINE OIL PRESSURE TEST |
54 |
| C. REGULAR MAINTENANCE |
55 |
| I. ENGINE OIL AND FILTER CHANGE |
55 |
| II. ENGINE COOLANT REPLACEMENT |
56 |
| III. AIR FILTER ELEMENT REPLACEMENT |
60 |
| IV. SPARK PLUG REPLACEMENT |
61 |
| V. FUEL FILTER REPLACEMENT |
63 |
| VI. AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT |
64 |
| 5. REPAIR AND INSPECTION DETAILS |
65 |
| A. ACCESSORY DRIVING BELT |
65 |
| B. TIMING CHAIN |
65 |
| C. CYLINDER HEAD |
65 |
| D. VALVES |
66 |
| E. CYLINDER HEAD VALVE SEATS |
67 |
| F. ROCKER ARM AND SHAFTS |
67 |
| G. HYDRAULIC LASH ADJUSTER |
68 |
| H. CAMSHAFT |
68 |
| I. PISTON AND PISTON RINGS |
69 |
| J. CONNECTING RODS |
70 |
| K. CRANKSHAFT |
71 |
| L. CRANK CASE |
72 |
| M. FUEL TANK |
73 |
| N. CANISTER PURGE VALVE |
73 |
| O. CANISTER |
74 |
| 6. ENGINE SYSTEM |
75 |
| A. AIR INTAKE SYSTEM |
75 |
| B. BLOW BY SYSTEM |
77 |
| C. LUBRICATION SYSTEM |
78 |
| D. EXHAUST SYSTEM |
82 |
| E. COOLING SYSTEM |
84 |
| F. FUEL SYSTEM |
87 |
| 7. ENGINE ON VEHICLE SERVICE PROCEDURE |
90 |
| A. FUSE BOX SHIFTING PROCEDURE |
90 |
| B. ENGINE REMOVAL AND INSTALLATION |
91 |
| C. AIR FILTER ASSY |
97 |
| D. FUEL RAIL AND INJECTOR |
98 |
| E. SPARK PLUG |
99 |
| F. EXHAUST SYSTEM |
100 |
| G. FUEL SYSTEM |
103 |
| H. COOLING SYSTEM |
108 |
| I. COMPRESSOR AND ALTERNATOR BELT REMOVAL |
112 |
| J. TIMING BELT REMOVAL |
113 |
| K. WATER PUMP |
117 |
| L. SOLENOID |
118 |
| M. ELECTRONIC THROTTLE BODY |
118 |
| N. STARTER MOTOR |
119 |
| O. ALTERNATOR |
119 |
| P. COMPRESSOR |
120 |
| 8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
121 |
| A. ENGINE DIS-ASSEMBLY |
121 |
| I. REMOVAL OF INTAKE MANIFOLD |
121 |
| II. REMOVAL OF EXHAUST MANIFOLD |
122 |
| III. REMOVAL OF OIL SUMP |
124 |
| IV. REMOVAL OF SENSORS |
124 |
| V. REMOVAL OF ACCESSORIES |
125 |
| VI. REMOVAL OF TIMING CHAIN |
128 |
| VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
130 |
| VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
131 |
| IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
132 |
| B. ENGINE ASSEMBLY |
136 |
| I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
136 |
| II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
140 |
| III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES |
142 |
| IV. ASSEMBLY OF CYLINDER HEAD |
143 |
| V. ASSEMBLY OF ENGINE TIMING CHAIN |
145 |
| VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
148 |
| VII. ASSEMBLY OF SENSORS AND PERIPHERALS |
150 |
| VIII. ASSEMBLY OF OIL SUMP |
151 |
| IX. ASSEMBLY OF EXHAUST MANIFOLD |
151 |
| X. ASSEMBLY OF INTAKE MANIFOLD S |
153 |
| 9. ENGINE MANAGEMENT SYSTEM |
155 |
| A. ABBREVIATIONS |
155 |
| B. AN OVERVIEW |
156 |
| C. ELECTRONIC CONTROL UNIT |
157 |
| D. SENSORS |
162 |
| I. T-MAP SENSOR |
163 |
| II. LAMBDA SENSOR |
164 |
| III. CAMSHAFT POSITION SENSOR |
166 |
| IV. KNOCK SENSOR |
167 |
| V. CRANKSHAFT POSITION SENSOR |
168 |
| VI. COOLANT TEMPERATURE SENSOR |
169 |
| E. ACTUATORS |
171 |
| I. IGNITION COIL |
172 |
| II. PURGE CONTROL VALVE |
173 |
| III. SOLENOID VALVE (OCV) |
174 |
| IV. FUEL INJECTOR |
175 |
| V. ELECTRONIC THROTTLE BODY |
176 |
| F. SWITCH |
178 |
| I. OIL PRESSURE SWITCH |
178 |
| II. THROTTLE PEDAL SENSOR |
179 |
| III. CLUTCH SWITCH |
180 |
| IV. BRAKE SWITCH |
181 |
| V. VEHICLE SPEED SENSOR |
182 |
| VI. WHEEL SPEED SENSOR |
183 |
| 1.2L REVOTRON NGTC ENGINE |
184 |
| 1. GENERAL INFORMATION |
189 |
| A ENGINE INTRODUCTION |
189 |
| B ELECTRONIC FUEL INJECTION CONTROL |
190 |
| C TECHNICAL SPECIFICATION |
191 |
| D SPECIAL TOOLS |
192 |
| E ASSEMBLY CLEARANCES |
195 |
| F SEALANTS |
195 |
| G LEAKAGE RATES |
195 |
| F RECOMMENDED LUBRICANTS & COOLANTS |
195 |
| G SERVICE SCHEDULE |
195 |
| 2. TROUBLESHOOTING |
196 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
204 |
| A ENGINE LIFTING HOOKS |
204 |
| B INTAKE MANIFOLD |
205 |
| C CYLINDER HEAD COVER |
206 |
| D CYLINDER HEAD-A |
208 |
| E CYLINDER HEAD-B |
210 |
| F CYLINDER BLOCK |
212 |
| G LUBRICATION PUMP & COMPONENTS |
214 |
| H PISTON, CRANKSHAFT & COMPONENTS |
217 |
| I ENGINE TIMING |
220 |
| J TURBOCHARGER, CATCON & COMPONENTS |
222 |
| K FUEL INJECTION EQUIPMENT |
224 |
| L AIR INTAKE SYSTEM |
226 |
| M WATER PUMP, THERMOSTAT AND COMPONENTS |
228 |
| N STARTER MOTOR AND ALTERNATOR |
230 |
| O COMPRESSOR, AUTO TENSIONER AND BELT |
231 |
| P ENGINE SUSPENSION |
232 |
| Q INTERCOOLER AND HOSES |
234 |
| 4. ENGINE TESTS AND MAINTENANCE |
236 |
| A PRELIMINARY INSPECTION |
236 |
| B ENGINE TESTS |
237 |
| I ENGINE COMPRESSION TEST |
237 |
| II ENGINE OIL CONSUMPTION TEST |
238 |
| III ENGINE OIL PRESSURE TEST |
239 |
| C REGULAR MAINTENANCE |
240 |
| I ENGINE OIL AND FILTER CHANGE |
240 |
| II ENGINE COOLANT REPLACEMENT |
242 |
| III AIR FILTER ELEMENT REPLACEMENT |
246 |
| IV SPARK PLUG REPLACEMENT |
247 |
| V AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT |
249 |
| 5. REPAIR AND INSPECTION DETAILS |
251 |
| A ACCESSORY DRIVING BELT |
251 |
| B TIMING CHAIN |
251 |
| C CYLINDER HEAD |
251 |
| D VALVES |
252 |
| E CYLINDER HEAD VALVE SEATS |
254 |
| F ROLLER FINGER FOLLOWER |
255 |
| G HYDRAULIC LASH ADJUSTER |
255 |
| H CAMSHAFT |
256 |
| I PISTON AND PISTON RINGS |
257 |
| J CONNECTING RODS |
258 |
| K CRANKSHAFT |
260 |
| L CRANK CASE |
262 |
| M FUEL TANK |
263 |
| N CANISTER PURGE VALVE |
263 |
| O CANISTER |
264 |
| 6. ENGINE SYSTEM |
265 |
| A AIR INTAKE SYSTEM |
265 |
| B BLOW BY SYSTEM |
268 |
| C LUBRICATION SYSTEM |
269 |
| D EXHAUST SYSTEM |
273 |
| E COOLING SYSTEM |
277 |
| F FUEL SYSTEM |
280 |
| 7. ON VEHICLE SERVICE PROCEDURE |
283 |
| A ENGINE REMOVAL AND INSTALLATION |
283 |
| B AIR FILTER ASSY |
289 |
| C FUEL RAIL AND INJECTOR |
290 |
| D SPARK PLUG |
291 |
| E EXHAUST SYSTEM |
291 |
| F FUEL SYSTEM |
295 |
| G COOLING SYSTEM |
300 |
| H COMPRESSOR AND ALTERNATOR BELT REMOVAL |
305 |
| I TIMING BELT REMOVAL |
306 |
| J WATER PUMP |
310 |
| K SOLENOID |
311 |
| L ELECTRONIC THROTTLE BODY |
311 |
| M STARTER MOTOR |
312 |
| N ALTERNATOR |
312 |
| O COMPRESSOR |
313 |
| 8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
314 |
| A ENGINE DIS-ASSEMBLY |
314 |
| I REMOVAL OF INTAKE MANIFOLD |
314 |
| II REMOVAL OF CLOSED COUPLED CATCON AND TURBOCHARGER |
316 |
| III REMOVAL OF OIL SUMP |
318 |
| IV REMOVAL OF SENSORS |
319 |
| V REMOVAL OF ACCESSORIES |
320 |
| VI REMOVAL OF TIMING CHAIN |
322 |
| VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
325 |
| VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
327 |
| IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
329 |
| B ENGINE ASSEMBLY |
333 |
| I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
333 |
| II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
337 |
| III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES. |
339 |
| IV ASSEMBLY OF CYLINDER HEAD |
341 |
| V ASSEMBLY OF ENGINE TIMING CHAIN |
343 |
| VI ASSEMBLY OF CYLINDER HEAD COVER AND PERIPHERALS |
346 |
| VII ASSEMBLY OF SENSORS |
349 |
| VIII ASSEMBLY OF OIL SUMP |
350 |
| IX ASSEMBLY OF CLOSED COUPLED CATCON AND TURBOCHARGER |
351 |
| X ASSEMBLY OF INTAKE MANIFOLD |
353 |
| 9. ENGINE MANAGEMENT SYSTEM |
355 |
| A ABBREVIATIONS |
355 |
| B AN OVERVIEW |
356 |
| C ELECTRONIC CONTROL UNIT |
357 |
| D SENSORS |
364 |
| I T-MAP SENSOR |
365 |
| II LAMBDA SENSOR |
366 |
| III CAMSHAFT POSITION SENSOR |
368 |
| IV KNOCK SENSOR |
369 |
| V CRANKSHAFT POSITION SENSOR |
371 |
| VI COOLANT TEMPERATURE SENSOR |
372 |
| E ACTUATORS |
374 |
| I IGNITION COIL |
375 |
| II PURGE CONTROL VALVE |
376 |
| III SOLENOID VALVE (OCV) |
377 |
| IV FUEL INJECTOR |
378 |
| V ELECTRONIC THROTTLE BODY |
379 |
| F SWITCH |
381 |
| I OIL PRESSURE SWITCH |
381 |
| II THROTTLE PEDAL SENSOR |
382 |
| III CLUTCH SWITCH |
383 |
| IV BRAKE SWITCH |
384 |
| V WHEEL SPEED SENSOR |
385 |
| VI ELECTRONIC VACCUM REGULATING VALVE (EVRV) |
386 |
| VII START STOP SWITCH |
387 |
| VIII AC PRESSURE SENSOR |
388 |
| 1.5L REVOTORQ ENGINE |
389 |
| CONTENTS |
390 |
| 1. GENERAL INFORMATION |
394 |
| A. ENGINE INTRODUCTION |
394 |
| B. TECHNICAL SPECIFICATION |
395 |
| C. SPECIAL TOOLS |
396 |
| D. ASSEMBLY CLEARANCES |
400 |
| 2. TROUBLESHOOTING |
401 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
405 |
| A. Engine Lifting Hook |
405 |
| B. Intake Manifold and Fuel Injection System |
406 |
| C. Lubrication system |
408 |
| D. Air Filter, Snorkel, Blow By Pipe |
411 |
| E. Starter Motor, Compressor and Alternator |
413 |
| F. Timing Belt, Auto Tensioner, Water pump |
415 |
| G. Exhaust manifold, CATCON, Turbocharger |
417 |
| H. Cylinder head and Components |
420 |
| I. Piston, Crankshaft and Components |
423 |
| J. Engine Suspension |
425 |
| K. EGR Valve, Thermostat and Components |
427 |
| L. Crankcase and Components |
430 |
| 4. ENGINE TESTS AND MAINTENANCE |
432 |
| A. PRELIMINARY INSPECTION |
432 |
| B. ENGINE TESTS |
432 |
| C. REGULAR MAINTENANCE |
437 |
| 5. REPAIR AND INSPECTION DETAILS |
448 |
| A. TIMING BELT |
448 |
| B. FUEL TANK |
448 |
| C. CYLINDER HEAD |
449 |
| D. VALVES |
449 |
| E. VALVE SEATS |
451 |
| F. CRANKCASE |
452 |
| G. VALVE SEAT INSERT |
453 |
| H. HYDRAULIC LASH ADJUSTER |
453 |
| I. VALVE GUIDES |
454 |
| J. CAMSHAFT |
455 |
| K. PISTON AND PISTON RINGS |
456 |
| L. CONNECTING ROD |
457 |
| M. CRANK SHAFT |
459 |
| 6. ENGINE SYSTEMS |
461 |
| A. AIR INTAKE SYSTEM |
461 |
| B. EXHAUST SYSTEM |
464 |
| C. COOLING SYSTEM |
468 |
| D. LUBRICATION SYSTEM |
471 |
| E. EXHAUST GAS RECIRCULATION SYSTEM (EGR) |
475 |
| F. BLOW-BY VENTILATION SYSTEM |
477 |
| G. VACUUM MANAGEMENT SYSTEM |
478 |
| H. FUEL SYSTEM |
479 |
| 7. ENGINE ON VEHICLE SERVICEPROCEDUR |
485 |
| A. FUSE BOX SHIFTING PROCEDURE: |
485 |
| B. ENGINE REMOVAL |
486 |
| C. ENGINE INSTALLATION |
492 |
| D. EXHAUST SYSTEM |
493 |
| E. COOLING SYSTEM |
496 |
| F. FUEL SYSTEM |
501 |
| G. TURBOCHARGER REMOVAL ANDREFITMENT |
508 |
| H. TIMING BELT REMOVAL AND REFITMENT |
510 |
| I. STARTER MOTOR REMOVAL ANDREFITMENT |
511 |
| J. ALTERNATOR MOTOR REMOVAL ANDREFITMENT |
512 |
| K. COMPRESSOR MOTOR REMOVAL ANDREFITMENT |
513 |
| L. HIGH PRESSURE PUMP REMOVAL ANDREFITMENT |
514 |
| 8. ENGINE OVERHAULING |
517 |
| A. ENGINE DIS-ASSEMBLY |
517 |
| i. ON OVERHAUL STAND |
517 |
| ii. REMOVAL OF EGR VALVE & OIL FILTER |
521 |
| iii. REMOVAL OF INTAKE MANIFOLD |
522 |
| iv. REMOVAL OF EXHAUST MANIFOLD |
524 |
| v. REMOVAL OF EVRV AND THERMOSTAT |
525 |
| vi. REMOVAL OF OIL SUMP |
526 |
| vii. REMOVAL OF TIMING BELT |
527 |
| viii. REMOVAL OF CYLINDER HEAD |
532 |
| ix. REMOVAL OF CYLINDER HEAD SUBASSEMBLIES |
533 |
| x. REMOVAL OF CYLINDER BLOCK SUBASSEMBLI |
536 |
| xi. PISTON CONNECTING RODDISASSEMBLY |
538 |
| B. ENGINE ASSEMBLY |
544 |
| i. FITMENT OF CYLINDER HEAD SUBASSEMBLIES |
544 |
| ii. FITMENT OF PISTON AND CONNECTINGROD SUB-ASSEMBLIES |
545 |
| iii. FITMENT OF CYLINDER BLOCK SUBASSEMBLIE |
546 |
| iv. FITMENT OF CYLINDER HEAD ONCYLINDER BLOCK |
548 |
| v. FITMENT OF TIMING BELT |
550 |
| vi. FITMENT OF ENGINE SUPPORT |
554 |
| vii. FITMENT OF OIL SUMP |
555 |
| viii. FITMENT OF EXHAUST MANIFOLD ANDOTHER COMPONENTS |
556 |
| ix. FITMENT OF INTAKE MANIFOLD |
560 |
| x. FITMENT OF PERIPHERALS |
562 |
| 9. ENGINE MANAGEMENT SYSTEM |
565 |
| A. ABBREVIATIONS |
565 |
| B. AN OVERVIEW |
565 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
566 |
| D. EMS SENSORS |
571 |
| CLUTCH DIESEL |
586 |
| 1.1. GENERAL INFORMATION |
589 |
| A. CLUCTH MASTER CYLINDER |
590 |
| B. CONCENTRIC SLAVE CYLINDER (CSC) |
590 |
| C. PEAK TORQUE LIMITER |
590 |
| D. HYDRAULIC ADAPTER |
590 |
| E. SINGLE MASS FLYWHEEL |
591 |
| F. CONVENTIONAL CLUTCH |
591 |
| 1.2. TECHNICAL SPECIFICATIONS |
592 |
| A. CLUTCH DISC ASSEMBLY |
592 |
| B. CONVENTIONAL CLUTCH |
593 |
| C. SINGLE MASS FLYWHEEL (FOR DIESEL VERSION) |
594 |
| 1.3. TIGHTENING TORQUES |
595 |
| 1.4. SPECIAL TOOLS |
596 |
| 1.5. MAINTENANCE, INSPECTION ANDTESTS |
597 |
| 1.5.1. PRELIMINARY INSPECTION |
597 |
| 1.5.2. REGULAR MAINTENANCE |
598 |
| A. CLUTCH SWITCH ADJUSTMENT |
598 |
| B. CLUTCH BLEEDING PROCEDURE |
598 |
| C. CLUTCH FLUID DRAINING PROCEDURE |
599 |
| 1.6. GENERAL SYMPTOMS DIAGNOSIS |
600 |
| 1.7. EXPLODE VIEWS |
602 |
| A. CLUTCH PEDAL ASSEMBLY |
602 |
| B. CONVENTIONAL CLUTCH ASSEMBLY |
603 |
| C. CLUTCH HYDRAULIC SYSTEM COMPONENTS |
604 |
| 1.8. ON VEHICLE PROCEDURES |
605 |
| A. FUSE BOX SHIFTING PROCEDURE |
605 |
| B. CLUTCH PEDAL REMOVAL |
606 |
| C. CONTROL BRACKET ASSEMBLYREMOVAL |
607 |
| D. CONVENTIONAL CLUTCH ASSEMBLYREMOVAL |
608 |
| E. CLUTCH MASTER CYLINDER REMOVAL |
609 |
| F. FLYWHEEL REMOVAL |
611 |
| CLUTCH PETROL |
612 |
| 1. GENERAL INFORMATION |
615 |
| 2. TECHNICAL SPECIFICATIONS |
616 |
| A. CLUTCH DISC |
616 |
| B. CLUTCH PLATE |
618 |
| C. FLYWHEEL |
620 |
| 3. TIGHTENING TORQUE |
622 |
| 4. SPECIAL TOOLS |
623 |
| 5
. DIAGNOSIS OF CLUTCH |
624 |
| 6. MAINTENANCE, TESTS AND FACTOR AFFECTING |
627 |
| A. INSPECTION OF COMPONENTS |
627 |
| B. TEST |
627 |
| C. FACTORS AFFECTING CLUTCH |
627 |
| 7. CONSTRUCTIONAL DETAILS |
628 |
| 8. ON VECHILE PROCEDURE |
630 |
| A. FUSE BOX SHIFTING PROCEDURE |
630 |
| B. CLUTCH CABLE REMOVAL ANDINSPECTION |
631 |
| C. REMOVAL OF CLUTCH |
632 |
| D. FLYWHEEL |
633 |
| E. CLUTCH ADJUSTMENT PROCEDURE |
634 |
| TRANSAXLE (TA65 Star) |
661 |
| 1. TECHNICAL SPECIFICATIONS |
665 |
| 2. PRECAUTIONS |
665 |
| 3. GENERAL DESCRIPTION |
666 |
| 4. TIGHTENING TORQUES |
667 |
| 5. SPECIAL TOOLS LIST |
668 |
| 6. DIAGNOSIS |
672 |
| 7. CONSTRUCTIONAL DETAILS |
673 |
| 8. CUT SECTION OF TRANSAXLE TA 65 STAR |
674 |
| 9. CUT SECTION OF TOP COVER ASSEMBLY |
675 |
| 10. EXPLODED VIEWS OF TRANSAXLE |
676 |
| A. TRANSAXLE HOUSING |
676 |
| B. TOP COVER ASSEMBLY |
677 |
| C. DIFFERENTIAL |
678 |
| D. SHIFTER FORK |
679 |
| E. GEAR SHIFT LINKAGE ASSEMBLY |
680 |
| F. LAY SHAFT AND INPUT SHAFT |
681 |
| 11. FUSE BOX SHIFTING PROCEDURE |
683 |
| 12. REMOVAL OF TRANSAXLE FROMVEHICLE |
684 |
| 13. ON VEHICLE ASSEMBLY OFTRANSAXLE |
687 |
| 14. TRANSAXLE TA65 STAR (ON BENCH)DISASSEMBLY |
689 |
| 15. INPUT SHAFT DEEP GROOVEBEARING REMOVAL |
694 |
| 16. INPUT SHAFT DEEP GROOVEBEARING ASSEMBLY |
694 |
| 17. DISASSEMBLY OF LAY SHAFT |
695 |
| 18. IDNETIFICATION OF COMPONENTS |
697 |
| A. ENGAGING GEARS |
697 |
| B. SHIFTER SHAFT SUB ASSEMBLY |
698 |
| C. SHIFTER FORKS |
698 |
| D. SHIFTER SHAFTS |
699 |
| F. SYNCHROCONE |
699 |
| G. SUB ASSEMBLIES |
699 |
| 19. LAY SHAFT ASSEMBLY |
701 |
| 20. DIFFERENTIAL ASSEMBLY: |
704 |
| 1. DISASSEMBLY |
704 |
| 2. ASSEMBLY |
705 |
| 21. TRANSAXLE ASSEMBLY |
706 |
| 22. DISASSEMBLY OF TOP COVER |
711 |
| 23. ASSEMBLY TOP COVER |
712 |
| 24. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX |
714 |
| 25. REMOVAL OF GEAR SHIFTER ANDSELECTOR CABLE |
715 |
| 26. GEAR SHIFTER CABLE ASSEMBLY |
716 |
| TRANSAXLE (TA5260) |
717 |
| 1. TECHNICAL SPECIFICATIONS |
721 |
| 2. PRECAUTIONS |
721 |
| 3. GENERAL INFORMATION TA5260 |
722 |
| 4. TIGHTENING TORQUES |
723 |
| 5. SPECIAL TOOL LIST |
727 |
| 6. DIAGNOSIS OF TRANSAXLE |
733 |
| 7. CUT SECTION OF TRANSAXLE TA 5260 |
734 |
| 8. CUT SECTION OF TOP COVER ASSEMBLY |
736 |
| 9. EXPLODED VIEWS OF TRANSAXLE |
737 |
| 10. FUSE BOX SHIFTING PROCEDURE |
744 |
| 11. REMOVAL OF TRANSAXLE FROMVEHICLE |
745 |
| 12. DISASSEMBLY OF TRANSAXLE (ONBENCH) |
748 |
| A. DISASSEMBLY OF INPUT SHAFT |
754 |
| B. ASSEMBLY OF INPUT SHAFT |
756 |
| C. REMOVAL OF DEEP GROOVE BALLBEARING FROM LAY SHAFT |
757 |
| D. ASSEMBLY OF DEEP GROOVE BALLBEARING ON LAY SHAFT |
758 |
| E. DISASSEMBLY OF LAY SHAFT |
758 |
| F. ASSEMBLY OF LAY SHAFT |
760 |
| G. DISASSEMBLY OF DIFFERENTIAL |
761 |
| H. ASSEMBLY OF DIFFERENTIAL |
763 |
| I. DISASSEMBLY OF TOP COVER |
764 |
| J. IDNETIFICATION OF COMPONENTS |
765 |
| I. SHIFTER SHAFTS |
765 |
| II. ENGAGING GEARS |
765 |
| III. SHIFTER SHAFT SUB ASSEMBLY |
766 |
| 13. ASSEMBLIES OF TRANSAXLE ONBENCH |
767 |
| 14. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE AT GEARBOX |
772 |
| 15. REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE |
773 |
| 16. ASSEMBLY OF GEAR SHIFTERHOUSING, GEAR SHIFTER ANDSELECTOR CABLE |
774 |
| 17. NEUTRAL SETTING PROCEDURE |
776 |
| DRIVE SHAFT PETROL |
777 |
| 1. INTRODUCTION |
781 |
| 2. DRIVESHAFT |
782 |
| 3. DRIVE SHAFT PARTS |
783 |
| 4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE |
783 |
| 5. TESTING FOR NOISE |
784 |
| 6. TIGHTENING TORQUES |
785 |
| 7. SPECIAL TOOLS |
785 |
| 8. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE) |
786 |
| 9. ON VEHICLE ASSEMBLY OF DRIVESHAFT (LH & RH SIDE) |
787 |
| 10. DISASSEMBLY PROCEDURE FOR DRIVESHAFT |
788 |
| 11. ASSEMBLY PROCEDURE FORDRIVESHAFT |
789 |
| 12. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT |
790 |
| 13. DISASSEMBLY PROCEDURE FOR(TRIPOT JOINT) |
791 |
| 14. DISASSEMBLY AND ASSEMBLY OF CVJOINT ASSEMBLY (OUTER) |
794 |
| 15. DO’S AND DON’T’S FOR DRIVE SHAFT |
798 |
| DRIVE SHAFT DIESEL |
799 |
| 1. INTRODUCTION |
803 |
| 2. DRIVESHAFT |
804 |
| 3. DRIVE SHAFT PARTS |
805 |
| 4. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE |
805 |
| 5. TESTING FOR NOISE |
806 |
| 6. TIGHTENING TORQUES |
807 |
| 7. SPECIAL TOOLS |
808 |
| 8. LH SIDE DRIVE SHAFT REMOVAL |
809 |
| 9. LH SIDE DRIVE SHAFT ASSEMBLY |
810 |
| 10. RH SIDE DRIVE SHAFT REMOVAL |
812 |
| 11. RH SIDE DRIVE SHAFT ASSEMBLY |
813 |
| 12. DISASSEMBLY PROCEDURE FOR DRIVESHAFT |
815 |
| 13. ASSEMBLY PROCEDURE FORDRIVESHAFT |
816 |
| 14. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT |
818 |
| 15. DO’S AND DON’T’S FOR DRIVE SHAFT |
819 |
| SUSPENSION |
820 |
| 1. GENERAL INFORMATION |
822 |
| 1.1. FRONT SUSPENSION |
822 |
| 1.2. REAR SUSPENSION |
823 |
| 1.3. SHOCK ABSORBER |
825 |
| 2. TECHNICAL SPECIFICATIONS |
826 |
| 3. TIGHTENING TORQUES |
827 |
| 4. SPECIAL TOOLS |
832 |
| 5. DIAGNOSIS |
837 |
| 6. PRECAUTIONS |
838 |
| 7. EXPLODED VIEWS FRONT SUSPENSION |
839 |
| A) ASSEMBLY FRONT STRUT EXPLODED VIEW |
839 |
| B) ANTI ROLL BAR MOUNTING EXPLODED VIEW |
840 |
| C) LOWER LINK EXPLODED VIEW |
841 |
| 8. EXPLODED VIEWS REAR SUSPENSION |
843 |
| A) REAR SHOCK ABSORBER AND SPRING EXPLODED VIEW |
843 |
| B) REAR HUB ASSEMBLY EXPLODED VIEW |
844 |
| C) REAR TWIST BEAM AND PIVOT BUSH EXPLODED VIEW |
845 |
| 9. ON VEHICLE AND ON BENCH REMOVALAND ASSEMBLY PROCEDURE |
846 |
| 9.1 ON VEHICLE FRONT STRUT REMOVALAND ASSEMBLY |
846 |
| 9.2 ON BENCH FRONT STRUT REMOVAL ANDASSEMBLY |
847 |
| 9.3 ON VEHICLE WHEEL HUB REMOVAL ANDASSEMBLY |
848 |
| 9.4 ON BENCH SUB ASSEMBLY OF KNUCKLEAND WHEEL HUB |
851 |
| 9.5 REMOVAL AND ASSEMBLY OFSUBFRAME ASSEMBLY |
852 |
| 9.6 ON VEHICLE REMOVAL AND ASSEMBLYOF ANTI ROLL BAR |
853 |
| 9.7 REMOVAL AND ASSEMBLY OF LOWERARM BALL JOINT |
853 |
| 9.8 ON BENCH LOWER ARM PIVOT BUSHREMOVAL AND ASSEMBLY |
855 |
| 9.9 ON VEHICLE SUBFRAME ASSEMBLY |
856 |
| 9.10 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING REMOVAL ANDASSEMBLY |
857 |
| 9.11 ON BENCH DISASSEMBLY ANDASSEMBLY OF REAR SHOCK ABSORBER |
858 |
| 9.12 ON VEHICLE REAR SHOCK ABSORBERAND COIL SPRING ASSEMBLY |
859 |
| 9.13 ON VEHICLE TORSION BEAM REMOVALAND ASSEMBLY |
860 |
| 10 SUSPENSION PRE-LOADING CONDITION |
863 |
| STEERING (EPAS)-BOSCH |
865 |
| 1. GENERAL INFORMATION |
869 |
| 2. SYSTEM LAYOUT |
869 |
| 3. BLOCK DIAGRAM OF EPAS SYSTEM |
870 |
| 4. TIGHTENING TORQUES |
871 |
| 5. SPECIAL TOOLS |
873 |
| 6. MAINTENANCE, INSPECTION AND TEST |
875 |
| 6.1 PRELIMINARY INSPECTION |
875 |
| 6.2. REGULAR MAINTENANCE |
876 |
| 7. ON VEHICLE REPAIRS |
878 |
| 7.1. STEERING WHEEL REMOVAL |
878 |
| 7.2 STEERING COLUMN REMOVAL |
879 |
| 7.3 INTERMEDIATE SHAFT REMOVAL |
880 |
| 7.4. RACK & PINION ASSEMBLY REMOVAL |
881 |
| 8. OVERHAULING |
883 |
| 8.1. DISASSEMBLY OF RACK & PINON |
884 |
| 8.2. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE |
886 |
| 8.3. OBJ ON-VEHICLE REMOVAL |
887 |
| 8.4. WHEEL ALIGNMENT |
888 |
| 8.5. CAMBER ADJUSTMENT |
889 |
| 9. TROUBLESHOOTING AND DIAGNOSIS |
890 |
| 10. STEERING ANGLE CALIBRATION |
894 |
| 11. TUNING DATA SELECTION |
897 |
| STEERING (EPAS)-MANDO |
899 |
| 1. GENERAL INFORMATION |
901 |
| 2. SYSTEM LAYOUT |
901 |
| 3. BLOCK DIAGRAM OF EPAS SYSTEM |
902 |
| 4.
TIGHTENING TORQUES |
903 |
| 5. SPECIAL TOOLS |
906 |
| 6. MAINTENANCE, INSPECTION AND TEST |
907 |
| 6.1. PRELIMINARY INSPECTION |
907 |
| 6.2. REGULAR MAINTENANCE |
908 |
| 7. ON VEHICLE REPAIRS |
910 |
| 7.1. STEERING WHEEL REMOVAL |
910 |
| 7.2. STEERING COLUMN REMOVAL |
911 |
| 7.3. INTERMEDIATE SHAFT REMOVAL |
913 |
| 7.4. ECU REMOVAL |
914 |
| 7.5. MOTOR REMOVAL |
915 |
| 7.6. RACK & PINION ASSEMBLY REMOVAL |
916 |
| 8. OVERHAULING |
918 |
| 8.1. EXPLODED VIEWS OF STEERING RACK & PINION ASSEMBLY |
918 |
| 8.2. DISASSEMBLY OF RACK & PINOIN |
919 |
| 8.3. INSPECTION OF DISMANTLED PARTS |
920 |
| 8.4. ASSEMBLY OF RACK & PINOIN |
920 |
| 8.5. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE |
921 |
| 8.6. OBJ ON VEHICLE REMOVAL |
922 |
| 8.7. DO'S & DON’T'S |
922 |
| 8.8. WHEEL ALIGNMENT |
925 |
| 8.9. CAMBER ADJUSTMENT |
926 |
| 9. TROUBLESHOOTING AND DIAGNOSIS |
927 |
| 10 STEERING ANGLE CALIBRATION |
931 |
| 11 FLOW CHART FOR STEERING ANGLE CALIBRATION |
935 |
| 12 TUNING DATA SELECTION |
938 |
| 13 EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
939 |
| BRAKES |
943 |
| 1. TECHNICAL SPECIFICATIONS |
949 |
| 2. TIGHTENING TORQUES |
950 |
| 3. SPECIAL TOOL |
951 |
| 4. PRECAUTIONS |
951 |
| 5. DIAGNOSIS |
952 |
| 6. NESSECITY OF ABS WITH EBD |
955 |
| 7. BRAKE HYDRAULIC LINES |
956 |
| 8. VACUUM BRAKE BOOSTER |
957 |
| 9. WORKING OF ANTI-LOCK BRAKING (ABS) SYSTEM |
958 |
| 10. ABS COMPONENTS |
962 |
| 10.1. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU) |
963 |
| 10.2. HYDRAULIC CONTROL UNIT |
964 |
| 10.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED) |
964 |
| 10.4. ABS SYSTEM FAILURE WARNING LIGHT |
965 |
| 11. MAINTENANCE, ADJUSTMENTS & TEST |
966 |
| 11.1. FRONT BRAKE MAINTENANCE |
966 |
| 11.2. REAR BRAKE MAINTENANCE |
968 |
| 11.3 BRAKE TROUBLE SHOOTING |
974 |
| 11.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
975 |
| 12. BRAKE PEDAL ASSEMBLY |
977 |
| 13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE |
978 |
| 14. REPAIRS |
979 |
| 14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT |
980 |
| 14
.2. REMOVAL OF FRONT BRAKE DISC |
987 |
| 14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY |
988 |
| 14.4. REAR BRAKE ASSEMBLY |
990 |
| 14.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY |
991 |
| 14.6.
REMOVAL AND INSTALLATION OF PARKING BRAKE LEVER (LOW VERSION) |
997 |
| 14.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE (LOW VERSION) |
998 |
| 14.8 PARKING BRAKE CABLE ADJUSTMENTPROCEDURE (FOR HIGH & LOW END |
999 |
| 14.9 REMOVAL OF PARKING BRAKE LEVER (HIGH VERSION) |
1000 |
| 14.10 REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE (HIGH VERSION) |
1001 |
| 14.11. REMOVAL AND REFITMENT OF ABSECU / HCU |
1002 |
| 14.12. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR |
1003 |
| 14.13. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR |
1004 |
| 15. TROUBLE SHOOTING & DIAGNOSIS |
1006 |
| 16. ABS ECU CONNECTOR (K2) |
1008 |
| BODY |
1010 |
| 1 TECHNICAL SPECIFICATION |
1015 |
| 1.1 LAYOUT |
1015 |
| 1.2 TIGHTENING TORQUES |
1016 |
| 1.3 SPECIAL TOOL |
1018 |
| 2 ON VEHICLE REPAIRS |
1019 |
| 2.1 BONNET |
1019 |
| 2.2 ARM REST |
1021 |
| 2.3 FLOOR CONSOLE |
1022 |
| 2.4 DASHBOARD SKIN |
1024 |
| 2.5 COCKPIT REMOVAL ( COMPLETE ASSY) |
1028 |
| 2.6 GLOVE BOX |
1032 |
| 2.7 SIDE AIR VENTS |
1033 |
| 2.8 FRONT BUMPER |
1034 |
| 2.9 REAR BUMPER |
1035 |
| 2.10 FRONT DOOR |
1036 |
| 2.11 FRONT DOOR TRIMS |
1037 |
| 2.12 DOOR INNER LOCK HANDLE |
1038 |
| 2.13 FRONT OUTER DOOR HANDLE |
1039 |
| 2.14 FRONT DOOR LATCH |
1039 |
| 2.15 FRONT DOOR GLASS AND WINDOWWINDING MECHANISM |
1040 |
| 2.16 REAR DOOR |
1041 |
| 2.17 REAR DOOR TRIM |
1042 |
| 2.18 REAR OUTER DOOR HANDLE |
1044 |
| 2.19 DOOR LATCH REAR |
1045 |
| 2.20 TAIL GATE |
1046 |
| 2.21 INNER REAR VIEW MIRROR |
1048 |
| 2.22 ORVM |
1048 |
| 2.23 FRONT ROW SEAT |
1049 |
| 2.24 REAR ROW SEAT |
1050 |
| 2.25. FRONT SEAT BELT |
1051 |
| 2.26 REAR SEAT BELT |
1053 |
| 2.27 “A” PILLAR TRIM |
1053 |
| 2.28 FRONT SCUFF PLATE |
1054 |
| 2.29 “B” PILLAR TRIMS |
1054 |
| 2.30 “C” PILLAR TRIMS |
1055 |
| 2.31. GRAB HANDLE |
1055 |
| 2.32 SUNVISOR |
1056 |
| 2.33 ROOF LINEAR |
1056 |
| 2.34 PLENUM COVER |
1057 |
| 2.35 GEAR LEVER BOOT |
1057 |
| 2.36 BONNET INSULATION |
1057 |
| 2.37 GLASS |
1058 |
| 2.38 FUEL FILLER ASSEMBLY |
1059 |
| 2.39 FRONT WHEEL ARCH LINER |
1060 |
| 2.40 REAR WHEEL ARCH LINER |
1061 |
| 2.41 FRONT FENDER |
1062 |
| 2.42 REAR WIPER MOTOR |
1063 |
| 2.43 FRONT WIPER |
1063 |
| ELECTRICAL |
1065 |
| 1. TECHNICAL SPECIFICATION |
1069 |
| 2. GENERAL PRECAUTIONS |
1071 |
| 3. FUSE BOX / RELAY LOCATIONS (Applicable for RHD variants) |
1075 |
| 4. BATTERY |
1076 |
| 5. ALTERNATOR |
1078 |
| 5.1. CHECKS ON ENGINE |
1078 |
| 5.2. DIAGNOSTIC INFORMATION AND PROCEDURES FOR ALTERNATOR & BATTERY |
1079 |
| 6. STARTER MOTOR |
1082 |
| 7. LIGHTING SYSTEM |
1090 |
| 7.1. BULB SPECIFICATIONS |
1090 |
| 7.2. FASTENERS TORQUE VALUE TABLE |
1091 |
| 7.3. GENERAL SYMPTOMS AND DIAGNOSTICS |
1091 |
| 7.4. HEADLAMP |
1094 |
| 7.5. SIDE REPEATER LAMP (LH/RH) |
1099 |
| 7.6. ROOF LAMP |
1099 |
| 7.7. HIGH MOUNTED STOP LAMP |
1100 |
| 7.8. TAIL LAMP |
1101 |
| 7.9. FRONT FOG LAMP |
1104 |
| 7.10. REGISTRATION PLATE LAMP |
1105 |
| 8. HORN |
1106 |
| 9. WIPER & WASHER SYSTEM |
1107 |
| 9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT |
1107 |
| 9.2. FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
1108 |
| 9.3. WIPER AND WIPER CARE |
1111 |
| 10. POWER SOCKETS |
1113 |
| 11. GLOWPLUG CONTROL UNIT |
1113 |
| 12. FUEL GAUGE AND FUEL LEVEL METER |
1115 |
| 13. INSPECTION OF FUEL GAUGE |
1115 |
| 14 COMBI-SWITCH |
1116 |
| 14.1 COMBI SWITCH CONNECTION DETAILS |
1117 |
| 14.2 REMOVAL & REFITMENT OF COMBISWITCH |
1119 |
| 14.3 COMBI STALK REPLACEMENTPROCEDURE |
1120 |
| 15. FASCIA SWITCHES (IF APPLICABLE |
1122 |
| 16. STEERING CUM IGNITION SWITCH (IF APPLICABLE) |
1124 |
| 17. HAZARD SWITCH |
1125 |
| 19. MIRROR SWITCH (IF APPLICABLE) |
1127 |
| 20. SILVER BOX |
1129 |
| 20.1 SILVER BOX (XZ-HIGH VERSION) |
1129 |
| 20.2. SILVER BOX (XM-MID VERSION) |
1131 |
| 21. INFOTAINMENT SYSTEM |
1133 |
| 21.1 INFOTAINMENT SYSTEM (XZ – HIGH) |
1133 |
| 21.2. INFOTAINMENT SYSTEM (XM – MID) |
1135 |
| 21.3 USB PORT |
1137 |
| 21.4 SPEAKERS |
1138 |
| 21.5 ANTENNA (IF APPLICABLE) |
1139 |
| 21.6. MICROPHONE (XZ-HIGH) |
1140 |
| 21.7. MICROPHONE (XM - MID |
1141 |
| 21.8. TWEETERS |
1141 |
| 21.9. DTC FOR INFOTAINMENT SYSTEM |
1143 |
| 22. WINDOW WINDING MODULE |
1144 |
| 23. POWER WINDOW SWITCHES & INHIBITSWITCH |
1147 |
| 24. STEERING WHEEL SWITCHES |
1152 |
| 25. IGNITION E-KEY (IF APPLICABLE) |
1154 |
| 26. INSTRUMENT CLUSTER |
1157 |
| 26.1. BASIC FUNCTIONAL MATRIX |
1162 |
| 26.2. MAIN CONNECTOR PIN-OUTS |
1163 |
| 26.3. FUEL GAUGE DETAILS |
1164 |
| 26.4. TEMPERATURE BAR GRAPH DETAILS |
1165 |
| 26.5. CHIME TABLE |
1166 |
| 27. IMMOBILIZER SYSTEM (IF APPLICABLE) |
1167 |
| 27.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB |
1171 |
| 27.2. IMMOBILIZER SYSTEM STATUS IN EMS ECU |
1172 |
| 27.3. IGNITION KEY LEARNINGPROCEDURE |
1174 |
| 28. BODY CONTROL MODULE (BCM |
1176 |
| 28.1 CONNECTION DETAILS (PINOUT DEATAILS) |
1177 |
| 28.2 BCM SPECIFICATION |
1181 |
| 28.3 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX |
1182 |
| 28.4 BCM FEATURES (IF APPLICABLE) |
1187 |
| 28.5 BCM FUNCTIONS |
1189 |
| 28.6 BCM REPLACEMENT STRATEGY |
1190 |
| 29. FUSE AND RELAY BOX DETAILS |
1192 |
| 30. REVERSE PARK ASSIST SYSTEM |
1200 |
| 31. PASSIVE ENTRY PASSIVE START(PEPS) |
1214 |
| 32. RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE) |
1223 |
| 33. TELEMATICS |
1228 |
| HVAC |
1231 |
| 1. HVAC SYSTEM LAYOUT |
1237 |
| 2. TECHNICAL SPECIFICATIONS |
1238 |
| 3. TIGHTENING TORQUES |
1241 |
| 4. PRECAUTIONS |
1244 |
| 5. HVAC SYSTEM LAYOUT AND WORKING |
1245 |
| 6. CONTROL PANEL |
1247 |
| 7. HVAC UNIT COMPONENTS |
1249 |
| 8. COMPRESSOR |
1250 |
| 9. CONDENSER |
1252 |
| 10. RECEIVER DRIER (R.D) |
1252 |
| 11. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT) |
1252 |
| 12. TRINARY PRESSURE SENSOR |
1253 |
| 13. MODE & TEMPRATURE CONTROL ACTUATOR |
1254 |
| 14. INSPECTION OF MODE AND TEMPERATURE ACTUATOR |
1255 |
| 15. TROUBLESHOOTING |
1257 |
| 16. MAINTENANCE |
1267 |
| A. PRELIMINARY INSPECTION |
1267 |
| B. REGULAR MAINTENANCE |
1269 |
| 17. ON VEHICLE REPAIRS |
1273 |
| A. AC FILTER REMOVAL AND ASSEMBLY |
1273 |
| B. COMPRESSOR REMOVAL AND ASSEMBLY |
1273 |
| C. CONTROL PANEL REMOVAL AND ASSEMBLY |
1274 |
| D. BLOWER MOTOR REMOVAL AND ASSEMBLY |
1275 |
| E. FRONT HVAC UNIT REMOVAL AND ASSEMBLY |
1276 |
| F. CONDENSER REMOVAL AND ASSEMBLY |
1277 |
| 18. DO’S AND DONT’S FOR A/C SYSTEM |
1279 |
| HVAC (ETC) |
1281 |
| CONTENTS |
1282 |
| 1 HVAC SYSTEM LAYOUT |
1284 |
| 2 TECHNICAL SPECIFICATIONS |
1285 |
| 3 TIGHTENING TORQUES |
1289 |
| 4 PRECAUTIONS |
1291 |
| 5 HVAC SYSTEM LAYOUT AND WORKING |
1292 |
| 6 CONTROL PANEL |
1294 |
| 7 WORKING / FUNCTION OF ETC |
1295 |
| 8 CONNECTOR DETAILS |
1297 |
| 9 HVAC UNIT COMPONENTS |
1298 |
| 10 COMPRESSOR |
1299 |
| 11 CONDENSOR |
1300 |
| 12 RECEIVER DRIER (R.D) |
1300 |
| 13 TRINARY PRESSURE SENSOR |
1300 |
| 14 TROUBLESHOOTING |
1301 |
| 15 MAINTAINANCE |
1311 |
| 16 ON VEHICLE REPAIR |
1317 |
| 17 DO’S AND DONT’S FOR A/C SYSTEM |
1323 |
| FATC |
1324 |
| 1. FATC (FULLY AUTOMATIC TEMPERATURE CONTROL) SYSTEM |
1330 |
| 2. FATC SYSTEM LAYOUT |
1330 |
| 3. TECHNICAL SPECIFICATIONS |
1331 |
| 4. TIGHTENING TORQUES |
1335 |
| 5. PRECAUTIONS |
1338 |
| 6. HMI CLIMATE CONTRL DISPLAY |
1339 |
| 7. CONTROL PANEL |
1341 |
| 8. CONTROL PANEL MODULE CONNECTOR DETAILS |
1346 |
| 9. FATC UNIT |
1348 |
| A. BLOWER |
1348 |
| B. EVAPORATOR COIL AND TXV (THERMAL EXPANSION VALVE) |
1348 |
| C. HEATER COIL |
1348 |
| 10. FATC SENSOR & ACTUATOR |
1349 |
| A. EVAPORATER SENSOR |
1349 |
| B. TRINARY PRESSURE SENSOR |
1350 |
| C. INCAR SENSOR |
1350 |
| D. MODE ACTUATOR |
1351 |
| E. TEMPERATURE ACTUATOR |
1351 |
| F. FRESH AIR / RECIRCULATION ACTUATOR |
1351 |
| G. BLOWER CONTROL MODULE |
1352 |
| 11. COMPRESSOR |
1352 |
| 12. CONDENSER AND RECEIVER DRIER CONDENSER |
1353 |
| 13. TROUBLESHOOTING |
1354 |
| 14. MAINTENANCE |
1365 |
| A PRELIMINARY INSPECTION |
1365 |
| B. REGULAR MAINTENANCE |
1367 |
| 15. ON VEHICLE REPAIR |
1371 |
| A. AC FILTER REMOVAL AND ASSEMBLY |
1371 |
| B. CONTROL PANEL REMOVAL AND ASSEMBLY |
1371 |
| C. BLOWER MOTOR REMOVAL AND ASSEMBLY |
1372 |
| D. FRONT HVAC UNIT REMOVAL AND ASSEMBLY |
1373 |
| E. REAR VENT REMOVAL AND ASSEMBLY |
1375 |
| F. COMPRESSOR REMOVAL ANDASEMBLY |
1376 |
| G. CONDENSER REMOVAL AND ASSEMBLY |
1376 |
| 16. DO’S AND DONT’S FOR A/C SYSTEM |
1378 |
| SUPPLEMENTARY RESTRAINT SYSTEM
(SRS) |
1379 |
| 1.1. WORKING OF RESTRAINTS |
1381 |
| 1.2. SYSTEM LAYOUT |
1383 |
| 1.3. SAFETY PRECAUTIONS |
1384 |
| 1.4. DISPOSAL OF FAULTY AIR BAG UNIT |
1386 |
| 1.5. SRS POST ACCIDENT PROCEDURE |
1387 |
| 1.6. TIGHTENING TORQUES |
1388 |
| 1.7. COMPONENTS |
1392 |
| 1.7.1. RESTRAINT WITHOUT AIRBAGS |
1392 |
| 1.7.2. RESTRAINT WITH AIRBAGS |
1392 |
| 1.7.2.1. ECU |
1392 |
| 1.7.2.2. FRONT IMPACT SENSOR (FIS) |
1396 |
| 1.7.2.3. AIR BAGS |
1398 |
| 1.7.2.4. RPLL BELTS |
1400 |
| 1.7.2.5. CLOCK SPRING |
1403 |
| WHEELS AND TYRES |
1406 |
| 1.1 GENERAL INFORMATION |
1410 |
| A. SPECIFICATIONS |
1410 |
| B. CONSTRUCTION |
1411 |
| C. TIGHTENING TORQUES |
1413 |
| 1.2 GENERAL SYMPTOMS DIAGNOSIS |
1414 |
| A. DIAGNOSIS CHART |
1414 |
| B. TYRE WEAR PATTERN |
1416 |
| C. WEAR CAUSES |
1417 |
| D. TYRE VIBRATION DIAGNOSIS |
1418 |
| 1.3 MAINTENANCE, INSPECTION AND TESTS |
1419 |
| A. PRELIMINARY INSPECTION |
1419 |
| B. REGULAR MAINTENANCE |
1420 |
| I. INFLATION |
1420 |
| II. WHEEL BALANCING |
1420 |
| III. TYRE ROTATION |
1421 |
| IV. WHEEL RUN OUT |
1422 |
| V. DO'S AND DON’TS |
1422 |
| 1.4 WHEEL AND TYRE REPLACEMENT |
1423 |
| A. PRECAUTIONS DURING TYREREPLACEMENT |
1423 |
| B. TYRE REPLACEMENT |
1424 |
| C. WHEEL ASSEMBLY REPLACEMENT |
1424 |
| D. WHEEL REMOVAL |
1424 |