Workshop Manual Indica Workshop Manual Indica: Group Index

WORKSHOP MANUAL INDICA

GROUP INDEX

All specifications are given in C.G.S. System (Metric System) unless otherwise specified.

Reproduction or translation of the whole or part of the workshop manual without our written approval is prohibited.

Created by :

Tata Motors Ltd. PCBU - International Business. Mumbai

ii

Subject to modification in Design, Specification and Equipment.

GROUP INDEX

MAIN INTRODUCTION

INTRODUCTION:

This manual brings to you the technical know-how on the repairs and overhaul of Indica MPFI - Euro II cars, assuming that the workman is fully conversant with general automobile practices. The repair procedures outlined in this manual emphasize the special aspects of the product. This will enable you to build and maintain a reputation of quality service. The manual includes instructions on aggregates manufactured by Tata Motors. For repairs of proprietary aggregates such as Brakes, Power Steering, Airconditioning etc., the instructions of the respective proprietary manufacturers are included in this manual.The main idea behind incorporating these instructions in this manual is to enable workmen to understand their functions properly and thus judge the performance of the car as a whole. All data contained in this manual is based on the latest product information available at the time of publication.

How to use this manual : This manual is divided into 16 groups. Each group includes : • Technical specifications • Tightening torques • List of special tools • Disassembly / Assembly procedures • Use of special tools • Inspection of parts • Trouble shooting. The corresponding pages of each group are marked with black tabs & these lines up with one of the thumb index tab on the group index page. You can quickly find the first page of each group without looking through a full manual. The symbol printed at the top corner of each page can also be used as a quick reference system.

The right is reserved to make changes in design, specification and equipment at any time without notice. For any further technical advice or clarification please contact or write to : Tata Motors Ltd. Passenger Car Business Unit, International Business, Shivsagar Estate, Block-A, Dr. Annie Besant Road, Worli, Mumbai - 400 018. India.

GROUP INDEX

iii

GROUP INDEX GENERAL

G

ENGINE (475 SI MPFI) FUEL SYSTEM EXHAUST CLUTCH TRANSAXLE DRIVE SHAFT SUSPENSION BRAKES ABS MECHANICAL STEERING POWER STEERING WHEELS AND TYRES BODY AIR CONDITIONING ELECTRICAL DIAGNOSTICS

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GENERAL

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GENERAL

GENERAL

INTRODUCTION :

This manual provides the information on good workshop practices and safety precautions, chassis & aggregate numbering system, location of chassis & aggregate numbers, broad technical specification and filling capacities. It also provides information on fuel, lubricants and coolants required for Indica MPFI - Euro II cars. All lubrication & maintenance work should be carried out as recommended in this manual.

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G

GENERAL

GENERAL

CONTENTS Sr. No.

Description

Page No.

1.

Good workshop practices and safety precautions

1

2.

Lifting and jacking points

5

3.

Chassis Type No. & Sales designations

6

4.

Chassis Numbering System & Location

7

5.

Aggregate Numbering System & Location

8

6.

Technical Specifications

9

7.

Tightening Torques of Standard Bolts & Nuts

17

8.

Filling Capacities

18

9.

Fuel, Lubricants & Coolants (Details)

19

10.

Branded Lubricants and Coolants / Recommended Oils, Lubricants

20

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GENERAL

G GENERAL

GOOD WORKSHOP PRACTICE & SAFETY PRECAUTIONS Following are some safety precautions to be observed in the workshop. l

Always ensure that all the repair / maintenance work carried out should be as per the instructions provided in the workshop manual.

l

Use protective clothing, apron, hand gloves, and safety shoes while working in the workshop. Do not wear watch, rings and belt while serving the vehicle.

l

Keep your work area, equipment and tools clean at all times.

l

Make sure you use the proper tool for the job and use it the rightway. The improper tool or its incorrect use can damage the part you are working on or cause injury or both.

l

Never keep the tools on the floor/vehicle. The tools should be kept in the tool box after use.

l

Cover fenders, seats, steering wheel and any other parts those are likely to get scratched/soiled before starting any service work (Fig. 1).

l

While servicing the vehicle in engine running condition make sure that the gear shifting lever is in neutral position and parking brake is fully applied. Never run the engine without proper ventilation and adequate means of getting rid of exhaust gases.

l

Do not work near the radiator fan when engine is ‘ON’ to avoid getting injured by electrically operated radiator fan.

l

Prior to removing or disassembling parts, they must be inspected carefully to isolate the cause for which the service is called for (Fig. 2).

l

All the reusable dismantled components must be kept in a clean enamel coated white tray sequentially in an orderly manner to facilitate their accurate and proper reinstallation (Fig. 3).

l

Never reuse the parts like oil seals, gaskets, packing, O-rings, locking washers, split pins, self locking nuts and certain other parts.

l

Plug the ports / openings of aggregates such as FIP / Injectors, TMC, etc., whenever removed from the car.

Fig. 1

Fig. 2

Fig. 3

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1

GENERAL For correct reinstallation of vacuum fuel hoses attach a tag describing the correct positions (Fig. 4).

l

Make sure only the branded lubricants, coolant, corrosion protection coatings and sealants are used. To ma inta nif ke old

l

To Ca nis te r

GENERAL

G

Fig. 4 l

Check all the lines for leaks related to the systems like fuel, oil, coolant, vacuum, exhaust and brakes after servicing (Fig. 5).

Fig. 5 Precaution for Catalytic Converter (MPFI Petrol Engine) : (Fig. 6). Caution : If large amount of unburnt fuel goes into the converter, it may overheat and creat a fire hazard. To prevent this, observe the following precautions. l

Use only unleaded gasoline.

l

Engine compression checks should be carried out within the shortest possible time only.

l

If necessary then only conduct a spark jump test within the shortest possible time.

l

Do not run the engine when the fuel tank is nearly empty to avoid engine misfire and damage to catalytic converter.

Fig. 6 2

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GENERAL

G GENERAL

Precaution for Electrical circuit service : l

Disconnect the negative cable of the battery while servicing the electrical parts that do not require battery power (Fig. 7).

l

While removing the battery first disconnect the negative cable and then the positive cable. While reinstalling the battery, first connect the positive cable and then negative cable.

Fig. 7 l

Be sure to turn the ignition switch off before disconnecting and connecting coupler to avoid electronic parts damage (Fig. 8).

l

Do not touch the electrical terminals of parts which use microcomputers (e.g. electronic control units like ECM etc.) to avoid damage to these parts from static electricity from your body (Fig. 8).

l

Always use the correct voltmeter, ohmmeter for taking measurement to avoid damage to the electronic control unit and sensors.

l

Make sure to insert the probe from wire harness side of the connector for taking measurement.

Fig. 8 l

Make sure the connector halves are mating properly and terminals seating precisely in the connector body (Fig. 9).

Fig. 9

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3

GENERAL GENERAL

G

l

Dirt / corroded terminals result in improper contact. The terminals should be cleaned carefully.

l

Improper contact pressure between mating terminals disturbs the connectivity between them.

l

Replace the damaged connector body to avoid exposure of the terminals in case of inadequate contact pressure.

l

Ensure proper connection between the terminal to the wire. Rectify the loose connection by repairing / replacing the wire harness (Fig. 10).

l

Worn out insulation of the wire may result in short circuit.

l

Avoid water entering the connectors.

Fig. 10 Towing the Vehicle : (Fig. 11a & 11b). l

For towing a car, the best way is to use a wrecker. Alternatively use a rigid tow bar.

l

Avoid using a flexible cable or rope as your car may crash into the car towing your car when it stops suddenly.

l

Switch ‘ON’ the hazard warning signals of both the cars to warn other road users.

l

Where possible, keep the engine idling so that power steering assistance and brake vacuum are available.

l

Limit the speed to 20-30 Kmph.

l

In case of brake failure, use the parking brake to control the car.

Towing hook front

Fig. 11a Rear Tow Hook : l

Boltable tow hook is provided in the toolkit.

l

Remove cover on rear bumper.

l

Bolt the tow hook (ensure proper fitment).

l

Whenever tow hook is not required unscrew the tow hook and keep it in toolkit.

l

Press the cover to close the hole for tow hook in rear bumper.

Cover tow hook

Rear tow hook

Fig. 11b 4

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GENERAL

G GENERAL

LIFTING AND JACKING POINTS

Rear LH

Rear RH

Front LH

Front RH

Fig. 12 USING THE HOIST Make sure you follow the hoist manufacturers instructions while lifting the car on two pole hoist (Fig. 12). Always ensure vehicle balance in service while applying hoist to under body. Care should be taken that the hoist arm is not in contact with the bracket, brake or fuel pipes etc. Before servicing, make sure to lock the hoist after the vehicle is lifted up. When using the floor jack : Use the jacks at the locations indicated (Fig 13). Rear Jacking Point

Do not apply the jack against any part which may get deformed. If front end or rear end of the vehicle is to be jacked ensure the wheels on ground are blocked with wheel chocks for safety.

Front Jacking Point

Fig. 13

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5

GENERAL

G

CHASSIS TYPE NO. AND SALES DESIGNATIONS GENERAL

CHASSIS TYPES PETROL VERSIONS Chassis

Sales Designation

Description

600 234

INDICA LEi

Indica car with MPFI 75 PS, Euro-II, Petrol Engine, Power Steering, heating demist.

600 206

INDICA LSi

Indica car with MPFI 75 PS, Euro-II, Petrol Engine, Power Steering, HVAC.

600 260

INDICA LX

Indica car with MPFI 85 PS, Euro-II, Petrol Engine, Power Steering, HVAC, DAB & ABS.

600 261

INDICA LXi

Indica car with MPFI 85 PS, Euro-II, Petrol Engine, Power Steering, HVAC, DAB, PAB & ABS.

6

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GENERAL

G GENERAL

CHASSIS NUMBERING SYSTEM & LOCATION (for location see fig. 14) Chassis number consists of 17 digits as given below : MAT

XXXXXX

X

X

X

XXXXX

Indicates produced in TATA Motors Limited, India Chassis type No. (Model, execution wheel base etc.)

Serial No. to start every year with 00001 on First April

Year of Production

Drive Type - R - For RHD L - For LHD

Year 1.4.2003 to 31.3.2004 1.4.2004 to 31.3.2005 1.4.2005 to 31.3.2006 1.4.2006 to 31.3.2007 1.4.2007 to 31.3.2008

Code 4 5 6 7 8

Plant location P For K Block, Pune

Example : MAT 600 260 4PR 00065 indicates Indica MPFI 85 PS, Euro-II, Petrol Engine, Power Steering, HVAC, DAB & ABS, produced between 1.4.2003 to 31.3.2004 in K-block Pune, Right hand drive for export and Sr. No. of the car is 00065.

CHASSIS NUMBER (on dashboard corner)

Chassis No.

VIN No.

Fig. 14

Engine Number

Fig. 15

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GENERAL GENERAL

G Barrel

AGGREGATE NUMBERING SYSTEM & LOCATION: (for location see fig. 15) ENGINE : Numbering XXXXX

XX

1 Barrel

2 1

3 4

XX

X

5

6

XXXXX 7

: Indicates engine model

475 SI Barrel

X X

: For MPFI engine 2

: Variation in basic model

45

: 475 SI Injected type petrol engine, 85 PS, @ 5500 rpm, MPFI, meeting EURO-III emission norms.

Barrel

3

: ‘L’ in case of LHD executions Punching of ‘L’ is not required if engine is same for RHD and LHD executions.

Barrel

4

: Month of production.

Month

Code

Month

Code

Month

Code

January

A

May

E

Sept.

J

February

B

June

F

October

K

March

C

July

G

Nov.

L

April

D

August

H

Dec.

M

Barrel

5

: Year of production

WZ VZ UZ TZ

-

For 2003 For 2004 For 2005 For 2006

SZ

- For 2007

Barrel

6

: Indicates plant location. P - for ‘K’ block, pune

Barrel

7

: Serial No. Indicates Serial No. Of engine. The barrel consists of 5 digits and commences from serial number 00001 & will start every year on first January.

1

: Indicates basic model 21 For TA 65 Transaxle Barrel 2 : First digit indicates control of vehicle as below : 1 - For normal control vehicle 3 - Full forward control vehicle Second digit indicates first and second gear speed ratio with version of gear box as below Eg. : F - for first gear ratio 3.42 / second gear ratio 1.95 with 5 gear version, Gear final 65/14 with speedo ratio 19/17. Barrel 3 : Indicates year of production 3 for - 2003 4 for - 2004 5 for - 2005 6 for - 2006 7 for - 2007 Barrel 4 : Indicates plant location P for ‘K’ Block Pune Barrel 5 : Indicates Serial no. of Transaxle, consists of 5 digits and commences from serial no. 00001 and will start every year on first January. Example - 211F 3P 00005 BODY SHELL : Numbering XX X X XXXXX 1 2 3 4 Barrel 1 : - Indicates, Basic model M1 for Indica MPFI - Euro III Barrel 2 : - Indicates year of production 3 for 2003 4 for 2004 5 for 2005 6 for 2006 7 for 2007 Barrel 3 : - Indicates plant location P for K Block Pune Barrel 4 : - Indicates cumulative serial number to start every year with 00001 on first January. Example : M1 3P 00001

Example 475 SI 45 FWZ P 00451 TRANSAXLE : NUMBERING (for location see fig. 16) XX

XX

X

X

1

2

3

4

XXXXX Transaxle Number

5

Fig. 16 8

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GENERAL

G GENERAL

TECHNICAL SPECIFICATIONS VEHICLE

LEi & LSi

LX & LXi

1. ENGINE

:

Petrol

Petrol

Model

:

''TATA 475 SI'' 43 (75 PS)

''TATA 475 SI'' 44 (85 PS)

Type

:

Petrol Engine, Water cooled multi point fuel injection system

Petrol Engine, Water cooled multi point fuel injection system with catalytic converter

No. of Cylinders

:

4 inline

4 inline

Bore / Stroke

:

75 / 79.5 mm

75 / 79.5 mm

Capacity

:

1405 cc

1405 cc

Max. Engine Output

:

55.2 KW @ 5500 rpm as per ISO 1585

62.5 KW @ 5500 rpm as per ISO 1585

Maximum Torque

:

110 Nm@ 3000 rpm as per ISO 1585

115 Nm @ 3000 rpm as per ISO 1585

Compression Ratio

:

9.5:1

9.5:1

Firing Order

:

1-3-4-2

1-3-4-2

Single plate dry friction diaphragm type.

Single plate dry friction diaphragm type.

2. CLUTCH

Outside diameter of Clutch lining

:

190 mm

190 mm

Friction Area

:

285 sq.cm.

285 sq.cm.

Front wheel drive through constant velocity joints

Front wheel drive through constant velocity joints

3. TRANSAXLE

Model

:

TA 65-5/3.42 (5 speed) with overdrive

TA 65 -5/3.42 (5 speed) with overdrive

Type

:

Synchromesh on all forward gears. Sliding mesh for reverse gears

Synchromesh on all forward gears. Sliding mesh for reverse gears

No. of gears

:

5 forward 1 reverse

5 forward 1 reverse

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GENERAL GENERAL

G

VEHICLE

LEi & LSi

LX & LXi

Gear ratios

:

1st - 3.42 2nd - 1.95 3rd - 1.36 4th - 0.95 5th - 0.77 REV. - 3.58

3.42 1.95 1.36 0.95 0.714 3.58

Final drive ratios

:

4.06

4.64

Gear shift

:

Floor mounted with international “H” pattern with fifth and reverse inline. (in all models)

4. REAR AXLE

:

Non driven axle independently suspended. (in all models)

Front

:

Independent, Lower wishbone, McPherson Strut type (in all models)

Rear

:

Independent, Semi-trailing arm with coil spring mounted on hydraulic shock absorbers. (in all models)

Antiroll Bar

:

At front

At front

Type

:

Hydraulic assisted Powerl Rack & Pinion Steering Gear with collapsible steering column

Hydraulic assisted power Rack & Pinion Steering Gear with collapsible steering column

Steering Wheel

:

380 mm dia.

380 mm dia.

Service Brakes

:

Dual circuit, diagonal split hydraulic brakes through tandem master cylinder.

Dual circuit, diagonal split hydraulic brakes through tandem master cylinder, vacuum assisted 9'' Booster. ABS :Standard (can be optional)

Front Brakes

:

231 mm dia., 17mm thick, ventilated disc brake

231 mm dia., 20mm thick. ventilated disc brake

Rear Brakes

:

180 mm dia. drum brake

200 mm dia. drum brake

Parking Brakes

:

Lever type, Console mounted, Cable operated mechanical linkage acting on rear wheel. (in all models)

5. SUSPENSION

6. STEERING

7. BRAKES

10

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VEHICLE

LEi & LSi

LX & LXi

GENERAL

8. WHEELS AND TYRES Tyres

:

165/65 R13

175/60 R14

Wheel Rims

:

4.5 J x 13 Stylised steel rims

5 J x 14 steel rims

No. of Wheels

:

Front - 2, Rear - 2, Spare - 1

Front - 2, Rear - 2, Spare - 1

:

37 litres

37 litres

:

Semi-mono Volume, Mini size, 5 door hatchback, steel monocoque body with coated sheets

Semi-mono Volume, Mini size, 5 door hatchback, steel monocoque body with coated sheets

9. FUEL TANK Capacity

10. BODY

Other Body Features Side Impact Protection Beams in Front & Rear Door Assemblies Energy Absorber at Front & Rear Bumpers Bumber, Outer Door Handles & ORVM (Foot & HSG) painted in Body Colour. Body Coloured Bumpers with Black Emboss ''B'' Piller Exteriar (Between Front & Rear Doors) in Black Colour splash Guard Below the Bumper

11. ELECTRICAL SYSTEMS

:

12 Volts -ve earth

12 Volts -ve earth

Battery

:

12V, MF 40 (high density)

12V, MF 40 (high density)

Alternator Capacity

:

12V 75 Amps

12V 90 Amps with internal fan

Starter Motor 0.8 kW

Starter Motor 0.8 kW

155 Kmph

160 Kmph

Other standard Equipment :

12. PERFORMANCE Max. speed at rated GVW

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GENERAL GENERAL

G

VEHICLE

LEi & LSi

LX & LXi

13. MAIN CHASSIS DIMENSIONS AS PER ISO : 612 IN MM (NOMINAL) (Fig. 17). (TOLERANCES AS PER INTEREUROPE STVZO) Wheel Base

:

2400

2400

Track Front

:

1400

1380

Track Rear

:

1380

1374

Front Overhang

:

785

785

Rear Overhang

:

490

490

Overall Length

:

3675

3675

Max. Width a) Over body b) Over outer rear view mirror in folded condition

: :

1665 1915

1665 1915

Overall Height (Unladen)

:

1485 - Unladen

1500 - Unladen

Minimum Turning Circle Dia :

9.8 m

9.8 m

Minimum Turning : Clearance Circle Dia Ground Clearance (Unladen) :

10.2 m

10.2 m

166 mm - unladen

165 mm - unladen

14. WEIGHTS (kg) (TOLERANCES AS PER EEC 92/21) Complete vehicle kerb weight as per ISO : 1176 (with spare wheel & tools)

:

1005

1045

Gross Vehicle Weight

:

1405

1445

Payload

:

400

400

Net inside loadings space

:

0.22 Cubic Meter Upto rear seat back rest 0.61 Cubic Meter Upto front seat back rest when rear seats folded

0.22 Cubic Meter Upto rear seat back rest 0.61 Cubic Meter Upto front seat back rest when rear seats folded

16. PASSENGER CAPACITY

:

2 Front + 3 Rear

2 Front + 3 Rear

15. LUGGAGE SPACE

12

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VEHICLE

LEi & LSi

GENERAL

LX & LXi

17. EXCLUSIVE CHASSIS FITMNETS Power Steering

:

Standard

Standard

Radial ply tyres

:

Standard

Standard

Steering Wheel

:

Four spoke soft feel

Four spoke soft feel (pu) with leather grip

18. EXCLUSIVE ELECTRICAL ITEMS Windshield Wiper (Front) Intermittent working

:

Standard

Standard

Motorised Head lamp levelling device

:

Standard

Standard

Halogen head lamps with turn signal lamp

:

Clear Lens

Clear Lens

Hazard flashing lights

:

Standard

Standard

Roof lamp delayed turn-off :

Not provided

Standard (incorporetes spot (Reading) lamp)

Engine compartment light

Not provided

Standard

Luggage compartment light :

Standard

Standard

Car Radio cum cassette player

:

Provision in wiring harness Available

Provision in wiring harness Available

Windshield mounted internal antenna

:

Standard

Standard

Tripmeter

:

Standard

Standard with Markings in Kms

Digital Clock (Quartz)

:

Standard

Standard

Water Temperature indicator :

Standard

Standard

Engine oil low pressure indicator lamp

:

Standard

Standard

Brake fluid low level warning lamp + Parking brake warning lamp.

:

Standard

Standard

RPM Meter

:

Standard

Standard

Panel light dimmer and facia switches

:

Instrument light dimmer & facial switches standard

Instrument light dimmer & facial switches standard

Seat belt warning lamp for Driver

:

Not provided

Standard + Audo warning (with Reduced Volume)

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GENERAL GENERAL

G

VEHICLE

LEi & LSi

LX & LXi

Rear fog lamp

:

Not Provided

Standard

Key IN, Parking lamp ON Audio Warning

:

Not Provided

Standard

Side repeater lamp

:

Standard

Standard clear lens with Amber bulbs

Fuel Gauge

:

Standard

Standard

Battery charge indication lamp

:

Standard

Standard

Horn

:

High & Low tone

High & Low tone

REAR WIPER/WASHER : with Defogger on Rear Glass

Standard

Standard

Motorised Head lamp levelling device

:

Not Provided

Standard

High Mounted stop lamp (Spoiler mounted)

:

Standard

Standard

Low Fuel warning lamp

:

Standard

Standard

Immobiliser

:

Standard with Remote Sense

Standard with Remote Sense

Tail lamp and rear registration plate lamp

:

Standard

Registration Plate Lamp Standard Direction Indicator with Clear Lens and Amber bulb Other Standard Items/Features Spot (Reading) Lamp in Cabin Lamp Security System on Indicator

Mobile Charger Socket

:

Standard

Standard

Remote release for tailgate : opening

Standard

Standard

Remote Release for fuel filler cap

:

Standard

Standard

Vanity Mirror on Sunvisor on : co-driver side

Standard

Standard

Ash Tray : Front

:

Standard

Standard

Ash Tray : Rear

:

Not provided

Standard

Console

:

Full size

Full size

Height adjustable front headrest

:

Standard

Standard

19. EXCLUSIVE BODY FITMENTS

14

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VEHICLE

LEi & LSi

Integral Head Rest for Rear Seats

LX & LXi

GENERAL

:

Standard

Standard

Outside left rear view mirror :

Standard

Standard on Driver & Co-Driver side with manual adjustment facility from inside

Rear seat (Somersaulting)

:

40:60 Split Type with Integral Head Rest, Double Folding and Cushion

40:60 Split Type with Integral Head Rest, Double Folding and Cushion

Front seat belt with retractor

:

Standard

Standard

Inner rear view mirror

:

Anti Glare

Anti Glare

Central Locking

:

Not provided

Standard

Heating element on tailgate : glass & rear wiper with wash

Provided

Standard

Power windows Front & Rear

:

Not provided

Standard (For Both Front & Rear)

Air Conditioner

:

-

Parts of HVAC

Heating Demisting

:

Standard for LEi version

Parts of HVAC

Heating Ventilation & Air Conditioning (HVAC)

:

Standard (for LSi version)

Comprehensive HVAC system with cabin air outlet valve

Cigarette Lighter

:

-

Provision through power socket

Reflex Reflectors on the doors

:

Standard

Standard

Child safety lock on rear doors.

:

Standard

Standard

wheel Covers

:

Full Size

Full Size

Parcel Shelf

:

Standard

Standard

Rear seat belts

:

Standard, 3 point belts for outboard passengers & Lap belt for middle passenger (for both vehicle)

Drive side Air Bag

:

Not provided

Standard

Passenger side Air Bag

:

Not provided

Standard only for LXi, not provided on LX

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15

785 mm

INDEX 490 mm

1485 mm (LEi/LSi) & 1500 mm (LX/LXi) 1665 mm

16

GROUP INDEX 3675 mm

2400 mm

MAIN CHASSIS DIMENSIONS

1380 mm (LEi/LSi) 1374 mm (LX/LXi)

1400 mm (LEi/LSi) 1380 mm (LX/LXi)

GENERAL

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GENERAL

Fig. 17

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unladen

GENERAL

G GENERAL

TIGHTENING TORQUES OF STANDARD BOLTS & NUTS Wherever the tightening torques are not specified use the following values for these fastners. Grade

Bolt or Nut Size

Pitch (mm)

Tightening N-m

Torque kg M

M6

1.0

8.5 - 10

0.85 - 1.0

M8

1.25

21 - 25

2.1 - 2.5

M10

1.5 1.0

41 - 51 46 - 56

4.1 - 5.1 4.6 - 5.6

M12

1.75 1.5

72 - 88 75 - 91

7.2 - 8.8 7.5 - 9.1

M14

2.0 1.5

113 - 138 126 -154

11.3 - 13.8 12.6 - 15.4

M16

2.0 1.5

176 - 215 189 - 231

17.6 - 21.5 18.9 - 23.1

M6

1.0

12 - 14

1.2 - 1.4

M8

1.25 1.0

29 - 35 32 - 39

2.9 - 3.5 3.2 - 3.9

M10

1.5 1.0

58 - 70 64 - 78

5.8 - 7.0 6.4 - 7.8

M12

1.75 1.5

99 - 121 104 - 127

9.9 - 12.1 10.4 - 12.7

M14

2.0 1.5

162 - 198 176 - 215

16.2 - 19.8 17.6 - 21.5

M16

2.0 1.5

248 - 303 266 - 325

24.8 - 30.3 26.6 - 32.5

Bolt 8.8 Nut 8.0

Bolt 10.9 Nut 10.0

1. This standard is applicable to bolts having the following marks embossed on the bolt head and punch mark on the nut head. Grade 8.8 For The Bolt 10.9 For The Bolt 8 For The Nut 10 For The Nut Note : Always use the calibrated torque wrenches.

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GENERAL GENERAL

G

FILLING CAPACITIES

ENGINE OIL UPTO DIPSTICK MAX.MARK @ 4.0 Litres FUEL TANK CAPACITY @ 37 Litres

* PREMIXED READY TO USE ENGINE COOLANT @ 6 Litres WINDSHIELD WASHER RESERVOIR . With Front & Rear Washer @ 3.5 Litres . With Only Front Washer @ 1.5 Litres

BRAKE FLUID @ 0.270 Litres

TRANSAXLE OIL @ 3.3 Litres

TYRE SIZE

TYRE (TUBELESS) PRESSURE FRONT

REAR

175/60 R 14

28 psi (1.9 bar)

24 psi (1.6 bar)

165/65 R 13

30 psi (2 bar)

28 psi (1.9 bar)

IMPORTANT : For petrol cars fitted with Catalytic Converter always use only unleaded petrol with an octane rating of not less than 91 RON

* If concentrated antifreeze agent is used mix it with soft water in the ratio of 50:50.

Fig. 18

18

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GENERAL

G GENERAL

FUEL, LUBRICANTS & COOLANTS (Details) Fuel : For Petrol car (with catalytic converter)

Transaxle :

Unleaded regular grade petrol conforming to SABS 1598 (or equivalent) and octane rating not less than 91 RON (RON stands for Research Octane Number) is recommended to be used as fuel.

Use recommended brand of gear oil 75W90 GL4 Synthetic

Do not use leaded petrol in a car fitted with catalytic converter.

Brake fluid :

Even single fill of leaded petrol will seriously damage the catalytic converter.

Grease for axle bearings : Lithium base complex grease

IS 8654/DOT 4 Power Steering : ATF 206/ Dexron Coolants :

Lubricants:

Presence of dirt in the coolant chokes up passages in the radiator,

Engine oil (Petrol Engine) : Recommended grade of engine oil conforming to 10W40 API SL (ACEA A2/B2) specification and range of ambient temperature at which these can be used are given in the table below.

cylinder head and cylinder block, thereby causing insufficient cooling of engine.

Ambient Temp. in deg. C

Engine oil grade

To prevent rust formation and freezing of coolant inside the

-20 deg. to 40 deg.

SAE 10W/40

passages of radiator, cylinder block and cylinder head, use only

Below -20 deg.

SAE 5W/30 or Lower viscosity grade

branded premixed engine coolant. Engine Coolant Antifreez : Coolant as per class II, JIS K 2234

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19

GENERAL GENERAL

G

BRANDED LUBRICANTS & COOLANTS : USE ONLY GENUINE ENGINE OILS, COOLANTS AND OTHER LUBRICANTS RECOMMENDED BY TATA FOR OPTIMUM PERFORMANCE

RECOMMENDED OILS, LUBRICANTS AND FILLING CAPACITIES AGGREGATE

SPECIFICATION

FILLING CAPACITY

Engine

(-200 to 400C) 10W40 API SL (ACEA A2/B2)

4.0 Litres

0

(below -20 C ) SAE 5W/30 or Lower viscosity grade Transaxle

SYNGEAR EP 75W 90 GL4

2.9 Litres

Power Steering

ATF Type A 206 / Dexron

1.2 Litres

Brake Fluid

IS 8654/DOT 4

0.270 Litres

Wheel Bearing

Lithium base complex grease

110 gm

Coolant

Class II JIS k 2234 (50:50)

6 Litres

Clutch release

Multipurpose grease LIT MP

As required

20

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ENGINE (475 SI MPFI)

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ENGINE 475 SI MPFI

ENGINE

INTRODUCTION :

Tata Indica (Petrol) is available in 4 versions namely LEi, LSi, LX & LXi. LX & LXi are powered by 475 MPFI engine which produces 85 PS @ 5500 rpm and a torque of 115 Nm @ 3000 rpm. LEi & LSi are powered by 475 MPFI engine which produces 75 PS @ 5500 rpm and a torque of 110 Nm @ 3000 rpm. Tata 475 SI MPFI is a spark ignition multipoint fuel injection water cooled, petrol engine with SOHC (Single OverHead Cam) valve mechanism in ‘V’ type arrangement. All inlet valves on one side & all exhaust valves on other side. 475 MPFI engine is fitted with 16 Bit inbuilt microprocessor intelligence into the engine control system. 475 MPFI engine provides better engine performance, better cold starting and warm up, better fuel economy, quick response and confirms the EURO II emission norms.

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i

ENGINE 475 SI MPFI CONTENTS Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

19. 20.

21.

22. 23. 24. 25. 26. 27. 28. 29. 30.

Description

Page No.

Technical specifications List of special tools Tightening torques Carburetted engine vs MPFI engine MPFI engine advantages MPFI schematic circuit diagram Features of MPFI engine MPFI sensors / actuators Intank fuel pump Ignition Coil Assembly ECU Trouble shooting of MPFI sensors ECU Handling & care Preliminary inspection of engine Exploded Views Removal & installation of engine from the car Radiator, removal and installation Alternator/Power steering pump & A. C. compressor belts removal, inspection, & fitment a. For 85 PS Engine b. For 75 PS Engine Timing belt Removal / Fitment Cylinder Head Sub-assembly a. Disassembly, inspection of Rocker shafts & arms, spark plug camshaft, valves, valve guides, valve seats and valve seat inserts b. Assembly of cylinder head c. Valve clearance adjustment Cylinder block sub assembly a. Disassembly, inspection & assembly of : Pistons & piston rings, Connecting rods, Crankshaft, cylinder block, oil pump, water pump, thermostat assembly b. Removal, installation & machining of cylinder liners Lubrication system Cooling system Air intake system Air cleaner Accelerator Cable Assembly Foot Control Engine Testing Evaporative Emission Circuit Trouble Shooting

ENGINE

1 2 3 6 7 8 9 12 26 27 30 32 36 37 40 58 60 61 63 64

67 82 84 87 101 103 105 113 114 115 116 117 118 119

Note : This section is common for both 85 PS & 75 PS engines, but following pages are exclusive for respective engines: l

For 85 PS : 41, 51, 56 & 61

INDEX

l

For 75 PS : 42, 50, 57 & 63. Please also check page no. 65 for selection of camshaft.

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iii

ENGINE 475 SI MPFI TECHNICAL SPECIFICATION ENGINE

ENGINE

Model

:

TATA 475 SI MPFI

Type

:

Water cooled Multi Point Fuel Injection Petrol Engine

No. of cylinders

:

4 inline

Bore / Stroke

:

75 mm x 79.5 mm

Capacity

:

1405 cc

Max. engine output (For LX & LXi) (For LEi & LSi)

: :

85 PS (62.5 kw) at 5500 rpm as per ISO : 1585 75 PS (55.2 kw) at 5500 rpm as per ISO : 1585

Max. torque (For LX & LXi) (For LEi & LSi)

: :

115 Nm at 3000 rpm as per ISO : 1585 110 Nm at 3000 rpm as per ISO : 1585

Compression ratio

:

9.5 : 1

Firing order

:

1-3-4-2

Fuel system

:

Grouped Injection with close loop Air / Fuel control supported by Hitachi EMS

Ignition system

:

Grouped Ignition supported by Hitachi EMS

Emission compliance

:

EURO II

Engine oil capacity

:

4 Litres

Cooling system capacity

:

6 Litres

Air filter

:

Dry (paper) type

Oil filter

:

Spin on full flow paper type

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1

ENGINE 475 SI MPFI LIST OF SPECIAL TOOLS ENGINE

Sr. No.

Description

Part No.

1.

Box spanner (16 A/F) for spark plug

2702 5890 06 01

2.

Extended socket (10mmA/F) for oil sump mounting screw

2702 5890 06 03

3.

Camshaft Locking Pin

2702 5890 06 04

4.

Flywheel locking pin

2702 5890 06 05

5.

Lock plate for camshaft gear washer

2702 5890 06 07

6.

Drift for crankshaft oil seal in rear cover

2702 5890 06 08

7.

Drift for removal / fitment of valve guide

2702 5890 06 11

8.

Spacer for valve guide fitment

2702 5890 06 12

9.

Drift for fitment of oil seal on valve guide

2702 5890 06 14

10.

Valve spring compressor

2702 5890 06 15

11.

Support rail

2702 5890 06 16

12.

Drift for valve guide seal fitment

2702 5890 06 17

13.

Drift for oil pump oil seal

2702 5890 18 01

14.

Spanner for oil filter

2702 5890 18 02

15.

Bracket (LH) for mounting engine on stand

2702 5890 24 02

16.

Bracket (RH) for mounting engine on stand

2702 5890 24 03

17.

Engine repair stand

2573 5890 24 01

18.

Drift for fitment of camshaft oil seal

2654 5890 05 08

19.

Engine support stand

2702 5890 24 01

20.

Hitachi HDM 2000 diagnostic monitor with accessories and Telco cartridge 1.20

2932 9900 60 54

2

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ENGINE 475 SI MPFI TIGHTENING TORQUES : The fasteners should be tightened to specified torque at recommended intervals (km). If various fasteners are not tightened to specified torques, that is either over tightened or let loose, it will result in leakage at joints and damage to the parts/threads. It will also adversely affect the performance of the parts/systems as clearances/ bearing plays in the aggregates are governed by the tightening torques of the fasteners. When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths of its capacity. Before tightening, clean the threads and apply a little oil. Serial No.

Description

Torque in mkg.

1.

Main Bearing Cap bolt M10 x 1

5.5 #

2.

Cylinder head bolts M10 x 1.1

3, 5, 7.5 (Ref. Note) #

3.

Spark plug in cylinder head M14 x 1.5

4.

Cylinder head cover bolts M6

5.

Oil sump Screw M6 x 1

6.

Sealing plug for oil gallery block rear M14 x 1.5

3.5

7.

Oil sump drain plug M12 x 1.5

3.5

8.

Rear timing cover to block M6 x 1

1.0

9.

Rear timing cover to head cover M6 x 1

1.0

10.

Timing belt cover M6 x 1

1.0

11.

Rear cover crank case on cylinder block screw M6 x 1

1.0 #

12.

Connecting rod cap Nut M9 x 1

5.25 #

13.

Flywheel mounting screw M10 x 1

5.0 #

14.

Crankshaft gear to crankshaft bolt M14 x 1

15.

Vibration damper / 4 groove A/C pulley to crankshaft gear

2.5

16.

Belt tensioner adjuster bolt M10 x 1.5

3.0

17.

Cam thrust plate

1.0

18.

Timing belt idler to cylinder block bolt M10 x 1.5

19.

Camshaft gear to camshaft screw M12 x 1.25

8.0

20.

Lock Nut (Rocker adjusting screw) M9 x 1

3.5

21.

Assembly Fuel feed pump on cylinder head screw M8 x 1.25

2.0 #

22.

Exhaust manifold mounting bolts on cylinder head M8 x 1.25

2.0 #

23.

Starter motor on Transaxle bolt M8 x 1.25

2.4

24.

Alternator bracket to cylinder crankcase M8 X 1.25

2.0

25.

Alternator to bracket M10

2.0

INDEX

2.5 1.0 # 0.6 to 0.7 #

GROUP INDEX

4+60 0 #

4.5 #

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3

ENGINE

ENGINE 475 SI MPFI Serial No. ENGINE

Description

Torque in mkg.

26.

Adapter to cylinder head Stud M6 x 1

2.0 #

27.

Alternator tensioner bracket to block M8 x 1.25

2.0

28.

Alternator to tensioner bracket screw M8 x 1.25

1.5

29.

Oil pump on cylinder block

30.

Assembly Strainer to oil pump M6 x 1

31.

Assembly oil filter to cylinder crankcase M12 x 1.5

32.

Oil pressure switch on cylinder crankcase M20 x 1.5

33.

Water pump to cylinder crankcase screw M6 x 1

1.0 #

34.

Water outlet elbow to intake manifold Nut M6 x 1

1.0 #

35.

Water inlet elbow to cylinder crankcase screw M8 x 1.25

2.0

36.

Temperature Transducer on cylinder head M14 x 1.5

1.5

37.

Water inlet elbow to intake manifold nut M6 x 1

1.0

38.

Thermostat cover to intake manifold nut M6 x 1

1.0

39.

Lifting hooks to cylinder head screw M8 x 1.25

2.5

40.

Engine mounting bracket to block M10 x 1.5

4.5

41.

Engine mounting bracket to arm

4.0

42.

Power steering pump mounting on bracket screw M8 x 1.25

2.5

43.

A/C Compressor bracket to cylinder block screw M8 x 1

2.5

44.

A/C Compressor to A/C compressor bracket bolt M8 x 1.25

2.5

45.

Power steering pulley to power steering pump Nut M12 x 1.25

8.0

46.

Assembly Idler to Slider (A/C compressor belt tensioner) Nut M8 x 1.25

2.5

1.0 # 1.0 Ref. Note @ # 3.0

Tolerance on Torque values + 5% for those marked # and + 10% for others Note @ Apply oil on seal face and screw in until seal touches face. Tighten further by 3/4 turn. Do not over tighten.

4

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INDEX

GROUP INDEX Power Steering Pump

85 PS ENGINE

Vibration Damper

AC Compressor

Timing Cover

Exhaust Manifold

Cylinder Head Cover

Alternator

Cylinder Block

Throttle Body

Inlet Manifold

Oil Filling Cap

Vibration Damper

AC Compressor

Timing Cover

Exhaust Manifold

ENGINE 475 MPFI - EURO II

Alternator

Cylinder Block

Throttle Body

Oil Filling Cap Inlet Manifold

75 PS ENGINE

Power Steering Pump

Cylinder Head Cover

ENGINE 475 SI MPFI

ENGINE

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5

ENGINE 475 SI MPFI

ENGINE

CARBURETTED ENGINE V/s MPFI ENGINE

Primary main jet

Typically a carburetted engine differs from petrol injected engine in following aspects.

Slow air hole no. 1

l

Fuel Metering

l

Ignition System

l

Cold Start

l

Change in Atmospheric Condition Response (Altitude, Temperature etc.)

Primary slow jet

Carburetted Engine : (Fig 1). l

l

In this case fuel metering is done by carburettor i.e. fuel quantity is controlled by fuel jet and air flow into the engine due to the vacuum available at the venturi. Fuel quantity is a continuously variable function with respect to air flow. Ignition system consists of a Distributor driven by a camshaft. The Distributor timing is a continuously variable function as engine speed and load changes. Due to Mechanical make/break system, the Ignition energy is low (low dwell time) at high speeds.

Bypass port Primary main jet Idle port

Fig. 1 Carburettor system - illustration 2 1. Fuel 2. Air 3.Throttle valve 4. Intake manifold 5. Injector 6. Engine

1

5

3

Petrol Injected Engine : l

l

In this case fuel delivery to the engine is through one or more than one Injectors. (See illustration for Single point and Multipoint fuel injection System Fig. 2). The amount of fuel going into the engine is controlled by an ECU depending upon engine speed and load. The fuel delivery is not a continuously variable function but a discrete function as ECU calculates optimum fuel quantity required for any speed and load condition of the engine. The correction in fuel quantity is almost instantaneous (less than one cycle time). Ignition system of Petrol Injection engine consists of Ignition Coil with built in Power Switch and the spark timing is controlled by ECU. Ignition timing is varied discretely, depending upon the engine speed and load. This system maintains optimum Ignition energy levels for a good spark in both low and high speed of the engine. No wear parts like points, Distributor cap etc., and hence better reliability.

4

6

SINGLE POINT FUEL INJECTION (THROTTLE BODY INJECTION) 2 1. Fuel 2. Air 3.Throttle valve 4. Intake manifold 5. Injectors 6. Engine

3

4

1 5

6

M U LTI POINT FUEL INJECTION

Fig. 2 6

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ENGINE 475 SI MPFI

Manifold pressure sensor

ENGINE

Throttle body Cylinder head cover

LTRS arrangement

Blow by hose

ISC Valve

Canister purge valve

Fuel rail

Cylinder head

Intake manifold

Ignition coil

Fig. 3 Intake Manifold with throttle body speed is increased as a function of Water and Air temperature inputs to the ECU.

475 SI MPFI ENGINE ADVANTAGES 475 MPFI engine uses HITACHI multipoint fuel injection system. Seven sensors located at various points in the engine, sense important parameters of the engine operation & send signals to a ECU located under dashboard. Based on predetermined engine mapping, the ECU precisely controls the fuel delivery injection timing to ensure optimum fuel utilisation with minimum emission. MPFI engine provides the following advantages : l

Better Cold Starting and Warm up : ECU identifies cranking condition and quick starting is ensured by providing sufficient fuel quantity and optimum spark timing. For quicker warm up, idling

INDEX

Emission : The petrol injection engine has low emissions because the air fuel ratio is controlled to stoichiometric using lambda sensor. Faster warm up from cold start ensures early operation of catalytic converter in turn reducing the emission.

l

Fuel Economy : The petrol injection engine has a better fuel economy because the engine is optimised at each operating point, discretly.

Better Engine Performance : Optimum fuel quantity and Spark timing is calculated by ECU for any operating condition.

l

l

l

Quick Response : The petrol injection engine will have a better driveability and better acceleration since the fuel delivery and spark timing are controlled by ECU, which quickly responds to engine/Driver demands.

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7

ENGINE 475 SI MPFI

MPFI SCHEMATIC CIRCUIT DIAGRAM

ENGINE

8

INDEX

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ENGINE 475 SI MPFI FEATURES OF MPFI FEATURE

HOW ACHIEVED

USER BENEFIT

CRANKING MODE :

ENGINE

Variable Injected Quantity

Injector pulse width starts with very high value and drops as cranking rpm, Air & Water temperature increases.

Good Cold starting

Divided fine injection pulse width method

Further total pulse width is divided into fine pulse widths for efficient mixture formation

Low Emissions

Fuel is cut if Throttle valve is opened

When throttle valve is opened more than 700 ECU cuts the fuel by reducing pulse width to very low value

Good startability in all conditions (both hot & cold)

Ignition timing for starting is calculated

ECU identifies cranking mode and calculates spark timing depending upon water temperature and engine speed.

Good startability in all conditions (both hot & cold)

A/C Compressor is kept ‘OFF’

ECU identifies cranking mode and switches ‘OFF’ the A/C relay.

Good startability due to reduced engine load

Fuel pump is kept ‘ON’ during Cranking only NOT OTHERWISE

If the engine is not started or stalls due to absence of rpm signal, Fuel pump is cut ‘OFF’.

Safety

Canister Purge Valve is kept ‘OFF’

ECU identifies cranking mode and switches ‘OFF’ CPV

Good startability

Based on inputs to ECU

Better Idle stability

ISC Valve position (steps) is continuously memorised and renewed in memory.

Better Idle stability whenever Idle state changes.

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IDLING MODE : Idle speed is dependent on l Water temperature l Engine Load (A/C) l Battery Voltage l Manifold Vacuum. and speed is maintained by Closed Loop control ISC Valve memorises the previous position (Learned Function)

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9

ENGINE 475 SI MPFI

ENGINE

FEATURE

HOW ACHIEVED

USER BENEFIT

‘LIMP HOME’ Idle Speed

When the following sensors are ‘No Good’, then idle speed assumes default value for Throttle position sensor, MAP Sensor, Vehicle speed sensor, air temperature sensor, water temperature sensor.

Flexibility and user convenience

‘LIMP HOME’ ISC Valve

When ISC Valve fails in closed condition, open throttle marginally to start the engine.

User convenience

Engine Stall protection

When engine rpm is as low as 650 rpm, ECU cuts A/C relay.

Better Idle stability and user convenience

High Engine Speed Control

Fuel is cut beyond 6500 rpm

Engine safety

High Vehicle Speed Control

Fuel is cut beyond 165 Kmph

Vehicle Safety

Zero Vehicle Speed Fuel cut

Fuel is cut if ‘no load acceleration’ is sustained beyond certain time say, 180 sec.

Better fuel economy

Variable Acceleration Enrichment

Four levels of acceleration is detected depending upon throttle position and vehicle speed and injected quantity is varied.

Better Fuel economy Better Emissions Better Overtaking ability

Anti Surge Function

Ignition timing is varied to dampen sudden torque variations.

Driving comfort

High water temperature A/C cut ‘OFF’ beyond 1100c.

ECU cuts A/C relay when the water tempeture increases

Engine Safety

A/C compressor is kept ‘OFF’ during ‘rapid’ acceleration

A/C relay is cut-off depending upon vehicle speed and throttle position.

Better over taking ability

ACCELERATION MODE :

DECELERATION MODE : Fuel Cut during deceleration

10

INDEX

ECU cuts the fuel depending upon Better fuel economy throttle position and rate of change of rpm.

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ENGINE 475 SI MPFI FEATURE

HOW ACHIEVED

USER BENEFIT

Anti-Surge Function

Ignition timing is varied to dampen sudden torque variations.

Driving comfort

Accurate Basic Map Data for efficient Injection and Ignition control

High resolution data on a 16 x 16 matrix

Best compromise for Driveability and Fuel economy

Closed Loop Air/Fuel ratio control

Lambda sensor input to ECU maintains Stoichiometric Air/Fuel ratio

‘LIMP HOME’ mode When one or many sensors fails to function (Except crank angle sensor) the vehicle will run in default and the engine check lamp on the instrument cluster will glow continuously. The car can be driven to the nearest workshop for rectification.

ECU assumes default values

Inertia Switch (Fig. 4).

When the Vehicle collision occurs, inertia switch cuts ‘OFF’ fuel pump

Safety (Fire Protection)

Immobiliser (If fitted)

Remote operated Immobiliser cuts supply to Main Relay and Fuel Pump.

Safety (Anti-theft device)

ENGINE

STEADY STATE MODE :

Emission Compliance

Safety and Comfort

Fig. 4 Inertia switch under driver’s seat

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11

ENGINE 475 SI MPFI MPFI SENSORS / ACTUATORS CRANK ANGLE SENSOR : (Fig.5 & 6). ENGINE

Type : RS 313 B Inductive pick up (Variable reluctance) 2 Pin connector Working Principle An A.C. voltage is induced in sensor coil when flywheel holes pass through the sensor by rotation. This A.C. voltage is directly proportional to the speed of rotation. System Integration : This sensor provides speed and crank angle input signals to ECU when placed over rotating flywheel with 7 holes, located at different angular dispositions.

Fig. 5 Crank angle sensor

Fitment Data : This sensor is mounted on the cylinder block over the flywheel (Fig. 5). Sensor Gap = 1.5 + 0.5 mm Stand Alone Diagnosis : Use Multimeter Coil resistance = 1200 W + 15% @ 200 C Check gap between flywheel and sensor tip Sensor end

Pin assignment ECU 20 = (CR+)

20

21

ECU 21 = (CR-) Measure resistance across pin 20 & 21

Fig. 6 Crank angle sensor

System Diagnosis : Use Hitachi Diagnostic Tester Check for crankshaft position signal “ON” during cranking. Electrical Circuit : SENSOR SHIELD EWH

W 0.75

CRANK ANGLE SENSOR 21 (CR+) CRANK ANGLE SENSOR 20 (CR-) CRANK ANGLE SENSOR SHIELD 19 (CRS)

CRANK ANGLE SENSOR

FWH

EWH

B 0.75

[ MAKE HITACHI ]

FWH FWH W/Y

EWH

AV 0.75

ECU

12

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ENGINE 475 SI MPFI AIR & WATER TEMPERATURE SENSOR : (Fig. 7 & 8) Type :

ENGINE

TT-20 Negative Temperature Coefficient (NTC) 2 Pin connector Working Principle A semiconductor material changes its resistance when exposed to variable temperature source. Resistance decreases as temperature increases. System Integration : This sensor provides air temperature or water temperature input to ECU when placed in air/water stream.

Fig. 7 Air temperature sensor

Fitment Data : (ATS = AIR TEMPERATURE SENSOR) (WTS = WATER TEMPERATURE SENSOR) ATS is fitted on air filter (Clean side of air filter) (Fig. 7) WTS is fitted on thermostat housing (Before thermostat) (Fig. 8) Stand Alone Diagnosis (See Illustration) : for both ATS & WTS Use Multimeter Thermister resistance 2.5 k W+ 0.25 k W @ 200 + 10C 0.84 k W+ 0.10 k W @ 500 + 10C

W

Air temperature sensor : Sensor end Pin assignment ECU 18 ’ TA 18

26

Fig. 8 Water temperature sensor

Electrical Circuit :

ECU 26 ’ TAG Measure the resistance across pins 18 & 26

EWH

Water temperature sensor : Sensor end Pin assignment ECU 24 ’ TW 24

WATER TEMP. SENSOR 24 SIGNAL (TW)

32

ECU 32 ’ TWG Measure the resistance across pins 24 & 32 System Diagnosis :

WATER TEMP. SENSOR 32 GND. (TWG)

R/G FWH

BR/W

Check for ‘Air Temp’ or ‘Water Temp’ values during Idling.

INDEX

EWH

0.75

AIR TEMP. SENSOR [ MAKE HITACHI ]

FWH

BR/B

AIR TEMP.SENSOR 26 GND. (TAG)

Use Hitachi Diagnostic Monitor

0.75

FWH

W/P

AIR TEMP SENSOR 18 SIGNAL (TA)

WATER TEMP. SENSOR [ MAKE HITACHI ]

0.75

0.75

FWH

ECU

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13

ENGINE 475 SI MPFI MANIFOLD AIR PRESSURE SENSOR (MAP) (Fig. 9 & 10) Type :

ENGINE

PS-60-01 Peizo - Resistive type 3-Pin Connector Working Principle A DC signal volt is produced by this semiconductor device when varying manifold air pressure acts on the semiconductor diaphragm. To produce this output the semiconductor device has to be excited. This signal output increases with increase in absolute manifold vacuum.

Fig. 9 Manifold air pressure sensor

System Integration : This provides manifold vacuum (abs.) signal input to ECU. The sensor is activated by excitation voltage supplied by ECU. Fitment Data : This sensor is a part of Integrated Throttle Body which is fitted on Inlet manifold upstream side (Fig. 9) Stand Alone Diagnosis : Use Multimeter With ignition “ON”. Supply volt » 5.12 vdc ~ ~ ~ ~

Signal volt » 4.2 vdc @ 710 mmHg of Atm pr. (abs) = 4.6 vdc @ 760 mmHg of Atm pr.(abs) Sensor end

31

22

112

Fig. 10 Manifold air pressure sensor (Top view)

Pin assignment ECU 31 ’ supply, VCC ECU 22 ’ signal, PM ECU 112’ ground, GNDS

Measure signal volt at pin 22 & 112 with sensor connected to wiring harness.

Electrical Circuit : EWH

System Diagnosis :

W/Y

SENSOR POWER SUPPLY 31 (+5V)(VCC)

Use Hitachi Diagnostic tester Check for ‘Intake manifold pressure’ value during cranking.

PRESSURE SENSOR 22 SIGNAL (PM) SENSOR GND. 112 (GNDS)

AV 0.75 EWH

FWH W/O

0.75 EWH

FWH BR/R

PRESSURE/MAP SENSOR [ MAKE HITACHI ]

0.75

FWH

EWH 0.75

ECU To Throttle Position Sensor

14

INDEX

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ENGINE 475 SI MPFI THROTTLE POSITION SENSOR (TPS) Fig. 11 & 12 Type :

ENGINE

SERA 483-06 Linear Potentiometer type 3-Pin Connector Working Principle : A fixed input DC volt to a potentiometer provides a variable output DC volt when the circuit resistance is varied externally. Output voltage increases when circuit resistance reduces. System Integration :

Fig. 11 Throttle Position Sensor (TPS)

Sensor provides variable signal Input to ECU when throttle lever is operated (opened / closed). This requires a supply volt of 5.12 VDC from ECU. Fitment Data : This sensor is a part of Integrated Throttle Body which is fitted on inlet manifold upstream side. Throttle lever shaft is extended to a crank lever which operates the sensor (varies the circuit resistance). Fig. 11 Stand Alone Diagnosis : Use Multimeter With ignition “ON”. Supply volt » Signal volt

» =

5.12 vdc 0.5 vdc at Idle position 4.5 + 0.15 vdc at WOT position

Sensor end

31

23

Pin Assignment

30

Fig. 12 Throttle Position Sensor (Side view)

ECU 31 ’Supply VCC ECU 23 ’ Signal THS ECU 30 ’ Ground THSG

Measure signal voltage across pin 23 & 30 with sensor connected to wiring hamess. System Diagnosis :

Electrical Circuit :

Use Hitachi Diagnostic tester From Pressure/Map Sensor

Check for ‘Throttle sensor’ voltage by pressing the accelerator pedal in and out. THROTTLE SENSOR 23 SIGNAL (THS) THROTTLE SENSOR GND 30

V/R

0.75

EWH

0.75

EWH

FWH BR/G

THROTTLE POSITION SENSOR [ MAKE HITACHI ]

FWH

ECU

INDEX

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15

ENGINE 475 SI MPFI LAMBDA SENSOR (O2 Sensor) Fig. 13 & 14 Type : ENGINE

LSH 24

Heated Ceramic Oxygen Sensor 3 Pin Connector Working princple (See Illustration) : A special ceramic body with gas permeable platinum electrodes on its surface, operates, depending upon ceramic material’s porosity which allows oxygen in the air to diffuse when the ceramic body is exposed to temperatures above 350 0 C. Voltage is generated across the electrodes which are exposed to gas with different levels of oxygen contents. System Integration :

Fig. 13 Lambda sensor fitted ON Exhaust pipe

This sensor provides Air/Fuel ratio signal in the form of mV to ECU as a function of varying Air/Fuel ratio Typical values at 3500C: = 0.95 ’ 840 + 70mv (rich) = 1.05 ’ 20 + 50mv (lean) Fitment Data : Fitted on the exhaust pipe as shown in Fig. 13 Stand Alone Diagnosis : Use Multimeter Heater function (Coil resistance : 4.2 Wat 300C) Sensor end Pin assignment A

B 17

A ’ Heater (+) B ’ Heater (_)

Fig. 14 Lambda sensor (O2sensor)

ECU 17 Signal w.r.t. engine ground. Measure the signal volt - mV, across ECU pin no. 17 and engine ground with sensor connected to wiring harness. Electrical Circuit :

System Diagnosis : Use Hitachi Diagnostic tester Check for ‘Front O2 Sensor’ value at idling. (200mv to 600mv continuously varying due to lambda control function).

LAMBDA SENSOR (A +ve) (B -ve)

GY/O

17 LAMBDA SENSOR(O2)

0.75

GND(ENGINE)

25 LAMBDA SENSOR SHIELD ECU

16

INDEX

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ENGINE 475 SI MPFI LAMBDA SENSOR : l

Lambda oxygen sensor located in exhaust pipe Fig. 15. 1. 2. 3. 4. 5. 6. 7. 8.

5

Special ceramic coat Electordes Contact Housing Exhaust pipe Ceramic Shield (porous) Exhaust gas. Air

7

6

4

8

ENGINE

3

1

2

Fig. 15 Lambda Sensor l

Lambda (oxygen) sensor voltage curve at 6000C operating temperature Fig. 16

mV a

1000

Oxygen-sensor voltage

a) Rich mixture (air deficiency) b) Lean mixture (excess air)

b

800 600 400 200 0

0.8 0.9 1 1.1 Excess-air factor

1.2

Fig. 16 Lambda Sensor Voltage Curve l

Heated Lambda (oxygen) sensor Fig. 17 1. Probe housing 2. Ceramic Shield tube

1

2

3

3. Electrical connections 4. Shield tube with slits 5. Active ceramic sensor layer 6. Contact 7. Shield 8. Heating lement 9. Clamp connections for heater element

5

6

7 8 9

Fig. 17 Heated Lambda Sensor

INDEX

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17

ENGINE 475 SI MPFI VEHICLE SPEED SENSOR (VSS) Fig. 18 & 19 ENGINE

Type : VDO Reed Switch Part of Instrument Cluster Working Principle : This reed switch in a circuit provides ON/OFF pulses by making/breaking the contacts. The contacts are made/broken by a rotating magnet. System Integration : This provides vehicle speed input signal to ECU in the form of ON/OFF pulses. When a reed switch is driven through speedometer cable. Specification : 4 pulses per revolution & 2550 contacts per km.

Fig. 18 Instrument cluster (rear view)

Fitment Data : This reed switch is integral part of instrument cluster and is driven by Speedometer cable Fig. 18. Stand Alone Diagnosis : Use Multimeter Manually rotate the speedometer cable and check for contact make & break pulses 4 times/rev.

VSS

With Ignition ‘ON’, Pulse volt in ‘ON’ condition = 4.5 Volt DC Measure pulse volt across ECU pin no. 6 and car body as ground with wiring harness connected to ECU. System Diagnosis :

Fig. 19 Vehicle Speed Sensor (VSS)

Use Hitachi Diagnostic tester Check for Vehicle speed sensor ‘Value’ during driving. NG condition : 2 km/hr irrespective of vehicle speed.

Electrical Circuit : R/Y

VEHICLE SPEED PULSE 6 (SPD)

PIN NO:1 INST CLUST [ MAKE PRICOL/VDO ]

FWH

ECU TO VEHICLE SPEED SENSOR

18

INDEX

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ENGINE 475 SI MPFI ISC VALVE (IDLE SPEED CONTROL VALVE) Fig. 20 Type :

ENGINE

Fig. 20 Throttle Body showing Idle Speed control valve fitted ISC Valve in inset 0.75

AEP 125-1 Stepper motor type 6 Pin connector Working Principle : Fig. 22 & 23 A linear flow pneumatic valve allows accurate flow control by varying flow cross section area.This is done by a moving spindle in both open/close directions operated by a stepper motor. System Integration : ECU provides drive signal to the stepper motor of ISC valve to allow more/less air depending upon engine demand to maintain target speed of 750 rpm ( N = 50 rpm) in hot condition. Also, the input from various other sensors helps ISC valve to maintain the target Idle Speed for various engine loads e.g. : A/C idle speed = 800 rpm Engine water temp dependent Speed, say at 300C = 1100 rpm. Fitment Data : This actuator is part of Integral Throttle Body which is fitted on inlet manifold upstream side. Fig. 20 Stand Alone Diagnosis : Use Multimeter Single Phase coil resistance = 49 W Actuator end Pin assignment ECU 2 ’ Coil A P1 ’ Supply (+) 3 2 P1 ECU 3 ’ Coil A’ 9 P2 10 P2 ’ Supply (+) ECU 10 ’ Coil B’ Measure coil resistance across pins = P1 & 2, P1 & 3, P2 & 9, P2 & 10 System Diagnosis : Use Hitachi Diagnostic tester Check for ISC valve steps For normal idling at hot condition ISC valve steps = 20 + 3 steps. AIR FLOW (L/min) Illustration of graph showing air flow and step number on ISC valve.

0.75 P1

P2 LG/B

0.75 FWH

G/R

0.75 FWH

3 ISC S/M ØA (ISCA)

0.75

R/L

M

2 ISC S/M ØA (ISCA)

FWH 0.75

W/V

FWH

9 ISC S/M ØB (ISCB)

10 ISC S/M ØB (ISCB) ECU

STEPPING MOTOR TYPE ISC VALVE [ MAKE HITACHI ]

Fig. 21 Electric Circuit of ISC Valve

Throttle Body

600 500

Air Cleaner

400

Air Outlet

Stepper Motor

300 200

Air Inlet

100 0 0

20

40 60 80 Step Number

INDEX

100

120

Throttle Plate

Intake Manifold

Fig. 22 ISC valve illustration

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19

ENGINE 475 SI MPFI INTEGRAL THROTTLE BODY ENGINE

Type : RTT 38 Æ 38 mm throttle valve, integrated with MAP sensor Throttle position sensor & ISC valve Air flow control valve. Working Principle : Air flow into the engine is varied by varying the cross section area. In addition, flow rate is dependent on engine speed. System Integration : This Integral Throttle Body is with a throttle valve (See Illustration) in the air flow path (of ø 38 mm). The throttle is actuated by the lever and the shaft assembly which in turn operates Throttle position sensor to provide engine load signal.

Fig. 23

Manifold air pressure sensor fitted on the air flow passage downstream of the throttle valve provides manifold pressure signal. An ISC valve fitted on the throttle body allows the air flow into the engine by-passing the main air flow path. Hot water passage is provided for cold climatic operations (de-iceing). Fitment Data : Fitted on the upstream of the inlet manifold. Fig. 24 Stand Alone Diagnosis : Use Multimeter

Fig. 24 Integral throttle body

Refer to MAP sensor, TPS sensor and ISC valve. System Diagnosis : Use Hitachi Diagnostic tester 2000 Refer to MAP sensor, TPS sensor and ISC Valve.

20

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ENGINE 475 SI MPFI CANISTOR PURGE VALVE Fig. 25 & 26 Type : ENGINE

TEV 2 BOSCH Solenoid valve 2 Pin connector Working Principle : Fig. 27 & 28 A solenoid valve opens and closes the gas passage depending upon ECU signal to the solenoid valve. Gas (petrol vapour) flows into manifold from canistor and the flow rate varies depending upon valve duty cycle ratio (open time to close time ratio) and pressure differential between canistor and inlet manifold. System Integration : ECU provides drive signal to this solenoid valve to purge the petrol vapour from canistor into the engine (inlet manifold) at appropriate speed and load of engine as decided by ECU. This valve is kept open (to purge) depending upon the duty cycle ratio drive signal from ECU.

Fig. 25 Location of purge valve

Fitment Data : This valve is mounted on the engine block. In petrol vapour circuit this valve connects canister purge line to intake manifold, downstream side of integrated throttle body. Fig. 25 Stand Alone Diagnosis : Use Multimeter Solenoid coil resistance = 26 W @ 200 C Actuator end P

Pin assignment

11

Fig. 26 Purge valve

P ’ supply (+) main relay ECU 11 ’ CP

Measure the resistance across pin P & 11 System Diagnosis :

Electrical Circuit :

Use Hitachi Diagnostic tester Check for CPC solenoid ‘ON/OFF’ condition by freely accelerating the engine from idle to 4000 rpm.

CANISTER PURGE VALVE 0.75 EWH

EWH [ MAKE HITACHI ]

Y/L

FWH

11 CANISTER PURGE (CP) ECU

INDEX

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21

ENGINE 475 SI MPFI CANISTER PURGE VALVE - ILLUSTRATION : 1. HOSE CONNECTION

1

2. NON RETURN VALVE 3. LEAF SPRING

2

4. SEALING ELEMENT

3

5. SOLENOID ARMATURE

4

6. SEALING SEAT

5

7. SOLENOID COIL.

6 7

1

Fig. 27

3.5

3.0

2.5

FLOW IN M3 / H

ENGINE

0.2 2.0

0.1

1.5

1.0

0.5 0.0 0

-100

-200

-300

-400

-500

-600

-700

-800

-900

DIFFERENTIAL PRESSURE PE IN MBAR

Fig. 28 22

INDEX

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ENGINE 475 SI MPFI FUEL INJECTOR Fig 29 & 30 Type : ENGINE

JS 2J - 3 Ball valve and Top feed 2 Pin Connector Working Principle : Fig. 31 A solenoid valve, normally closed by a ball and cone seat, opens when the electromagnetic core is energised. Fuel under pressure flows through swirler and metering orifice on the ball seat. This ensures fine atomisation and consistent flow rate for a given Injector opening time.The ball type seating valve acts as a good anti-deposit.

Injectors

System Integration : ECU provides drive signal to Injector (normally closed valve) to open and remain in open condition (pulse widthms) depending upon the engine operating conditions (speed/load). Also the pulse width is compensated for low battery voltage condition. The concept of Grouped injection means when ECU provides drive signal, two injectors (either for cyl 1&4 or cyl 2&3) are simultaneously opened, one in end of compression and one in end of exhaust. This means approximately half of the required quantity of fuel for one power output is provided in two stages. This enables efficient control of Air/Fuel ratio by modifying injected fuel quantity in the second half of the injection.

Fig. 29 Fuel Injectors location in the engine

Fitment Data : Four numbers of injectors are fitted on inlet manifold and fuel is fed by a common fuel rail so that the fuel spray from each injector is directed towards the inlet valve, inside the inlet port. Fig. 29

System Diagnosis : Use Hitachi Diagnostic tester. Check for ‘Fuel injection 01 pulse Values during idling : 2.0 to 2.5 ms

Injector coil resistance 8.6 W Actuator end Pin assignment 1

’ Power supply, main relay

101

ECU 101 or ECU 102

’ Injector 1 & 4 ’ Injector 2 & 3

NOTE : Pulse width will continuously vary to maintain stoichiometric Air/Fuel ratio. Electrical Circuit : 1.0

Measure the resistance across the pin P and ECU101

1 CYL

R/B

L/G

0.75

EWH

(or ECU 102). With ignition ON, measure the supply voltage w.r.t. engine ground at the wiring harness end by removing all injector connectors.

EWH

4 CYL 2 CYL

101 INJECTOR (IJ1) 1CYL, 4CYL.

Y/G

0.75 EWH

3 CYL

FWH

0.75

Use multimeter

FWH

102 INJECTOR (IJ2) 2CYL, 3CYL

0.75

Stand Alone Diagnosis :

1

Fig. 30 Fuel Injector

ECU

INJECTOR 8.6_ X 4 [ MAKE HITACHI ] (+ ve)

INDEX

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23

ENGINE 475 SI MPFI FUEL INJECTOR - ILLUSTRATION : ENGINE

FILTER

FUEL IN

(1) TERMINAL (Driving Signal) from E.CU.)

(3) CORE

(2) COIL (COPPER)

(5) YOKE A

(4) PLUNGER ROD (6) SWIRLER

(7) BALL VALVE (8) NOZZLE

ORIFICE FUEL OUT

Fig. 31 24

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ENGINE 475 SI MPFI FUEL PRESSURE REGULATOR Fig. 32 & 33 Type : ENGINE

MPDB 20 6A Diaphragm type valve (variable pressure) Pneumatic Regulator Working Principle : Fig. 34 A diaphragm operated valve regulates pressure at fuel inlet and returns the excess fuel back to the tank. The diaphragm is operated by differential pressure between fuel rail and intake manifold. System Integration : Intank fuel pump provides fuel at very high flow rates to common fuel rail where pressure regulator regulates according to the position of diaphragm. This diaphragm is held in an equilibrium position as a result of fuel pressure acting on one side and manifold vacuum acting on the other side of the diaphragm. The excess fuel, after regulation is returned back to fuel tank. This ensures a constant operating pressure of 3 bar across Injector inlet and outlet, at all engine operating conditions.

Fig. 32 Fuel pressure regulator

Fitment Data : This regulator is fitted on the Fuel rail. Fig. 32 Stand Alone Diagnosis : Check for leaking diaphragm. Leakage is confirmed if fuel traces are noticed on vacuum side. System Diagnosis :

Fig. 33 Fuel pressure regulator

Use Hitachi Diagnostic tester Check for ‘Front O2 sensor’ value for variations since lambda control is in progress to maintain stoichiometric Air / Fuel ratio.

AIR CHAMBER

VC PIPE

FUEL IN

DIAPHRAGM VALVE

TO FUEL TANK

OUTLET PIPE

Fig. 34 Fuel pressure regulator illustration

INDEX

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25

ENGINE 475 SI MPFI INTANK FUEL PUMP Fig. 35 & 36 Type : ENGINE

F002 KIA 004, BOSCH / PENTADEWA Intank - Electric Fuel Pump 2 Pin connector Working Principle : A positive displacement pump assy. is driven by a motor to provide continuous flow of fuel to high pressure fuel system from fuel tank. This Intank pump provides continuous flow of fuel to fuel rail where a variable fuel pressure is maintained by a fuel regulator as a function of varying manifold vacuum.

Fig. 35

Fitment Data : This Intank pump is fitted inside the fuel tank by immersing the pump’s suction end in the fuel. Fig. 35 Stand Alone Diagnosis : Use Multimeter Motor armature resistance = 20W @ 200C Actuator end (Pump) 2

1

Pin assignment 1 2

’ from relay ’ car body

Measure the coil resistance across Pin 1&2 Actuator end (Relay) P

108

Pin assignment P ’ Supply (+)

Fig. 36 Intank Fuel Pump

ECU 108 ’ FP

System Diagnosis : Use Hitachi Diagnostic tester Check for Fuel pump relay ‘ON/OFF’ condition. NOTE : With ignition ON, Fuel pump is switched off after 1 sec. if engine is not cranked.

26

INDEX

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ENGINE 475 SI MPFI IGNITION COIL ASSEMBLY Fig. 37 & 38 Type : ENGINE

CM12 - 100D Duel Spark Coil with built in Power Switch 4 Pin Connector Working Principle : This ignition coil operates on conventional principle of secondary (high) voltage generation by induction. However, primary current switching (ON/OFF) is triggered by an electronic circuit on ECU which also maintains constant dwell time (time required to energise primary coil) throughout the engine operating conditions. System Integration : ECU provides the trigger pulse to switch ON/OFF the power switch built in the coil which provides 2 sparks simultaneously in cylinders 1& 4 or 2&3 as both the ends of the secondary coil is ending with sparkplugs. This concept called Grouped Ignition, means two sparks occur for one useful power output (i.e. one spark in the end of compression & one spark at the end of exhaust). This enables maintenance of optimum dwell time at very high engine speeds.

Fig. 37 Ignition coil with built in power switch

Fitment Data : The ignition coil is fitted beneath the inlet manifold to have the shortest possible length for High tension cable to connect Sparkplugs. This is done to reduce the level of electromagnetic radiation from HT cables and possible interferance w.r.t. the functioning of ECU. Fig. 37 Stand Alone Diagnosis (See Illustration) :

Fig. 38

Use Multimeter Check for 12 V power supply P/G on wiring harness Firing order (1,3,4,2) & HT cable connections (See Illustration)

System Diagnosis :

Secondary coil resistance = 13 k W Actuator end

Measure supply volt across pin P and G on wiring harness with Ignition ON. Measure secondary coil resistance across High tension terminals of cyl. 1 & cyl. 4 (or cyl. 2 & cyl. 3).

Use Hitachi Diagnostic tester

Pin assignment

’ supply (use for cyl. 2&3) G ’ ground (engine) ECU 15 ’ signal (use for cyl. 1&4) ’ Power supply P

Check for ‘Ignition timing value’ during idling.

ECU 16

15 G 16 P

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27

ENGINE 475 SI MPFI Electrical Circuit : FROM IGNITION

ENGINE

H.T. CABLE 0.75

H.T. CABLE

H.T. CABLE AV 0.75

[ MAKE ANU/DELTRONIX ]

SPARK PLUGS

1

2

BODY EARTH [MAKE MICO]

15 IGNITION1(IG1) 1CYL, 4CYL

EWH

H.T. CABLE

H.T. CABLE

0.75 AV 0.75

3

4

EWH

16 IGNITION2(IG2) 2CYL, 3CYL ECU

IGNITION COIL [ MAKE HITACHI ] GND (ENGINE)

ENIGNE GND

28

INDEX

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ENGINE 475 SI MPFI IGNITION COIL ILLUSTRATION : ENGINE

PRINCIPLE OF OPERATION OF IGNITION COIL

VCC

IGN RELAY

91 W

IGNITION COIL

91 W

1g. Key S. W. CURRENT LIMIT CIRCUIT

POWER TRANSISTOR UNIT ENG. CONTROL UNIT

Fig. 39 FIRING ORDER (1,3,4,2) HEAT SINK & CONNECTOR FACING ‘UP’

4 - RS

CYL. 4 CYL. 1

ENGINE FRONT SIDE

CYL. 2 CYL. 3

Fig. 40

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29

ENGINE 475 SI MPFI ENGINE CONTROL UNIT (ECU) Fig. 41 & 42 ENGINE

Type : H8 536 16 Bit, 16 MHz CPU with 62k ROM & 2k RAM 48 pin connector Working Principle : Microprocessor based Engine Control System. System Integration (See Illustration) : All sensors (e.g. Water temperature sensor), input signals are processed by the microprocessor and control signals are provided for various actuators (e.g. ISC Valve) for satisfactory engine performance. Various control Algorithms (software) are used in conjunction with Map/table data to provide various control functions for optimum functioning of the engine, which in turn provides best fuel consumption/Emissions.

Fig. 41

Fitment Data : ECU is fitted below the steering column in the driver cabin. Fig. 41 Stand Alone Diagnosis (See Illustration) : Use Multimeter. Perform continuity check only on ECU connection at wiring harness end to any sensor/actuator depending upon engine symptom. System Diagnosis : Use Hitachi Diagnostic tester Check for all data when engine starting and idling normally (typical data for normal idling are given on page no. 34)

30

INDEX

Fig. 42 Electronic control unit

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ENGINE 475 SI MPFI ENGINE CONTROL UNIT - ILLUSTRATION : Block Diagram : ENGINE

Input

Control Unit

Output Injector * 4

Crank angle sensor Speed sensor

CPU : H8

Air temp.Sensor Throttle Position Sensor Water temp. sensor

Ignition Coil * 1 ISC solenoid

CPU Signal Condi-

ROM

tioner

A/D

RAM

Fuel pump relay Buffer

I/O

Battery

Diagnosis Lamp Others

Oxygen Sensor D/N Switch A/C switch

Voltage Regulator

Others

Watch dog timer

* D/N Switch - applicable for AUTOTRANSMISSION only.

Fig. 43

SPECIFICATIONS : Type :

Intelligent Driver ICs :

H8 536

1. Idle Speed control

Data Line :

2. Diagnostic line

16 Bit Clock Speed :

Diagnosis level :

16 MHz

3 levels

Memory :

a) Test switch (Actuators)

62k ROM

b) Read Memory switch (Blink code)

2K RAM

c) Diagnostic Monitor (HDM 2000)

A/D Convertor : 10 Bit (high accuracy) FEATURES : Grouped Ignition Grouped Injection Note : For MPFI ECU Schematic circuit refer electrical group.

INDEX

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31

ENGINE 475 SI MPFI TROUBLE SHOOTING OF SENSORS USED IN MPFI : ENGINE

Power Monitor Lamp

Method No. 1 HITACHI DIAGNOSTIC MONITOR ( HDM 2000 ) should be loaded with the cartridge TATA Indica Version 1.2. Fig. 44

Display Screen

Rubber Jacket

Key Pad

Power Switch

This is an user – friendly diagnostic kit, makes the Trouble Shooting simpler. This HDM 2000 can also be used as :

Wrist Strap

Cartridge LED Display

1. A multimeter Strap Hook

2. An Oscilloscope The monitor provides the diagnostic data for efficient trouble shooting.

Fig. 44

Connecting the Diagnostic Equipment : Note : Connect the HDM only with the Ignition switch in “OFF” position. HDM 2000 is given with an intermediate cable,one end of it is connected to HDM 2000 and the other end to the female socket below the co-driver's seat Fig. 45. The power supply for it is taken from the battery of the vehicle through the same cable. No need of separate power supply. During diagnosis this instrument provides data in graphical form. Also allows measurement and recording of data for analysis and efficient trouble shooting. Stores ‘No Good’ conditions of Sensors/Actuators as listed in Read Memory Switch’s diagnostic mode. That is in E C U’s memory.

Fig. 45 Female socket below co-driver seat

The error codes are stored in two areas : 1. Current Error Codes – to diagnose exiting faults. 2. History of Error Codes – to diagnose previous stored faults. NOTE : At the end of each diagnosis and rectification of the fault,‘HISTO RY CODES’isto be erased by opting ‘CLEAR MEMORY’ option in the menu and check for normal functioning of Engine/Vehicle

32

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ENGINE 475 SI MPFI EXPLANATION OF BUTTONS : On this instrument, you can select each mode from the menu display screen using the cursor.The following table shows the main functions of the keys.These key functions vary depending on the selected mode.

ENGINE

Moves up the cursor, and scrolls up the display screen. Increments a numeric value.

Moves down the cursor, and scrolls down the display screen. Decrements a numeric value.

Moves left the cursor, and scrolls left the display screen. Increments a numeric value.

Moves right the cursor, and scrolls right the display screen. Decrements a numeric value.

Use this key for item selection, deselection, execution, confirmation, etc.,

Use this key for item deselection, function turn-off, etc.

Goes back to the previous display screen or function.

Provides the shift function.

These keys for carrying out individual functions on each display screen.

Fig. 46

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33

ENGINE 475 SI MPFI TEST SWITCH MODE : Method No. 2 ENGINE

This mode is used to check the functioning of the following components. 1. Canister Purge Valve 2. Fuel pump relay 3. A/C Compressor TROUBLE SHOOTING PROCEDURE : 1. Turn the ignition ‘ON’ 2. Short the terminals of the connector (Test Switch connector) below co-drivers seat using a suitable connector. Fig. 47

Fig. 47 Test switch mode connector in shorted condition (Black Socket)

3. Switch ‘ON’ the blower and A/C Switch 4. Physically ascertain the functioning of A/C compressor, intank fuel pump and canister purge valve by hearing the respective relay sound, otherwise that particular component should be checked. N OTE:

At the end of each diagnosis and rectification of the fault, ‘HISTORY CODE’ is to be erased by opting for “CLEAR MEMORY” it in HDM 2000 or by removing the battery supply for atleast 3 minutes. Method No. 3 READ MEMORY SWITCH MODE (BLINK CODE) : Read memory switch mode method (Blink code method) is a manual diagnostic method used to check the malfunctioning of the following parts. 1. 2. 3. 4. 5. 6. 7.

Water temperature sensor Air temperature sensor Manifold air pressure sensor Idle speed control valve Throttle position sensor Lambada sensor Vehicle speed sensor

INDEX

DIAGNOSTIC TESTER

READ MEMORY

To check through this mode, we have to short the terminals of the Read Memory Switch mode connector which is situated below the co-driver’s seat as shown in Fig. 48. Blink Code checks the functioning of the Sensors/Actuators as indicated in the Blink code table.

34

Fig. 48 Read memory switch mode white connector in shorted condition.

WHITE CONNECTOR

TEST SWITCH

BLACK CONNECTOR

Fig. 49

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ENGINE 475 SI MPFI TROUBLE SHOOTING PROCEDURE :

HITACHI DIAGNOSTIC MONITOR DATA :

1. Short the terminals of the connector using suitable connector and OBSERVE the following :

TYPICAL DATA DURING NORMAL IDLING :

2. Turn the ignition ‘ON’

Value changes in accordance with the change in engine temperature.

a. If the ‘CHECK ENGINE’ lamp on the dash board blinks cyclically at every 0.5 secs, Then there is ‘NO TROUBLE’ with the engine sensors.

SR. NO.

PARAMETER

VALUE

1.

Battery Voltage

14.0 V

b. Otherwise the lamp blinking frequency is correlated to a trouble code and corresponding sensor/actuator is indicated to be faulty.

2.

Vehicle Speed

0.0 kmph

3.

Engine Speed

750 rpm

4.

Coolant Temperature

850C

BLINK CODE TABLE :

5.

Ignition Timing

9-100 BTDC

Read memory switch mode connector in following shorted condition.

6.

Throttle Position Sensor Volt

0.50 V

7.

Fuel Injection # 1 Pulse

2.30ms

Code

8.

ISC Valve Step

23.5 Step

Water temperature Sensor

31

9.

Engine Load

34.4%

Pressure Sensor

33

10.

Front O2 Sensor

0.24 to 0.68V

ISC Valve

34

11.

Max. Value of O2 Sensor

0.76v

Air Temperature Sensor

36

12.

Min. value of O2 Sensor

0.10v

Throttle Sensor

41

13.

A/F Correction # 1

-2.3 to -3.9%

O2 Sensor

42

14.

CPC Valve Duty Ratio

0%

Vehicle Speed Sensor

43

15.

Manifold Absolute Pressure

280/300 mm Hg

16.

Intake Air Temperature

28oC

17.

Ignition Switch

ON

18.

Test Mode Signal

OFF

19.

Read Memory Signal

OFF

20.

Idle Switch

ON

21.

A/C Switch

OFF

22.

A/C Relay

OFF

23.

Fuel Pump Relay

ON

24.

CPC Solenoid Valve

OFF

25.

Front O2 Rich Signal

OFF/ON

26.

Crank Shaft Position Signal

ON

Item

For Example : If the “Check Engine” lamp gives 3 slow blinks (of 1.2 Secs each) representing the first digit of the failcode viz.,”3" followed by 1 fast blink (of 0.16 Secs each) representing the second digit of the failcode viz.,”1" in a cyclic fashion, thus flashing the code “3 1” indicating that the water Temp Sensor is faulty (from the table below). If there are two or more sensors faulty, then the blink codes are repeated cyclically. For example, if the water temperature sensor and lambda sensor are faulty then the blinking codes will be repeated like ..31….42….31….42…. N OTE:

At the end of each diagnosis and rectification of the fault, ‘HISTORY CODE’ is to be erased by opting‘CLEAR MEMORY’ option in HDM 2000 or by removing the battery supply for atleast 3 minutes.

INDEX

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35

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ENGINE

ENGINE 475 SI MPFI

ENGINE

ECU HANDLING CARE :

l

Do not try to repair the ECU.

Earth (Ground) Connection

l

Use standard harness for circuit connections.

l

Connect GND - P, GND - I, GND - C each to the engine block.

l

Ensure that Do not try to insert any thing into the ECU case.

l

The above mentioned GND should be connected firmly using screws.

l

l

Ensure that the ignition coil GND and ECU GND - C are connected firmly together to the engine block by screws; and ensure that even if these are detached from the engine block, they are not detached from each other.

The installation should be done in such a way as to keep the connector side down and the wiring done accordingly (to avoid water penetration into the ECU through the wiring).

l

Take care to avoid any bending of the connector pins while inserting the connector.

l

Ensure that the connector is inserted in the end after all the installation is complete.

l

To carry out welding job on the car the ECU should be disconnected.

Power Supply l

The power for the ECU should be taken through the Main Relay. Do not take out the connector from the ECU for at least 5 sec after IGNITION OFF. Never take out the connector from the ECU during IGNITION ON.

l

Ensure that key SW is in OFF position while plugging - in the connector to the ECU.

l

Do not plug - in the connector again to the ECU for at least 100 sec after disconnecting it.

Input l

Ensure that the Input signal line is as far as possible from noise sources such as High Tension Cable, Horn relay, Motor etc.

l

Ensure that sealed wire are used for input line of O2 Sensor and Crank Angle Sensor, and the wiring is as far as possible from the noise sources similar to the ones above (Unsealed wire may be used for O2 sensor if the noise level is small enough so as not to affect the Air/Fuel control).

Output l

Take care to avoid dead - short (solenoid short - circuit etc.) and similar circuit misconnection while checking ( to avoid any damage to the Output Power Transistor). Use a solenoid which does not use a fly - back diode (reverse polarity may damage the Output Power Transistor).

Installation l

Ensure that the ECU is secured firmly to the body using screws.

l

Ensure that there is no water seepage into the ECU.

l

Do not use an ECU which has been dropped once.

36

INDEX

GROUP INDEX

NEXT

PREVIOUS

ENGINE 475 SI MPFI PRELIMINARY INSPECTION OF ENGINE :

gradually with left foot. If the engine stalls, it means that clutch does not slip.

Before proceeding to carry out actual overhauling of engine it is desirable to have a preliminary inspection of engine to ascertain whether an engine overhaul is necessary and to what extent.

OR Drive the car with weight equal to GVW in 3rd gear on level ground and let the speed drop down to approximately 15 kmph. Now press accelerator pedal fully. With slipping clutch, the car speed will not pick up and also clutch burning smell will be noticed. If this does not occur and car picks up speed, it indicates that clutch does not slip.

Most common reasons for which engine is overhauled are : 1.

Loss of power

2.

Excessive engine oil consumption

3.

Extremely low engine oil pressure

4.

Mechanical failures

e.

LOSS OF POWER

BRAKE BINDING During driving apply brake number of times and then shift the gear to neutral position Check brake drums for over-heating and if necessary jack up the car and check the wheels for free rotation.

To know exact reason and general condition of engine, proceed as follows : 1.

ENGINE

f.

Loss of engine power may be due to :

CHECKING ENGINE COMPRESSION PRESSURE If loss of power is not on account of defective fuel system, lack of air, choked exhaust silencer, clutch slipping and brake binding. check engine compression as follows :

a.

Defective Ignition system

b.

Defective Fuel system

c.

Clogged air cleaner/choked catalytic converter exhaust silencer

1.

Warm up engine preferably by road drive to get a temperature of about 75 to 85 0C.

d.

Clutch slippage

2.

Remove all spark plugs.

e.

Brake binding

3.

Remove air cleaner filter element.

f.

Loss of engine compression

4.

a.

IGNITION SYSTEM

Install Compression gauge (Range about 0 to 25 kg/cm2) into one of the spark plug hole.

Check all the sensors for proper function by using diagnostic monitor. Replace defective sensors. b.

Note : Use adaptor which is available commercially to suit the size of the spark plug threads.

FUEL SYSTEM Check condition of fuel filter. If found blocked replace fuel filter.

c.

CLOGGED AIR CLEANER/CHOKED EXHAUST SILENCER Check air filter element If found choked clean or replace.

d.

CLUTCH SLIPPAGE Clutch slipping can be confirmed by any of the following two methods : Drive the car in 1st or 2nd gear at maximum speed corresponding to that gear. With accelerator pedal fully pressed, apply brake

INDEX

Fig. 50

GROUP INDEX

NEXT

PREVIOUS

37

ENGINE 475 SI MPFI 5.

Disengage clutch (to reduce starting load on engine) and depress accelerator pedal all the way to make throttle valve open fully.

6.

Crank engine with fully charged battery, and read the highest pressure on compression gauge.

7.

Carry out steps 5 to 7 on each cylinder to obtain compression pressures. The specified compression pressure is 9.5 bar minimum.

ENGINE

8.

Variation in compression pressure between cylinders should not be more than 0.5 bar.

9.

Low compression pressure may be due to leakage past valves / piston rings/blown cylinder head gasket. To ascertain the point of leakage, spray small quantity of clean engine oil in to the cylinder showing low pressure and re-check compression pressure. If it improves, wear in piston rings/cylinder bore is indicated. If it does not, leakage past the valves is indicated. If compression pressure of adjacent cylinder is also on lower side, it may be due to blown cylinder head gasket.

2.

EXCESSIVE ENGINE OIL CONSUMPTION

High engine oil consumption may also lead to overhauling of the engine but before proceeding to overhauling, check following points : 1.

2.

Make sure that there is absolutely no external oil leak (i. e. from the camshaft oil seal, crankshaft oil seal, oil sump gasket, oil pump gasket, cylinder head cover gasket etc.) If no external leakage is found, determine the exact engine oil consumption, as per following procedure.

4.

Take a clean vessel, place it below the drain plug of oil sump.

5.

Drain the hot oil into the clean vessel. Drain it fully.

6.

Screw in oil sump drain plug and tighten it.

7.

Weigh the vessel along with oil let this weight be ‘w1’, gms.

8.

Refill the weighed oil into the oil sump. Do not spill any oil. The vessel used for draining should not be used for any other purposes.

9.

Drive the vehicle approx. 200 - 300 km. This drive should include at least 30 - 40 kms. of highway or similar road, vehicle running at about 60 kmph. Let this drive distance be ‘D’ kms.

10. Immediately after the test drive, place the vehicle at the same spot from where it started. 11. Place the same previously used vessel below the oil sump, unscrew the drain plug and drain off oil into the vessel. Drain the sump fully. 12. Weigh the vessel along with oil, now for the second time. Let this weight be ‘w2’ gms. 13. Find out standard oil consumption as Std. oil consumption = ‘C’ (litres/1000km)

(w1 - w2)(wt. of oil consumed, gms) x 1000 sp. wt. of oil (gm/cm3) x ‘D’ (drive dist. in km.)

w1 - w2 0.88 x D

‘C’

=

litres/1000km

3.

EXCESSIVE LOW OIL PRESSURE EXTREMELY

Check the following :

DETERMINING EXACT ENGINE OIL CONSUMPTION :

a.

External leakages.

CAUTION :

b.

Oil level in sump upto maximum mark on dipstick.

c.

Oil pressure transducer for proper functioning.

d.

Functioning of pressure relief valve on oil pump.

e.

Oil pump performance using a suitable pressure gauge.

Do not make a rough estimate of engine oil consumption by noting the kilometers covered by the car at any random stage and finding oil consumed from the topped up position taking into consideration dipstick level and oil sump capacity. PROCEDURE : 1.

Once it is doubted that engine oil consumption is higher, place the car on a level ground.

2.

Top up oil sump to its capacity of 4 litres.

3.

Warm up the engine so that oil temperature is 75 800 C.

38

INDEX

Oil pressure found to be less than 2.8 bar at maximum speed and 1.2 bar at idling speed, may be due to improper functioning of oil pump or defective oil pump relief valve. If low oil pressure is not on account of above factors, wear of journals/bearings is indicated for which overhaul of engine may be considered.

GROUP INDEX

NEXT

PREVIOUS

ENGINE 475 SI MPFI Checking oil pressure : Procedure for checking ENGINE

Before conducting the test ensure : 1. 2. 3.

Engine oil level is at high mark on dipstick, otherwise top up. No leakage. Correct grade of engine oil is used.

Remove electrical connection from oil pressure transducer. Remove oil pressure transducer from cylinder block. Install Oil pressure gauge in place of oil pressure transducer. Start engine and warm it up to normal operating temperature. Warm up the engine and measure oil pressure. It should be within specified limits. After checking oil pressure, stop engine and remove oil pressure gauge. Before reinstalling oil pressure transducer, be sure to apply sealant on screw threads and tighten transducer to specified torque. Tighten oil pressure switch to 1.2 - 1.5 mkg torque. 4.

MECHANICAL FAILURES

Metallic knocking sound from an engine may be due to faulty ignition, excessive clearance in main and big end bearings, small end bush, tappets, piston slap, seizing of piston rings, scored cylinder bore or breakage of any moving parts. Defective alternator can also be a source of mechanical noise. Defect can be located by replacing alternator or power steering pump (if fitted) or AC compressor (if fitted) or belt tensioner pulley with a new one. Dismantling of engine may be considered if still noise occur even after attending all above mentioned problems.

INDEX

GROUP INDEX

NEXT

PREVIOUS

39

40

INDEX

ASSY.LIFTING HOOK REAR

HEX.FL.SCREW M8X18

09

PAN HD SCR M6X8

05

08

ASSY.ENGINE COVER MTG.BKT. (FRONT)

04

ASSY.BUFFER (FOR ENG.COVER MTG.)

CR CSK SCREW M6X16

03

HEX FL NUT

ASSY.RUBBER GROMMET (ENGINE COVER MTG)

02

07

ASSY.ENGINE COVER

01

06

PART DESCRIPTION

SR. NO.

2.5

ENGINE

ENGINE COVER MOUNTING (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

GROUP INDEX

NEXT

PREVIOUS

INDEX

GROUP INDEX

HEX FL BOLT M8X38

HEX.BOLT (FOR CRANKSHAFT GEAR)

WASHER (FOR CRANKSHAFT GEAR)

05

06

07

ASSY.GEAR (FOR CRANKSHAFT) (SINTERED)

02

PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)

CYL PIN 8m6X16

01-b

PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC)

CRANKSHAFT-NORMAL

01-a

04

ASSY.CRANKSHAFT WITH PIN - NORMAL

01

03

PART DESCRIPTION

-Non Reusable Part

ASSY.FLYWHEEL COMPLETE.

SET THRUST WASHERS (BIMETAL)

SET MAIN BEARING SHELLS NORMAL (BIMETAL)

11 12

HEX.BOLT (FOR FLYWHEEL)

10

09-a DOWEL (FOR CLUTCH ON FLYWHEEL)

KEY

09

®

08

®

ASSY.CONNECTING ROD

5.5 #

PISTON SET WITH RINGS GRADE A (IP)

NEXT

PREVIOUS

14-b SET PISTON RINGS ABC STD (IP)

14-a PISTON SET WITHOUT RINGS GRADE A (IP)

14

13-c SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)

13-b NUT (FOR CONNECTING ROD)

13-a BOLT (FOR CONNECTING ROD)

13

MOVING PARTS (For 85 PS engine)

SR. NO.

®

# Allowed Tolerance of ±5%

- Specified Torque in Kgm

ENGINE 475 SI MPFI

ENGINE

41

42

INDEX

GROUP INDEX

HEX FL BOLT M8X38

HEX.BOLT (FOR CRANKSHAFT GEAR)

WASHER (FOR CRANKSHAFT GEAR)

05

06

07

ASSY.GEAR (FOR CRANKSHAFT) (SINTERED)

02

PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)

CYL PIN 8m6X16

01-b

PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC)

CRANKSHAFT-NORMAL

01-a

04

ASSY.CRANKSHAFT WITH PIN - NORMAL

01

03

PART DESCRIPTION

-Non Reusable Part

ASSY.FLYWHEEL COMPLETE.

SET THRUST WASHERS (BIMETAL)

SET MAIN BEARING SHELLS NORMAL (BIMETAL)

11

ASSY.CONNECTING ROD

PISTON SET WITH RINGS GRADE A (IP)

NEXT

PREVIOUS

14-b SET PISTON RINGS ABC STD (IP)

14-a PISTON SET WITHOUT RINGS GRADE A (IP)

14

13-c SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)

13-b NUT (FOR CONNECTING ROD)

13-a BOLT (FOR CONNECTING ROD)

13

5.5 #

ENGINE

12

HEX.BOLT (FOR FLYWHEEL)

10

09-a DOWEL (FOR CLUTCH ON FLYWHEEL)

KEY

09

®

08

®

MOVING PARTS (For 75 PS engine)

SR. NO.

®

# Allowed Tolerance of ±5%

- Specified Torque in Kgm

ENGINE 475 SI MPFI

INDEX

GROUP INDEX

OIL SEAL (CAMSHAFT-FRONT)

TIMING GEAR (CAMSHAFT)

WASHER (FOR CAMSHAFT GEAR)

HEX BOLT (CAMSHAFT GEAR MTG.)

ASSY.TENSIONER (TIMING BELT)

SPACER(TIMING BELT TENSIONER)

HEX FL BOLT M10X65

ASSY.IDLER (FOR TIMING BELT)

SPACER

HEX FL BOLT M10X65

CAM SHAFT *

ROCKER ARM

ADJUSTING SCREW (FOR ROCKER ARM)

ROCKER NUT

.ASSY.ROCKER SHAFT WITH SEALING CAP

SPRING (ROCKER ARM SHAFT)

ROCKER SPRING SEAT

SCREW-ROCKER SHAFT HOLDER.

CAM THRUST PLATE (FRONT)

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

CAP SCREW M6X20

TIMING BELT

1

21

PART DESCRIPTION

SR. NO.

4.5

1.0

®

®

ENGINE TIMING (same for 85 PS & 75 PS * engines) * View is same for 85 PS & PS engines, but for 75 PS engine camshaft is different

NEXT

PREVIOUS

- Specified Torque in Kgm

-Non Reusable Part

ENGINE 475 SI MPFI

ENGINE

43

44

INDEX

GROUP INDEX

ASSY.ACT.CARBON CANISTER (KOEL)

ASSY.BRACKET (FOR CARBON CANISTER MTG.)

HEX FL SCREW M6X16

17

SPRING CLIP (10)

16

SPRING CLAMP (14)

14

15

RUBBER HOSE-CPV TO INTAKE MANIFOLD (240)

RUBBER HOSE-CARBON CANISTER TO CPV (380)

13

HEX FL SCREW M6X10

11

12

CLAMP - CANISTER PURGE VALVE

06

10

HEX FL SCREW M8X16

05

09

SUPPORT BRACKET - CANISTER PURGE VALVE

04

CANISTER PURGE VALVE

SPRING CLIP (10)

03

RUBBER SLEEVE (CANISTER PURGE VALVE)

HOSE (PR.REGULATOR TO I.MANIFOLD)205

02

08

HEX FL SCREW M8X18

01

07

PART DESCRIPTION

ASSY.FUEL RAIL (CASTING)

SR. NO.

ENGINE

- Specified Torque in Kgm

FUEL INJECTION EQUIPMENT (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

NEXT

PREVIOUS

INDEX

GROUP INDEX

SR. NO. 01 01-a 01-b 01-c 01-d 01-e 01-f 01-g 01-h 01-i 02 02-a 02-b 03 04 05

1.0

1.0

®

1.0

1.0

1.0 #

ASSY.CYLINDER CRANKCASE HOLLOW DOWEL 14h6x10.5x14L DOWEL SLEEVE (FRONT HALF TO INT.PLATE (2) ) HOLLOW DOWEL 10h6x8.4x8L HOLLOW DOWEL 8h6x6.5x8L SEALING PLUG M14X1.5 SEALING WASHER 14X20 IS3175-CU HEX.BOLT (FOR M.B.CAP) DOWEL 6h6x10 (1-no screw behind) HOLLOW DOWEL 8h6X6.5X8L (6) .ASSY.REAR COVER CRANKCASE WITH OIL SEAL REAR COVER - CRANKCASE (HOLLOW DOWEL) 0IL SEAL-CRANKSHAFT (REAR) GASKET (REAR COVER CRANKCASE) ASSY HEX SCREW M6X20 (6-for rear cover) ASSY.DIPSTICK TUBE

PART DESCRIPTION

-Non Reusable Part

# Allowed Tolerance of ±5%

- Specified Torque in Kgm

®

06 07 07-a 07-b 07-c 08 09 10 11 12 13 14 15 16 17 18 19

®

1.0

® ASSY.DIPSTICK ASSY.OIL SUMP COMPLETE ASSY.OIL SUMP W/O DRAIN PLUG MAGNETIC DRAIN PLUG SEALING WASHER (OIL SUMP DRAIN PLUG) OIL SUMP GASKET HEX FL SCREW M6X14 (for oil sump) ASSY.TIMING COVER - REAR (LH BOTTOM) ASSY.TIMING COVER - REAR (RH BOTTOM) HEX FL SCR M10X14 (for timing cover) ASSY.FRONT COVER(LOWER)(TIMING COVER) HEX FL SCREW M6X14 COVER (TIMING BELT-FRONT) SEALING STRAP SHOULDER BOLT (FOR TIMING COVER) BRIGHT WASHER 10.5 RUBBER BUSH (TIMING COVER)

®

5.5 #

®

3.5

®

3.5

20 21 22 23 24 25 26 27 28 29 30 31 32 33

2.0

®

1.0 #

HEX SCREW M6X20 WASHER A6.4 IS5370 RUBBER BUFFER (FOR MTG.TIMING COVER) INSERT TUBE (FOR MTG.TIMING COVER) ASSY.OIL PUMP GASKET (FOR OIL PUMP) ASSY HEX SCREW M6X25 OIL SEAL-CRANKSHAFT (FRONT) ASSY.STRAINER (FOR OIL PUMP) GASKET (FOR OIL PUMP STRAINER) STUD CM6X16 HEX FL NUT BM6 ADAPTOR (OIL FILTER) ASSY.OIL FILTER

0.6 to 0.7#

®

CYLINDER BLOCK ASSY. (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

NEXT

PREVIOUS

ENGINE

45

46

INDEX

GROUP INDEX

19 20 21 22

18

17

®

®

ASSY.CYL.HEAD COMP(WITH VAL,RO.ARM,SP.PL VALVE GUIDE SEAL INTAKE VALVE EXHAUST VALVE SPRING SEAT VALVE SPRING VALVE SPRING RETAINER LOCK HALF SPARK PLUG ASSEMBLY.(M/S CHAMPION) ASSY.CYLINDER HEAD (WITHOUT VALVES) CYLINDER HEAD STUD CM8X25 (FOR INTAKE MANIFOLD) STUD CM8X20 (FOR PURGE VALVE MTG. BRACKET.) STUD CM8X25 (FOR EXHAUST MANIFOLD) GASKET (FOR CYL.HEAD)(1.1THK.) HEX BOLT (FOR CYL.HEAD) WASHER (FOR CYL.HEAD BOLT) ASSY.CYLINDER HEAD COVER COMPLETE (LMM) BAFFLE GASKET BAFFLE PLATE SCREW RUBBER HOSE (BLOWBY) (HEADCOVER-AIR FIL) HOSE CLAMP 25 HOSE CLAMP 16 'T' - CONNECTOR RUBBER HOSE-BLOW BY-HD.COVER TO MANIFOLD HOSE CLAMP 25 HOSE CLAMP 20 GASKET (FOR CYL.HEAD COVER) STUD (FOR CYL.HD.COVER) SPACER TUBE (FOR CYL.HD.COVER) ASSY.RUBBER BUSH (FOR CYL.HD.COVER) DOMED CAP NUT (FOR CYL.HEAD COVER MTG.) SEALING WASHER (FOR CYL.HEAD COVER) OIL FILLER CAP GASKET 21 VALVE GUIDE VALVE INSERT

PART DESCRIPTION

®

22

1.0

6.5

1.0

1-i-d

1.0

09

®

10

07

ENGINE

®

NEXT

PREVIOUS

12

08

- Specified Torque in Kgm

-Non Reusable Part

11

®

16

11 12 13 14 15

SR. NO. 01 01-a 01-b 01-c 01-d 01-e 01-f 01-g 01-h 01-i 01-i-a 01-I-B 01-I-C 01-I-D 02 03 04 05 05-a 05-b 05-c 06 07 08 09 10

CYLINDER HEAD & COVER (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

INDEX

GROUP INDEX

Oil Pump Strainer Gasket

10

Gasket

Gasket Elbow

Rear Crankshaft Oil Seal (Rear Crankcase Cover)

Camshaft Front Oil Seal

Front Crankshaft Oil Seal

12

13

14

15

16

Water Pump Gasket

Front Cover Gasket

9

®

11

Inlet Manifold Gasket

Exhaust Manifold Gasket

®

8

®

7

Oil Filler Cap Gasket

Cylinder Head Cover Gasket

4

Throttle Body Gasket

Cylinder Head Gasket

3

6

Oil Sump Gasket

2

®

5

Rear Gasket

1

®

PART DESCRIPTION

®

SR. NO.

GASKET KIT (same for 85 PS & 75 PS engines)

® -Non Reusable Part

® ®

ENGINE 475 SI MPFI

NEXT

PREVIOUS

ENGINE

®

®

®

®

® ® ®

47

48

INDEX

ASSY AIR FILTER MPFI ASSY.FILTER ELEMENT ASSY.ISOLATOR (FOR AIR FILTER) ISOLATOR (FOR AIR FILTER) ASSY.ADAPTER (BLOWBY CONN.ON AIR FILTER) SEALING WASHER 14X18 CU SEALING WASHER 12X15.5 CU ASSY.BRACKET FRONT (FOR AIR FILTER MTG.) BRACKET REAR (A/F MTG.ON BATTERY TRAY) HEX FL SCREW M8X12 HEX FL BOLT M8X25 ASSY.BRACKET (FOR RESONATOR BOX MTG.) HEX FL SCREW M6X10 RESONATOR BOX ASSY.ISOLATOR (FOR RESONATOR) RUBBER GROMMET (FOR RESONATOR BOX) HEX FL BOLT M8X25 AIR INTAKE SNORKEL ASSY.CLAMP (FOR SNORKEL MTG.) HEX FL SCREW M6X14 (FOR SNORKEL MOUNTING) HOSE (RESONATOR BOX) HOSE CLAMP (42 DIA.) INTAKE DUCT (FROM AIR INTAKE SYSTEM) HOSE (AIR FILTER TO INTAKE DUCT) HOSE CLAMP (72 DIA.) HEX FL NUT AM6 8C (FOR SNORKEL MOUNTING) PLUG (ON THROTTLE BODY) GASKET (FOR INTEGRATE THROTTLE BODY) HEX FL NUT AM6 8C RUBBER BELLOW (AIR FILTER TO THRO.BODY) HOSE CLAMP ( 53 DIA.) HOSE CLAMP (72 DIA.)

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

®

PART DESCRIPTION

SR. NO.

®

®

AIR INTAKE SYSTEM (same for 85 PS & 75 PS engines)

®

ENGINE

-Non Reusable Part

ENGINE 475 SI MPFI

GROUP INDEX

NEXT

PREVIOUS

INDEX

GROUP INDEX

STUD CM6X45 (FOR THROTTLE BODY)

SELF LOCKING NUT

EXHAUST MANIFOLD

GASKET EXHAUST MANIFOLD

.ASSY.HEAT SHIELD (FOR EXHAUST MANIFOLD) HEX FL SCREW M6X10

STUD CM8X32

09

10

11

12 13

14

GASKET (FOR INLET MANIFOLD)

08

07

HEX FL SCREW M6X12

04

ASSY.CABLE LEVER COMPLETE (FOR LTRS)

CYL PIN 4m6X8 IS2393

03

STICKER (FOR SPARK PLUG CONNECTION)

BRACKET (FOR ACC.CABLE MTG) (LTRS)

02

06

ASSY.INTAKE MANIFOLD COMPT (FOR LTRS)

01

05

PART DESCRIPTION

1234 1234 1234 1234 1234

SR. NO.

06

2.0

®

NEXT

PREVIOUS

- Specified Torque in Kgm

-Non Reusable Part

INTAKE & EXHAUST MANIFOLDS (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

ENGINE

®

® ®

49

- Specified Torque in Kgm

-Non Reusable Part

50

INDEX

GROUP INDEX

BRACKET (FOR 75 AMP ALT.& PSTG.) STUD (FOR A.C. & ALT. BRACKET) HEX FL SCREW M8X18 HEX FL NUT AM8 HEX FL BOLT M8X125 BRIGHT WASHER 8.4 NYLOC NUT M8 ASSY.CLAMP ROD COMP.WITH BRACKET (172mm)

® 8.0

4.0

2.0

08-a ASSY.CLAMP ROD (COMPLETE) 172 mm 08-a-a ASSY.CLAMP ROD WITH SILENT BLOCK 08-a-b ASSY.CLAMPING PIECE 08-a-b-a CLAMPING PIECE 08-a-b-c CYL PIN 8m6X25 IS2393 08-b ASSY.BRACKET (ALTERNATOR - UPPER) 08-c HEX FL BOLT M10X40 9 HEX FL SCREW M8X18 10 HEX FL BOLT M8X45

2.5

2.0

1.5

2.0

11 12 13 14 22 23 24 25

3.0

HEX THIN NUT M12 LOW OIL PRESSURE SWITCH POLY-V BELT (4 GROOVES-875) ALTERNATOR 12V 75A W/IEM W/O VP-OFFER POWER STEERING PUMP HEX FL SCREW M8X18 PULLEY (POWER STG.PUMP) 4 GROOVES HEX FL.NUT AM12X1.25

ENGINE ELECTRICAL EQUIPMENT (75 PS)

ENGINE

01 02 03 04 05 06 07 08

SR. PART DESCRIPTION NO.

®

ENGINE 475 SI MPFI

NEXT

PREVIOUS

INDEX

ASSY.TENSION PULLEY. (FOR A/C COMP.)(INA)

HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)

POLY VEE BELT (5 PK-1095)

ALTERNATOR 12V 90A W/VP W/IEM

PULLEY-PSTG.PUMP (5-GROOVES)

12

13

14

15

16

4.0

ASSY.SHAFT W/H DUST SHIELDFOR TENSIONER

HEX FL BOLT M8X25

07

11

BRACKET (FOR ALT.TOP SUPPORT)

06

SLIDER SCREW (FOR TENSIONER)

HEX FL SCREW M8X18

05

10

SUPPORT BKT.(FOR ALT.BKT.& TOP SUPPORT)

04

SLIDER (FOR TENSIONER MTG.) (ALUMINIUM)

HEX FL BOLT M8X25

03

WASHER (FOR AC COMPRESSOR IDLER)

HEX FL SCREW M8X18

02

09

BRACKET (ALTERNATOR,IDLER & PSTG.MTG.)

01

08

PART DESCRIPTION

SR. NO.

2.3

2.0

2.3

2.0

ENGINE ELECTRICAL EQUIPMENT (85 PS)

2.0

- Specified Torque in Kgm

2.0

ENGINE 475 SI MPFI

GROUP INDEX

NEXT

PREVIOUS

ENGINE

51

®

52

INDEX

GROUP INDEX

NEXT

PREVIOUS

- Specified Torque in Kgm

2.5 2.5

5.0

Part Description

DUST CAP SLIDER (FOR MTG.OF A/C IDLER) SCREW (FOR A/C COMP TENSIONER)

21-b 21-c 21-d

NYLOC NUT M8

ASSY.IDLER (FOR A/C COMP.) (AUTOLEC)

21-a

21-e

POLY-V BELT (4-GROOVES-730) SET ASSY.IDLER (AUTOLEC)

21

19 20

HEX FL NUT AM8 HEX FL SCREW M8X18

18

HEX FL SCREW M8X30 STUD (FOR A.C. & ALT. BRACKET)

17

ASSY.AIR COMPRESSOR (with sealed connector) 16-c

BRACKET(MTG.A/C COMPRESSOR)(HALLA-110CC) 16-b

SET ASSY.COMPRESSOR MTG.(HALLA-110CC)DLX

16 16-a

DUST CAP STARTER MOTOR 0.8KW. MALE TER.-M/S LTVS

15

HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)

02-e

02-d

02-a-b SPACER(FOR A/C BELT TENSIONER)-M/S INA.

02-a-a ASSY.TENSION PULLEY(FOR A/C COMP)INA.

Sr. No.

ENGINE

-Non Reusable Part

2.4

ENGINE ELECTRICAL/A.C. EQUIPMENT (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

®

INDEX

GROUP INDEX

SR. PART DESCRIPTION NO. 01 KIT-EMS BHARAT STAGE-II FE (HITACHI) 01-a ASSY.COIL WITH IGNITOR (HITACHI) 01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-c CRANK ANGLE SENSOR (HITACHI) 01-d WATER/AIR TEMP.SENSOR (HITACHI) 01-e ASSY.FUEL INJECTOR (HITACHI) 01-e-a O-RING (FOR FUEL INJECTOR)

1.4

01-e-bINSULATOR (FOR FUEL INJECTOR) 01-e-c RUBBER RING (FOR FUEL INJECTOR) 01-f INTEG.THROTTLE BODY(HITACHI) NEW PR.SEN. 01-g ASSY.PRESSURE REGULATOR (HITACHI). 01-g-a O-RING (FOR PR.REGULATOR) 02 HEX FL SCREW M5X12 03 ASSY HEX SCREW M6X25 (Ignition coil)

11

04 05 06 07 08 09 10 11 12

EMS KIT COMPONENTS (same for 85 PS & 75 PS engines)

NOTE : Vehicles speed sensor, one of EMS component, is a part of instrument cluster. (not shown)

12

- Specified Torque in Kgm

1.0

10

09

BRACKET (FOR CRANK ANGLE SENSOR) CR CSK SCREW M6X16 CYL PIN 6m6X14 HEX FL BOLT M6X20 MANIFOLD AIR PRESSURE SENSOR THROTTLE POSITION SENSOR ISC VALVE WATER TEMPERATURE SENSOR LAMBDA SENSOR

08

1.0

ENGINE 475 SI MPFI

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53

ENGINE

54

INDEX

GROUP INDEX THERMOSTAT HOUSING O-RING 42.52X2.62 A NITRILE HEX FL NUT AM8 STUD CM6X25 ASSY.COVER (THERMOSTAT) ASSY.THERMOSTAT (82 DEG.SOT ) SEAL THERMOSTAT HEX FL NUT AM6 SEALING WASHER 12X15.5 TEMPERATURE TRANSDUCER-M/S PRICOL

® 39 40 41 42 43 44 45 46 47 48

®

ASSY.ADAPTER (FOR HEATER CONNECTION) WASHER (18X22X2-Cu) ASSY.BANJO BOLT WITH NIPPLE (FOR HEATER) HOSE (FROM CYL.HEAD TO HVAC UNIT) SPRING BAND CLAMP FORM A 12X23D TS17665 ASSY.TUBE(CYL.HEAD VENT) SPRING BAND CLAMP FORM A 12X14D TS17665 ASSY.WATER PUMP (OFFER DRG.) GASKET (FOR WATER PUMP) ASSY HEX SCREW M6X20

®

10 11 12 13 14 15 16 36 37 38

1.0

2.0

®

SR. PART DESCRIPTION NO.

® ® 1.5

®

48

®

1.5

FROM RADIATOR TOP

1.0

49 50 51 52 53 54 55 56 57 58

TO HEATER

TO AUX. TANK

- Specified Torque in Kgm

-Non Reusable Part

SEALING WASHER 14X18 STUD CM6X16 ASSY.TUBE WATER BYPASS GASKET (FOR WATER BYPASS TUBE) HEX FL NUT BM6 ASSY.HOSE (WATER BYPASS) (SPR.BAND) HOSE CLAMP 35 ASSY.ELBOW (FOR WATER INLET GASKET (FOR WATER INLET ELBOW) HEX FL SCREW M8X18

2.0

1.0

®

ENGINE

NOTE : Please read this view in conjunction with view of Radiator (next page), as both are related.

ENGINE COOLING SYSTEM (same for 85 PS & 75 PS engines)

ENGINE 475 SI MPFI

®

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PREVIOUS

SR. NO. 01 02 03 04 05 06 07 08 09 14 15 16 17

GROUP INDEX

*

1.0

18 19 20 21 22 23 24 25 26 27 28

1.0

FROM HEATER

06

1.5 09

08

CLAMP FRONT (CYL.HEAD VENT HOSE) HEX FL SCREW M8X12 RUBBER HOSE (RADIATOR VENT)TOYO RAD.ONLY SPRING BAND CLAMP FORM A 12X14D SPRING BAND CLAMP FORM A 12X19D RUBBER HOSE-COVER THERMOSTAT TO RADIATOR SPRING BAND CLAMP FORM A 15X49D ASSY.AUX.WATER TANK W/H PR.CAP ASSY.BRACKET-REAR (FOR AUXILLIARY TANK) HEX FL SCREW M6X12 ASSY HEX SCREW M6X16

Fitted on Body

TO WATER ELBOW

Fitted on Body

07

08

29 29-a 29-b 30 31 32 33 34 35 59

1.5

1.5

TO BLO

18

CK

To Heater

19

17

ASSY.RADIATOR W/H TH.SW.(AC/NON AC) TOYO ASSY.THERMOSWITCH DRAIN PLUG WITH WASHER ASSY.SHROUD WITH FAN & MOTOR HEX FL SCREW M6X14 RUBBER GROMET (RAD MOUNT) ASSY.BKT.RAD.MTG.TOP RH COMPL ASSY.BKT.RAD.MTG.TOP LH COMPL HEX FL SCREW M6X12 SCREW FOR TOP MOUNTING BRACKET (AUX. TANK)

*

TO

M ER TH

TA T OS

INDEX

ASSY.INT.RUBBER HOSE RUBBER HOSE (INTEGRAL HOSE TO AUX.TANK) HOSE CLAMP (53 DIA.) SPRING BAND CLAMP FORM-A 12X28D SPRING CLIP (25) HOSE CLAMP (26 DIA.) HEX FL NUT BM6 ASSY.CLAMP (FOR INT.HOSE AUX.TANK BR.) HEX FL SCREW M6X10 SPRING BAND CLAMP FORM A 12X23D ASSY.TUBE(CYL.HEAD VENT) SPRING BAND CLAMP FORM A 12X14D HEX FL SCREW M6X10

PART DESCRIPTION

RADIATOR (same for 85 PS & 75 PS engines)

NOTE : Please read this view in conjunction with view of Engine Cooling System (previous page), as both are related.

ENGINE 475 SI MPFI

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ENGINE

55

ENGINE 475 SI MPFI ENGINE SUSPENSION (85 PS) ®

ENGINE

- Specified Torque in Kgm

®

1.5

-Non Reusable Part

4.0

2.5

2.5

c b

®

a

4.5

2.5

2.5

3.5

2.0

a

®

b

3.0 SR. NO.

PART DESCRIPTION

01 02 03 03-a 03-b 03-c 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

LIFTING HOOK (FRONT) HEX FL SCREW M8X18 ASSY.BRACKET ENG MTG. WITH STUDS BRACKET (FOR ENG.MTG.ARM) STUD BM10X50 STUD BM10X60 HEX FL BOLT M10X40 HEX FL BOLT M10X70 ENGINE MTG.ARM (FRONT) HEX FL NUT AM10 ASSY.ENGINE MOUNT-A(HYDRAULIC) NYLOC NUT M10 BRIGHT WASHER 10.5 ASSY.MOUNTING PLATE (B-MOUNT) ASSY.STOPER(ON B-MOUNT PLATE) HEX FL BOLT M8X25 ASSY.ENG.MOUNT-B (ON GEAR BOX) NYLOC NUT M12X1.5 WASHER (FOR B-MOUNT) .HEX FL NUT BM8 ASSY.ENGINE MOUNT-C (TC)

56

INDEX

8.0

SR. NO.

PART DESCRIPTION

19 20 21 22 23 24 24-a 24-b 25 26 27 28 29

ASSY.BRACKET ENGINE STOPPER (FABRICATED) HEX FL SCR M12X30 HEX FL BOLT M8X38 ASSY.RUBBER STOPPER HEX NUT M12 ASSY.C LINK & BODY MTG BKT COMPLETE ASSY.MOUNT INTERMEMEDIATE LINK (REAR) ASSY.BODY MTG.BRACKET (FOR C-MOUNT) HEX FL BOLT M10X55 NYLOC NUT M10 ASSY HEX SCR M12X1.25X30 HEX FL BOLT M10X75 HEX FL NUT AM10

GROUP INDEX

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ENGINE 475 SI MPFI ENGINE SUSPENSION (75 PS) ® - Specified Torque in Kgm

®

ENGINE

1.5

-Non Reusable Part

4.0

2.5

2.5

c b

®

a

4.5

2.5

2.5

3.5

2.0

a

®

b

3.0 SR. NO.

PART DESCRIPTION

01 02 03 03-a 03-b 03-c 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

LIFTING HOOK (FRONT) HEX FL SCREW M8X18 ASSY.BRACKET ENG MTG. WITH STUDS BRACKET (FOR ENG.MTG.ARM) STUD BM10X50 STUD BM10X60 HEX FL BOLT M10X40 HEX FL BOLT M10X70 ENGINE MTG.ARM (FRONT) HEX FL NUT AM10 ASSY.ENGINE MOUNT-A(HYDRAULIC) NYLOC NUT M10 BRIGHT WASHER 10.5 ASSY.MOUNTING PLATE (B-MOUNT) ASSY.STOPER(ON B-MOUNT PLATE) HEX FL BOLT M8X25 ASSY.ENG.MOUNT-B (ON GEAR BOX) NYLOC NUT M12X1.5 WASHER (FOR B-MOUNT) .HEX FL NUT BM8 ASSY.ENGINE MOUNT-C (TC)

INDEX

8.0

SR. NO.

PART DESCRIPTION

19 20 21 22 23 24 24-a 24-b 25 26 27 28 29

ASSY.BRACKET ENGINE STOPPER (FABRICATED) HEX FL SCR M12X30 HEX FL BOLT M8X38 ASSY.RUBBER STOPPER HEX NUT M12 ASSY.C LINK & BODY MTG BKT COMPLETE ASSY.MOUNT INTERMEMEDIATE LINK (REAR) ASSY.BODY MTG.BRACKET (FOR C-MOUNT) HEX FL BOLT M10X55 NYLOC NUT M10 ASSY HEX SCR M12X1.25X30 HEX FL BOLT M10X75 HEX FL NUT AM10

GROUP INDEX

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57

ENGINE 475 SI MPFI

ENGINE

REMOVAL OF 475 MPFI ENGINE FROM THE CAR : It is recommened to used two post hoist for removing engine from the car. Remove bonnet Disconnect electrical cable connections for : Fig. 51 l Battery (-ve first) l Starter motor l Alternator l Electrical connections of all sensors and actuators l Oil pressure switch l Water temperature transducer l Electric fan transducer l Reversing switch l A/C Compressor Disconnect cables for Accelerator, Speedometer drive, Clutch. Disconnect exhaust pipe from exhaust manifold

Fig.51

Drain coolant from cooling system Disconnect hoses from and to radiator and heater coil. Disconnect pipe from radiator to auxilliary tank and cylinder head to aux. tank. Remove AC pipe lines (if AC is fitted) Remove following sub assemblies : l Air filter l Gear shift linkages from transaxle Fig. 52 l Radiator (if required) Drain transaxle oil, Fig. 53.

Fig. 52

Fig. 53 58

INDEX

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ENGINE 475 SI MPFI Remove drive shafts (for procedure, see suspension group) Fix chain to front and rear engine lifting hooks and hold chain in position with crane. Fig. 54

ENGINE

Unscrew and remove nut on ‘B’ mount bracket. Fig. 55 Remove ‘A’ mount support arm. Fig. 55 Remove ‘C’ mount bracket. Fig. 55 Lift engine slightly on car with the help of crane. Place support stand under the engine & lower the engine along with transaxle assembly. Remove the chain. Lift the front end of the car till the engine is clear ( It is recommended to use two pole hoist to lift the car) Remove the engine alongwith transaxle. Remove starter motor. Disconnect transaxle Assembly from engine. (Ref. transaxle group) Remove alternator and its mounting bracket. Mount the engine on work stand with mounting bracket Pt. No. 2702 5890 24 02 & 2702 5890 2403 Drain engine oil. Fig. 56 INSTALLATION OF ENGINE ON THE CAR : l Check engine mounting pads for wear. Replace them if necessary. l Install the engine in reverse sequence of removal l

Tighten engine mounting bolts to specified torque

l

Connect all pipes, hoses and electrical connections

l

Fill specified quantity of oil in engine of recommended brand. Fill coolant in the cooling system through aux. tank

l l

l l l

Crank the engine momentarily. Let oil and coolant circulate through the system. Remove air trapped in cooling system with the air venting screw provided on outlet hose from cylinder head to radiator top. Confirm whether engine oil pressure indicator light is switching off when engine is started. Check for leakage, rectify if any.

2702 5890 24 01

Fig. 54 ‘C’ MOUNT

FRONT ‘B’ MOUNT

‘A’ MOUNT

Fig. 55

Top up coolant upto FULL mark in auxiliary tank, if necessary.

Fig. 56

INDEX

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59

ENGINE 475 SI MPFI REMOVAL OF RADIATOR FROM CAR (Front bumper, Splash guard already removed - For procedure refer Body group of this manual) ENGINE

1.

Drain the coolant.

2.

Remove all the hose connections i. e. i. From the thermostat ii. From the auxiliary tank. iii. To the outlet elbow.

3.

4.

1. 2.

3.

Disconnect the electrical connections, i. To the condenser fan (For AC version) ii. To the temperature sensor of cooling fan.

1. ASSY. RADIATOR COMPLETE

i.

Unscrew the 2 M8 bolts & remove the radiator bottom mounting member along with the radiator. Fig 57

3. RUBBER GROMET

ii.

Remove upper support bracket.

SPECIFICATIONS Leakage testing pressure

:

Auxillary Tank Cap Fig. 58 Pressure valve opening : Vacuum valve opening : (suction)

2. CROSS MEMBER RADIATOR MOUNTING

Fig. 57 AUXILLIARY TANK

1.5 bar

AUXILLIARY TANK CAP

1 bar 0.05 bar (max)

INSPECTION Check radiator for damages / leakages. Straighten bent fins if any. CLEANING Clean radiator frontal cores. Installation : 1. i. Fit the radiator along with the radiator bottom mounting member on to the car & tighten the mounting bolts. ii. Fit upper mounting bracket. 2. Fit back the 3 hose connections. 3. Connect the electrical connections for temperature sensor & condenser fan (For AC version) Fill branded coolant as per specification. Top up coolant through auxiliary tank cap upto ‘Full”mark. Fit Auxillary tank cap. Run engine for short duration and top up coolant if necessary. Remove the trapped air though venting screw. Bleeding procedure for cooling system : (For refilling or during reconditioning after complete draining)

60

INDEX

Fig. 58 a.

Fill branded premixed ready to use coolant in the auxiliary tank after ensuring all the hoses are secured and leak proof.

b.

During filling, keep the hose clamp loose at thermostat housing.

c.

During coolant filling, ensure that the air in the system is removed from this then tighten the hose, using a screwdriver.

d.

Start the engine & slowly raise the engine speed & wait for the temperature to reach 850 C to 900 C to allow the thermostat to open up. Engine running at idling speed, open the bleeding screw by using a screwdriver to allow any trapped air in the system to escape. Tighten the bleeding screw & top up with coolant to max. level.

GROUP INDEX

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ENGINE 475 SI MPFI ALTERNATOR / POWER STEERING PUMP BELT (specific to 85 PS engine) Removal :

ENGINE

l

Loosen both the slider mounting screws on alternator bracket.

l

Slide the slider to reduce the belt tension by rotating the slider screw at the bottom. Fig. 59.

l

Remove the alternator belt.

Inspection : l

Inspect the alternator belt for wear, cracks and signs of failure. Replace, if necessary.

Fitment : l

Adjust the slider at the higher most position and keep the screws loose but engaged.

l

Install alternator belt over Crankshaft, Alternator, Power Steering pump and the tensioner pulley.

l

Slide the slider by rotating the bottom slider screw till correct belt tension is set.

l

Retighten the slider screws.

l

The belt tension to be adjusted such that on the spans shown in the Fig. 60. 180+10/5 Hz. (For only Alternator configuration) and 200 +10/-5 Hz. ( For Alternator and power steering configuration) is measured by CLAVIS gauge. Alternately belt can be depressed by 11 to 13 mm (for only Alternator configuration) & 9 to 11 mm (for alternator and power steering configuration) with thumb pressure applied.

SLIDER SCREWS

Fig. 59

A.C. COMPRESSOR BELT REMOVAL 1.

Loosen belt tensioner bolt (Fig. 61) on idler / tensioner.

2.

Release tension load on the belt and remove the belt from the pulleys.

INSPECTION 1.

Inspect the A. C. compressor belt for wear, cracks, and signs of failures. Replace if necessary.

2.

Inspect pulley grooves.

SPAN

ALTERNATOR BELT TENSIONER BOLT

Fig. 60

INDEX

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61

ENGINE 475 SI MPFI FITMENT 1.

Install the belt over crankshaft and A. C. compressor pulleys.

2.

Press the tensioner against the belt and tight the tension bolt to specified torque.

3.

Check belt tension.

4.

The belt tension to be adjusted such that on the span shown in Fig. 12, 200 +10/-5 Hz is measured by CLAVIS gauge. Alternately belt can be depressed by 11 to 13 mm with thumb pressure applied.

ENGINE

SPAN

BELT TENSIONER ROLLER

BELT TENSION ADJUSTING SCREW

Fig. 61

62

INDEX

GROUP INDEX

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ENGINE 475 SI MPFI ALTERNATOR / POWER STEERING PUMP BELT (specific to 75 PS engine) ALTERNATOR / POWER STEERING PUMP BELT Removal : l Loosen alternator upper mounting Bolt and bottom mounting bolt Fig. 61a. For vehicles with power steering please refer 61b. l Slightly loosen banjo bolt connections on vacuum pump l Reduce alternator belt tension by loosening of tension adjusting nut and by pushing alternator towards engine. l Remove alternator belt. Inspection : l Inspect alternator belt for wear, cracks and signs of failure. Replace, if necessary. Fitment : l Install alternator belt over crank shaft, power steering pully and alternator pulleys (Fig. 61b). Note : incase of vehicle without power steering, power steering pulley will not be there Fig-61a). l Pull alternator away from engine for specified tension & tighten the nut to specified torque. l ALTERNATOR BELT TENSION IS CORRECT IF IT CAN BE DEPRESSED BY 10-11 mm (for engine with alternator) & 8-9 mm (for engine with A.C., Alternator and Power steering) WITH THUMB PRESSURE (1O KG APPROX.) APPLIED IN THE MIDDLE OF ITS LENGTH Fig. 61a & 61b. l Tighten alternator top mounting screw and bottom mounting bolt. l Tighten banjo bolt connections on vacuum pump A.C. COMPRESSOR BELT REMOVAL 1. Loosen belt tensioner bolt. (Fig. 61b) on idler / tensioner. 2. Release tension load on the belt and remove the belt from the pulleys. INSPECTION 1. Inspect the A. C. compressor belt for wear cracks, and signs of failures. Replace if necessary. 2. Inspect pulley grooves. FITMENT 1. Install the belt over crankshaft and A. C. compressor pulleys. 2. Press the tensioner againsts the belt and tight the tension bolt to specified torque. 3. Check belt tension. 4. A. C. Compressor belt tension is correcrt if it can be depressed by 8-9 mm with thumb pressure applied in the middle of its length between compressor and crankshaft pulleys.

INDEX

3

Crankshaft Pulley

4

5

ENGINE

6

2

10-11mm

1

Alternator

Engine with Alternator (without power steering) 1. Alternator mounting bottom bolt 2. Alternator mounting upper bolt 3. Clamping piece 4. Clamping bolt 5. Adjusting nut 6. Lock nut

Fig. 61a

Alternator Crankshaft Pulley

8-9 mm

Compressor Tensioner

Tensioner Bolt Power Steering Pump

8-9 mm

Fig. 61b

GROUP INDEX

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63

ENGINE 475 SI MPFI

ENGINE

TIMING BELT : Removal : Remove alternator and AC belt Unscrew the mounting screws & remove front timing gear train cover Fig. 62. Keep crank shaft rotating with socket spanner simultaneously pressing camshaft timing pin till it locks camshaft Fig. 63.

Fig. 62 Check at this position whether timing pin 2702 5890 0605 in crankcase locks the flywheel or not Fig. 64. Remove timing pin locking the camshaft & now ensure that flywheel is in locked position.

Fig. 63

Fig. 64 64

INDEX

GROUP INDEX

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ENGINE 475 SI MPFI Fit lock plate for camshaft gear washer on cylinder head as shown in Fig.65 Slacken the camshaft gear fixing bolt.

ENGINE

Slacken the mounting bolt of belt tensioner roller assembly and rotate the belt tensioner in anticlockwise direction to loosen the belt. Fig. 66 Remove timing belt. Inspection : Check belt in detail. If following flaws are evident, replace belt with new one. l

Back surface glossy, non elastic and so hard that even if finger nail is forced into it, no mark is produced.

l

Cracked back surface rubber

l

Cracked or exfoliated canvas

l

Cracked tooth bottom

l

Side of belt cracked

l

Side of belt excessively worn

l

Excessively worn teeth

l

Missing tooth

Fig. 65

NOTE : Normal belt should have clear cut sides, as if cut with a sharp knife. In the initial stage of wear, load side tooth flank will look like fluffy canvas fibre, rubber gone and colour changed to white. In the last stage of wear, canvas on load side tooth flank will be totally worn out exposding rubber. Fitment :

Fig. 66

Ensure that timing pin is in flywheel locked position.

Slacken the camshaft gear fixing bolt so that the camshaft gear is “Just” freely rotating on camshaft. Fit the camshaft gear washer lock plate as shown in Fig. 65

Check that the cam gear is “Just” freely rotating on the camshaft with mounting bolt in hand loose condition. Slacken all valve tappet clearance setting screws to such an extent that the screw bottom radius is just riding on the valve tips & tighten the locknuts. NOTE : This is to reduce the valve spring load on Camshaft, while rotating the camshaft. Using appropriate spanner on camshaft gear fixing bolt, rotate camshaft in clockwise direction with timing pin placed on the cylinder head reference hole, until the camshaft is locked in timing position. (Fig. 116)

INDEX

Check now that both the flywheel and camshaft are in locked in timing position. Fit timing belt on Crank shaft gear, water pump, tensioner roller and camshaft gear. Adjust the timing belt tension, by rotating tensioner roller clockwise and tighten the mounting screw, while tightening the mounting screw ensuring that the tensioner roller does not rotate further in clockwise direction. This will prevent overtensioning of timing belt. Tighten the cam shaft gear fixing bolt to a lower tightening torque of 1 mkg.

GROUP INDEX

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65

ENGINE 475 SI MPFI Remove cam shaft timing locking pin. Re-tighten the cam gear fixing bolt to the specified torque. ENGINE

Remove camshaft gear washer lock plate and flywheel locking pin. Set valve tappet clearance on the following rocker arms. Fig. 67 Tappet Cylinder valves :

Inlet = 30 Exhaust = 20

Inlet - 1 & 2 and Exhaust - 1 & 3 Rotate crank shaft in clockwise direction by one revolution and lock the flywheel. Set the valve tappet clearance on the reamaining rocker arms i. e., Inlet - 3 & 4 and Exhaust - 2 & 4 Rotate crankshaft in clockwise direction by more revolution and check whether flywheel and camshaft are in locked timing position. NOTE : In this procedure timing pin locking the camshaft is removed from the cylinder head timing reference hole, whenever camshaft is subjected to very high looserning and tightening torque through the gear fixing

Fig. 67 bolt. This is to prevent severe damage to cylinder head, camshaft timing slot and subsequent problem of very low oil pressure (due to increased bearing clearance on bearing No. 5 of cylinder. head). Special ‘C’ tool should be used whenever cam gear fixing bolt is to be tightened or loosened. Never use the timing pin in locked timing position to hold the camshaft during tightening or loosening process.

LOCK NUT (VALVE TAPPET CL. SCREW) ROCKER SCREW

Cylinder Head Exploded

ROCKER ARM

SPRING RETAINER LOCK HALF SPRING VALVE GUIDE SEAL VALVE GUIDE ROCKER SHAFT

CYLINDER HEAD CAM SHAFT TIMING GEAR INTAKE VALVE

EXHAUST VALVE

Fig. 68 66

INDEX

GROUP INDEX

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ENGINE 475 SI MPFI CYLINDER HEAD : (Engine on workstand) Disassembly: Remove electrical cable connections for : l

ENGINE

Spark plug leads. Fig. 69

Fig. 69 Remove l

Fuel pressure regulator

l

Canister purge valve

l

Bracket supporting fuel lines. Fig. 70

Fig. 70 l

Coolant bypass line. Fig. 71

Fig. 71

INDEX

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67

ENGINE 475 SI MPFI l

Blowby hose connection to cylinder head cover. Fig. 72

ENGINE

Fig. 72 l

Vacuum pipe from intake manifold to brake booster.

l

Vacuum pipe to canister purge valve Fig. 73.

Fig. 73 l

Inlet manifold with throttle body Fig. 74.

Fig. 74 68

INDEX

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ENGINE 475 SI MPFI l l

Exhaust manifold Fig. 75 Timing Cover ENGINE

Fig. 75 l

Cylinder head cover Fig. 76

Fig. 76 Keep crankshaft rotating by socket spanner simultenously, Insert flywheel locking pin and lock fly wheel. Fit lock plate for camshaft gear washer & loosen cam shaft gear mounting bolt. (Fig. 77)

Fig. 77

INDEX

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69

ENGINE 475 SI MPFI

ENGINE

Also remove l Timing belt Fig. 78 l Dip stick clamping screw

Fig. 78 Unscrew and remove cylinder head mounting screws in reverse order of tightening Fig. 79 Slightly lift cylinder head to clear locating hollow dowel in crank case and remove it. l Cam shaft gear Fig. 80

Fig. 79 l

Rocker arm shaft locking grub screws and rocker arm shafts. Fig. 81

Fig. 80 70

INDEX

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ENGINE 475 SI MPFI NOTE : 1) To ease the dismantling of rocker shaft relieve the valve spring load by slackening the tappet setting screws. In this condition do not attempt to rotate the cam shaft, if you do so valve tips will be damaged. (Fig. 81)

ENGINE

2) While pulling out Rocker arm shafts, take out the rocker arm with springs & spring seats carefully one by one. (Fig. 82)

Fig. 81

Fig. 82 INLET MANIFOLD WITH THROTTLE BODY (Removed from cylinder head)

Disassembly : Remove ignition coil assembly from inlet manifold Fig. 83 (Four bolt)

Fig. 83

INDEX

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71

ENGINE 475 SI MPFI Disconnect the tube from inlet manifold to fuel pressure regulator ENGINE

Remove the fuel rail mtg. bolt on inlet manifold Fig. 84

Fig. 84 Remove fuel rail alongwith injectors Fig. 85

Fig. 85 Detach injectors from fuel rail Fig. 86

Fig. 86 72

INDEX

GROUP INDEX

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ENGINE 475 SI MPFI Remove fuel pressure regulator from fuel rail Fig. 87

ENGINE

Fig. 87 Remove integral throttle body from inlet manifold. Fig. 88 Assembly of inlet manifold For assembling the MPFI system component proceed in reverse order of disassembly of component.

Fig. 88

SPARK PLUG l

Remove Spark plugs Fig. 89

Spark Plug

-

Champion

Spark Plug no.

-

C9YC

Spark Plug Gap

-

0.7 mm to 0.8 mm

You should inspect the spark plugs periodically for carbon deposits. When carbon accumulates on the spark plug, a strong spark will not be produced. Remove carbon deposits using a spark plug cleaner. Spark Plug Replacement : 1.

Clean up any dirt or oil that is collected around the spark plug caps.

INDEX

Fig. 89

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73

ENGINE 475 SI MPFI

ENGINE

2.

Pull out the spark plug cables by gripping at the connector.

3.

Remove the spark plug with the help of box spanner 2702 5890 06 01 (Fig. 89)

4.

Check and adjust the gap, it should be 0.7 mm to 0.8 mm. Fig. 90

5.

Replace the spark plug if the gap is more than 0.8 mm.

6.

Fix the spark plug and tighten it to the specified torque (dry.)

7.

Fit the spark plug cable.

Repeat the procedure for the other spark plugs. Tighten the spark plug carefully. Overtightening can damage the threads in the cylinder head. A loose spark plug can affect combustion and cause engine damage.

Fig. 90

SPARK PLUG DEFECTS The condition of spark plug firing ends can act as a guide to the state of tune and general condition of the engine. NORMAL Fig. 91 Core nose lightly coated with grey-brown deposits. Electrodes not burning unduly - gap increasing about 0.01 mm per 2000 km (with the use of unleaded fuel). Spark plugs ideally suited to engine. HEAVY DEPOSITS Fig. 92 Possible causes : Fuel or oil additives. Oil in combustion chamber. Worn valve guides. Unvarying speed (stationary engine). Replace spark plugs.

Fig. 91

Fig. 92

CARBON FOULING Characterised by dull black sooty deposits although unleaded fuel carbon fouling can appear as glossy deposits similar in appearance to oil fouling. Deposits can short circuit the firing end; weakening or eliminating the spark. Check for : Over-rich mixture setting, faulty choke mechanism or clogged air filter. Replace spark plugs. OIL FOULING Deposits can short-circuit the firing end, weakening or eliminating the spark. May be caused by worn valve guides,

Fig. 93 74

INDEX

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ENGINE 475 SI MPFI bores or piston rings, or whilst a new or overhauled engine is running-in. Cure the oil problem, if possible. Temporary use of the next hotter grade of spark plug may stop the misfire. Replace spark plugs.

ENGINE

OVERHEATING Likely causes are : Over-advanced ignition timing. incorrect distributor advanced curve. Use of fuel with insufficient octance rating. Weak mixture. Discard spark plugs showing signs of overheating, and cure the cause. INITIAL PRE-IGNITION Caused by serious overheating. Causes are those listed for overheating but may be more severe. Corrective measures are urgently needed before engine occurs. Discard plugs in this condition.

Fig. 94

SPLIT CORE NOSE Fig. 93 May appear initially as a hair-line crack. Probably caused by detonation waves, indicating : Overadvanced ignition timing. Incorrect distributor advance curve, use of fuel with insufficient octance rating, Weak mixture, Manifold air-leaks, Cooling system problems, Incorrect gap setting technique, etc. Cylinder head disassembly continued Remove : l

Cyl. head cover mounting studs and spacer tubes. (replace if required) Fig. 94

Fig. 95 l

Cam shaft locking plate from cam shaft bearing cap at the front

Push the cam shaft from rear and pull out from front, with oil seal Fig. 95 & 96 For Camshaft inspection go to Page No. 81

Fig. 96

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75

ENGINE 475 SI MPFI Fit support rail, (2702 5890 0616) to cylinder head Fig. 97 ENGINE

Fig. 97 With spring compressor (2702 5890 06 15) compress valve springs and remove valve lock halves Fig. 98 Remove valve lock retainers, valve springs, valve spring seats and valves. Place them in correct sequence.

Fig. 98

Mating Surface : Using a straight edge and feeler gauge, check cylinder head mating surface with crank case, Fig. 99 & 100. If unevenness exceeds, replace cylinder head.

Fig. 99 76

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ENGINE 475 SI MPFI CYLINDER HEAD TOP AND BOTTOM SURFACE REMACHINING, IN SERVICE IS NOT PERMITTED. Permissible unevenness of cyl. head overall mating surface (150 x 150) : cross wise 0.015 mm length wise 0.030 mm.

ENGINE

VALVES Fig. 101 Check valve leakages by pouring gasoline on valve head. Gasoline must not seep past valve seat. Valves with burnt heads, excessive scoring and wear on stem should be replaced.

Fig. 100

ROCKER SHAFT ROCKER SCREW ROCKER ARM CAM SHAFT

VALVE RETAINER LOCK HALF VALVE GUIDE SEAL

SPRING VALVE GUIDE

INTAKE PORT CYLINDER HEAD

VALVE

VALVE SEAT VALVE SEAT INSERT (external fitment)

Fig. 101 Valve Arrangement

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77

ENGINE 475 SI MPFI

ENGINE

Check valve seat run out with respect to valve stem. Fig. 102. If it exceeds specified limit (0.030 mm both inlet & exhaust) replace valve. No attempt should be made to straighten bent valves. If valve is free from any other defects except worn out seat, then only it can be rematched on valve grinding machine as follows. l Clamp valve on grinding machine jaws as close as possible to valve head. l Adjust grinding angle on graduated scale to achieve correct valve seat angle. l Feed valve slowly towards grinding wheel until wheel just touches valve head. l Grind at low feed until valve seat is just clean all around. NOTE :

After grinding, valve head thickness should not be less than 0.85 mm.

Fig. 102

EXHAUST VALVE

INLET VALVE VALVE STEM B

B VALVE SEAT C

C

45

0

A

VALVE SEAT ANGLE

C

C

A

D VALVE HEAD

Fig. 103 VALVE GUIDES : In case of valve stem sticking in valve guide before or excessive clearance between them, remove valve guide from cylinder head using drift (2702 5890 0611) Fig. 104

Fig. 104 78

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D

ENGINE 475 SI MPFI Valve dimensions : Fig. 101 INLET

EXHAUST ENGINE

Valve head dia. ‘A’ mm

36.6/36.8

30.9/31.1

Valve seat angle

450 +15'

450+15'

Valve stem dia ‘B’ mm

6.97-0.015

6.96-0.015

Maximum run out of valve face with respect to valve steam mm

0.2

0.2

Valve seat dia ‘C’ mm

35

29.2

2.65+0.1

2.82+0.1

Maximum run out of valve seat with respect to valve steam

0.030

0.030

Valve seat dia in cylinder head mm

34

28.0

14.4+0.05

14+0.05

0.030

0.030

Valve seat end distance from valve face ‘D’ mm

Distance between cylinder head mating surface with crank case to valve seat in cylinder head mm Maximum run out of valve seat in cylinder head with respect to valve guide axis mm

Remove valve guide seals. Check condition and replace if required with drift 2702 5890 0617 Fig. 105 Check valve guide bore diameter in cylinder head and if necessary, ream valve guide bore in cylinder head to next over size. (Refer table on next page)

Fig. 105

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79

ENGINE 475 SI MPFI Install matching size valve guide in cylinder head using drift 2702 5890 0611 and spacer, 2702 5890 0612 Fig. 106. ENGINE

Ream valve guide inside diameter to specified size. Fit valve guide oil seals.

VALVE SEATS OF VALVES Check valve seat (this is the position on valve seat insert, where valve face rest) height with respect to cylinder head mating surface. Replace valve seat inserts if they are worn out byond specified limit. Cut exhaust and inlet valve seats with a 450 cutter Fig. 107.

Fig. 106 Size

Valve guide bore in cyl. head

Valve guide OD,mm

Valve guide ID,mm

Normal

12.99+0.008/-0.01

13.0 + 0.046 + 0.028

7 7

+ 0.015 - 0 + 0.016 + 0.004

(Inlet) (Exhaust)

Normal 1

13.09+0.008/-0.01

13.1 + 0.046 + 0.028

7 7

+ 0.015 - 0 + 0.016 + 0.004

(Inlet) (Exhaust)

VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND WITHOUT ANY CHATTER MARKS If necessary lap valve seats to a smooth and even finish by using suitable hand pump grinder or a lapping paste and valve itself.

Valve guide length, mm 39.5 (Inlet) 46 (Exhaust)

suitable puller. In order to avoid damaging machined cylinder head mating surface with crank case, place any soft protective sheet metal under supports of puller. Measure valve seat insert bore in cylinder head & then select suitable insert after referring table on next page.

Smear valve seat with carbon blue. Install valve in guide and turn it slowly under axial pressure. CONTACT LINE ON VALVE SEAT MUST BE AROUND ENTIRE CIRCUMFERENCE AT EQUAL WIDTH Distance between narrow diameter of valve face to contact line should be minimum 0.5 mm Check for leakages through valve seat by pouring gasoline on valve head. Gasoline must not seep past valve seat.

VALVE SEAT INSERTS : For removing valve seat inserts from cylinder head use a suitable boring machine. Bore old insert thin (about 0.5 mm thickness) and then pry it out. Alternatively use a suitable turning tool to cut an annular groove into valve seat insert and then pull it out with a

Fig. 107 80

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ENGINE 475 SI MPFI If boring and prying is done carefully without damaging valve seat insert bore in cylinder head, fitment of an over size valve seat insert will not be necessary. ENGINE

Re-machined valve seat insert bore in cylinder head must be exactly at right angle to cylinder head mating surface with crank case. All specified dimensions should be strictly maintained to ensure proper interference of valve seat insert in its bore. Clean the valve seat insert and its bore in cylinder head thoroughly. Just before installation : l Place valve seat insert in a mixture of Methanol and dry ice for about 20-30 minutes to bring its temperature down to -150 deg. C. l

Fig. 108

Heat cylinder head to approximately 80 deg. C in water bath.

Install valve seat insert in cylinder head bore quickly by using mallet. Machine valve seat in cylinder head. Valve seat insert : Valve seat insert thickness Inlet Exhaust

Valve seat inside dia in insert Inlet Exhaust

- 6.5 + 0.05 mm - 6.5 + 0.05 mm

- 32 + 0.1mm - 26 + 0.1mm

Valve seat insert & bore dia. in cyl. head Stage

Valve seat insert bore diameter in cyl. head (mm)

Valve seat insert out side diameter (mm)

Normal Normal 1

38/38.03 38.23/38.28

38.13/38.155 38.43/38.455

EXHAUST - Normal - Normal 1

32.99/33.021 33.29/33.321

33.13/33.155 33.43/33.455

INLET -

CAM SHAFT INSPECTION Carry out visual inspection of cam shaft for : l Overall heating of journals, which is indicated by bluish/brown colour l Deep scoring marks on journals and cam lobes l Cracks, which should be checked on a magnetic crack detector.

INDEX

Check hardness of cam shaft journals and cam lobes. It should be 40 HRC min. Check cam shaft runout at 2nd, 3rd & 4th journal by supporting it on V-block at 1st and 5th journal. Fig. 108 Check cam shaft journal dimensions.

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81

ENGINE 475 SI MPFI Cam shaft journal & bearing bore dimensions (mm) : Journal No.

Cam shaft bearing journal bore diameter in cylinder head

1 2 3 4 5

42.000 - 42.025 41.500 - 41.525 41.000 - 41.025 40.500 - 40.525 40.000 - 40.025

41.925 - 41.950 41.425 - 41.450 40.925 - 40.950 40.425 - 40.450 39.925 - 39.950

Maximum permissible run out of cam shaft bearing journal Maximum permissible axial play of cam shaft in installed condition Runout of oil seal mating diameter.

0.025 mm 0.1/0.25 mm 0.02 mm

ENGINE

Cam shaft bearing journal diameter.

Cylinder head cover: Remove the baffle plate in the cylinder head cover by removing the screws Fig. 109. Check the baffle plate gasket if it is torn/damage, replace if necessary otherwise it might result in high engine oil consumption.

Fig. 109

Assembly of cylinder head : Install valves in their respective positions Install spring seat, valve springs and valve retainers. Fit support rail (2702 5890 0616) on cylinder head Fig. 110.

Fig. 110 82

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ENGINE 475 SI MPFI With spring compressor, (2702 5890 0615), compress valve springs and install valve lock halves Fig. 111. (Note : Camshaft for 85 PS engine & 75 PS engine are different).

ENGINE

Smear cam shaft journals and cam lobes with moly paste grease Install cam shaft and lock it by lock plate at the front Fig. 81 & Fig. 112. Insert the rocker arm shaft with rocker arm spring and spring seat one by one CAREFULLY. Rocker arm and rocker shaft dimensions: Rocker shaft dia. :15 Rocker bore dia. : 15

- 0.016 + 0.011

mm mm

Fig. 111

CAUTION : While inserting rocker arm shaft on inlet valves, ensure that tapped hole on the shaft is at the front end and for rocker arm shaft on exhaust valves the tapped hole - 0.027 on the shaft is at the rear end. - 0.000

Check cam shaft axial play. It should be within specified limits (0.1/0.25 mm) Fig. 113 Check camshaft for rotation. Fit camshaft oil seal with drift (Pt. No. 2654 5890 0508) Fit camshaft gear and hand tighten the mounting bolt. Measure piston projection above crank case and select correct thickness of cylinder head gasket PISTON PROJECTION mm

GASKET THICKNESS, mm

0.04 - 0.26

1.1

Fig. 112

MAXIMUM DIFFERENCE BETWEEN PISTON PROJECTIONS OF ANY TWO PISTONS IN CRANK CASE SHOULD NOT EXCEED SPECIFIED VALUE.

Fig. 113

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83

ENGINE 475 SI MPFI

ENGINE

Ensure that cylinder head locating hollow dowel is in position on crank case (Block). Ensure that flywheel locking pin 2702 5890 0605 is installed in position Fig. 114. Place cylinder head gasket of pre-determined thickness. Install cylinder head and tighten cylinder head mounting screws to 3 mkg torque in the correct sequence i.e. from

9

5

1 10

1

2 6

4

3 2

8

4 3

7

Fig. 114 centre to outwards.Then retighten screws to 5 mkg torque in the same sequence - Then loosen each screw by quarter turn and retighten to 7.5mkg. torque Fig. 115. Valve clearance adjustment. VALVE CLEARANCES SHOULD BE CHECKED ONLY WHEN ENGINE IS COLD. l

Fit camshaft gear

Fitment : Ensure that timing pin is in flywheel locked position. Check that the cam gear is “Just” freely rotating on the camshaft with mounting bolt in hand loose condition. Slacken all valve tappet clearance setting screws to such an extent that the screw bottom radius is just riding on the valve tips & tighten the locknuts. (Refer fig. 68)

Fig. 115

NOTE : This is to reduce the valve spring load on camshaft, while rotating the camshaft. Using an appropriate spanner on camshaft fixing bolt, rotate in camshaft in clock direction with timing pin placed on the cylinder head reference hole, until the camshaft is locked in timing position. Fig. 116 Slacken the fixing bolt so that the camgear is “Just” freely rotating on camshaft. Fit the camshaft gear washer locking plate. (Fig. 65) Check now that both the flywheel and camshaft are in locked timing position.

Fig. 116 84

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ENGINE 475 SI MPFI Fit timing belt on crank shaft gear, water pump tensioner roller and camshaft gear. Adjust the timing belt tension, (Fig. 117) by rotating tensioner roller clockwise and tighten the mounting screw, ensuring that the tensioner roller does not rotate further in clockwise direction. This will prevent overtensioning of timing belt.

ENGINE

Fig. 117 Tighten the cam gear fixing bolt to a lower tightening torque of 1 mkg Fig. 118. Remove cam shaft timing locking pin. Re-tighten the cam gear fixing bolt to the specified torque.

Fig. 118 l

Set the flywheel and cam shaft in No.1 cylinder firing position by inserting cam shaft timing locking pin.

l

Adjust the valve clearances of cylinder No. 1 & 2 on inlet valves and cylinder No. 1 & 3 on exhaust valves Fig. 119

l

Remove the camshaft locking pin and fly wheel locking pins.

Fig. 119

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85

ENGINE 475 SI MPFI

ENGINE

l

Rotate the crankshaft by one rotation in the clockwise direction and insert the flywheel locking pin.

l

Adjust the valve clearances of cylinder No. 3 & 4 on inlet valves and cylinder No. 2 & 4 on exhaust valves Fig. 120 INLET

EXHAUST

0.20

0.30

Specified

Assemblies l

Fig. 120

Spark plug. Fig. 121

Fig. 121 l

Exhaust manifold Fig. 122

Fig. 122 86

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ENGINE 475 SI MPFI l

Inlet manifold with throttle body and gasket. Fig. 123

l

Spacer tube on cylinder head cover mtg. studs.

l

Cylinder head cover along with camshaft gear rear cover. Replace the gasket if required.

l

Timing belt gear cover Fig. 124.

l

Thermostat cartridge

l

Thermostat cover with gasket

l

Bypass line

l

Dip stick clamp screw

l

Vacuum pipe canister purge valve to intake manifold.

l

Hoses from intake manifold to cylinder head cover and brake booster.

l

Bracket supporting fuel lines.

l

Spark plug leads.

ENGINE

Fig. 123

Fill recommended quantity of oil.

Fig. 124

CYLINDER BLOCK (Cylinder head assembly removed) Disassembly Uniformly and evenly unscrew clutch pressure plate mounting screws and remove clutch pressure plate and clutch disc Fig. 125.

Fig. 125

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87

ENGINE 475 SI MPFI Remove : l Vibration damper Fig. 126. ENGINE

Fig. 126 l l l l

Crankshaft gear Fig. 127. Water pump Timing belt tensioner Timing belt rear cover

Fig. 127 l l

Oil filter by using spanner (2702 5890 1802) Fig. 128 Engine mtg. bkt. (intermediate)

Fig. 128 88

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ENGINE 475 SI MPFI l

Oil sump by extended socket (2702 5890 0603) Fig. 129 ENGINE

Fig. 129 l l

Oil pump strainer Fig. 130a Oil pump Fig. 130b

Carefully remove combustion residues towards top end of cylinder bores, preferably by a broken piston ring or by a ridge cutter. Turn the crank shaft and bring a pair of piston to BDC

Unscrew connecting rod bearing cap mounting nuts Fig. 131

Fig. 130a

Fig. 131

Fig. 130b

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89

ENGINE 475 SI MPFI Remove connecting rod bearing caps with bearing shells.

ENGINE

Push these piston assemblies out of cylinders using the wooden handle of the mallet. Remove connecting rod bearing shells and duly mark them with paint on their backs in case these are to be reused. IT IS ESSENTIAL TO ASSEMBLE CONNECTING ROD BEARING CAPS TO THEIR RESPECTIVE CONNECTING RODS Verify serial numbers on connecting rod bearing caps and connecting rods. Remove remaining pistons in same manner Remove piston pin spring clips with suitable plier. Fig. 132

Fig. 132 Remove piston pins from piston by pushing them out using soft drift. Fig. 133 Remove connecting rod

Fig. 133

KEEP PISTONS AND PISTONS PIN IN SETS : Insert flywheel locking pin. Fig. 134

Fig. 134 90

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ENGINE 475 SI MPFI Unscrew flywheel mounting screws Fig. 135a Remove flywheel locking pin. ENGINE

Remove flywheel. Unscrew and remove crankcase rear cover with oil seals. Fig. 135b

Fig. 135a

Fig. 135b Removal o f Crankcase rear cover

Unscrew main bearing cap mounting bolts and remove main bearing caps. Fig. 136 Remove crank shaft main bearing shells and thrust washers from crank case. Duly mark the main bearing shells with paint on their backs, in case these are to be reused.

Fig. 136 Remove crankshaft Fig. 137 IT IS ESSENTIAL TO ASSEMBLE MAIN BEARING CAPS TO THEIR RESPECTIVE POSITIONS IN CRANK CASE.

Fig. 137

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91

ENGINE 475 SI MPFI PISTON AND PISTON RINGS : PISTON AND CYLINDER BORE SIZES : ENGINE

Type

Grade

Cylinder bore Diameter mm

Piston Diameter mm

A

75.00/75.01

74.96

B

75.01/75.02

74.97

C

75.02/75.03

74.98

Standard

PISTON RINGS : Type of ring

Axial clearance in piston groove

Butt clearance in cylinder bore

1st Compression ring

0.03 / 0.07 mm

0.15 / 0.3 mm

2nd Compression 0.02 / 0.06 mm ring

0.2 / 0.35 mm

3rd Oil control ring

0.2 / 0.6 mm

-

Fig. 138

Remove piston rings from piston using ring expander. Fig. 138 Remove the carbon deposits from the piston Clean the piston and piston rings thoroughly In case the cylinder bore taper and ovality is within specified limit, then same piston and piston rings may be reused. Examine the pistons for cracks, scoring, other damages, ring groove wear, piston pin bore wear, spring clip groove wear/damage etc.

Fig. 139

In case of any one piston with any one of this defect, complete piston set should be replaced. Examine piston rings for scoring, lateral clearance in piston ring groove and butt clearance in cylinder bore. Fig. 139 & 140 Piston pin dia. Piston Pin length Piston Pin bore in piston Height of Piston Piston to bore clearance Max. permissible difference in weights of pistons with pin & rings of an engine

20.00/19.996 mm 59.00/58.7 mm 19.998/20.003 mm 52.5 mm 0.040 - 0.050 mm

3 gms.

Fig. 140 92

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ENGINE 475 SI MPFI BUTT CLEARANCE OF PISTON RING SHOULD BE MEASURED IN UNWORN PORTION OF CYLINDER BORE. In case of any piston ring with any one of this defect, complete ring set should be replaced.

ENGINE

When cylinder bores are re-bored or honed, pistons and rings of appropriate size should be used. Piston size is stamped on piston crown. Install piston rings in their respective position on piston using ring expander, with “TOP”marking upward. Fig. 141 Ensure that piston & rings are clean. Assemble the expander of the oil ring in the 3rd groove & then the bottom & top rails. Do not wind in the rails on to the groove. AssembleTaper compression ring in the 2nd groove using ring plier.Ensure‘TOP’marking is towards the piston crown.

Fig. 141

Assemble the Gas nitrided steel ring in the top groove using a ring plier. Stagger the ring gap. Lightly oil the rings and use ring compressor, while inserting into the cylinder.

CONNECTING RODS Inspect connecting rod small end bush and if necessary, replace it. Check connecting rod small end parent bore dimension Fig. 142 If necessary machine connecting rod small end parent bore to next over size. NOTE : Ensure that the Connecting rod big end & small end axes are parallel to each other within specified limits. Ensure that centre distance between small end & big end is maintained within specified limit.

Fig. 142

Oil the parent bore in connecting rod. Install a new bush in such a way that slit is positioned approximately in vertical axis. Drill oil hole in the new bush Finish connecting rod small end bush bore on a connecting rod boring machine. Alternately connecting rod small end bush may be reamed. Install connecting rod bearing caps without bearing shells on connecting rod. Tighten connecting rod bearing cap mounting nuts to specified torque. Fig. 143

Fig. 143

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93

ENGINE 475 SI MPFI CONNECTING ROD (DIMENSIONS) : Connecting rod small end ENGINE

Stage

parent bore diameter mm

bush outside diameter mm

Normal

23.021/23.000

23.086/23.111

Normal I

23.221/23.200

23.286/23.311

Maximum permissible taper and ovality of connecting rod small end parent bore and cylindricity

0.004 0.008

mm mm

20.0+0.020/0.007

mm

Maximum permissible out of parallelism (bend) between connecting rod small end and big end parent bores.

0.050

mm

Centre to centre distance between connecting rod small end and big end parent bores.

141.65+-0.3

mm

Maximum permissible twist of connecting rod

0.050

mm

Connecting rod big end parent bore diameter

48.655 /48.671

mm

0.005 0.01

mm mm

0.024 to 0.075

mm

0.013-0.051

mm

5

gms

0.05 - 0.35

mm

Connecting rod small end bush inside diameter finished after installation) (Piston pin oiled has thumb push fit in small end bush).

Maximum permissible taper and ovality of connecting rod big end parent bore and cylindricity Bearing shells to be selected such that clearance is maintained as Pre-tension of connecting rod big end bearing shells Maximum permissible difference in weight of connecting rods in one engine Connecting rod big end axial play

94

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ENGINE 475 SI MPFI NOTE : Ensure that the identification numbers for connecting rod & connecting rod bearing cap are matched & notches for bearing shells are on same side.

ENGINE

Check twist and bend of connecting rod by using new piston pin in connecting rod small end bush. Measure twist and bend of connecting rod with feeler gauge with respect to vertical face of connecting rod alignment gauge in vertical and horizontal plane at a distance of 50 mm from the line joining centres of connecting rod small end and big end bosses. Fig. 144 & 145 If necessary, straighten the connecting rod in cold condition. Since a slight clearance exists between connecting rod bolts and corresponding connecting rod bearing cap holes, it is possible that connecting rod bearing cap once removed may be installed off centre, by which dimension of connecting rod big end parent bore will be different in different directions.

Fig. 144

If difference is noticed in connecting rod big end parent bore dimension, connecting rod bearing cap can be centralised by lightly tapping it with mallet in required direction after slightly loosening connecting rod bearing cap mounting nuts. Check connecting rod big end parent bore dimension. Fig. 146 If connecting rod big end parent bore is slightly more than maximum permissible limits, it is possible to reclaim connecting rod provided the wear is confined only to connecting rod bearing cap.

Fig. 145

Connecting rod bearing cap mating surface may be slightly faced. Parent bore should then be finished on a connecting rod boring machine. ENSURE THAT CONNECTING ROD BIG END AND SMALL END AXES ARE PARALLEL TO EACH OTHER WITHIN SPECIFIED LIMITS. CENTRE TO CENTRE DISTANCE BETWEEN CONNECTING ROD SMALL END AND BIG END IS MAINTAINED WITHIN SPECIFIED LIMITS. If one or more connecting rods are to be replaced, ensure that difference in weight of connecting rod in an engine is within permissible limits. Install new pair of connecting rod bearing shell according to size of crank pin journal diameter, making sure that securing lugs of bearing shells are properly seated in grooves of connecting rod and its bearing cap.

Fig. 146

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95

ENGINE 475 SI MPFI Install connecting rod bearing cap with bearing shell on connecting rod. ENGINE

Tighten connecting rod bearing cap mtg. nuts to specified torque Fig. 147

Fig. 147 Measure connecting rod bearing bore Fig. 148 IF CONNECTING ROD BIG END PARENT BORE DIMENSION IS MAINTAINED WITHIN SPECIFIED LIMITS. PROPER BEARING BORE DIMENSION IS AUTOMATICALLY ACHIEVED. However, it must be physically measured and confirmed . Measure pre-tension of connecting rod bearing shell with a feeler gauge after loosening connecting rod bearing cap mounting nut on opposite side of bearing shell lug. CONNECTING ROD BEARING SHELLS ARE PRECISION FINISHED AND SHOULD NOT BE BORED OR SCRAPED.

Fig. 148

96

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ENGINE 475 SI MPFI Crank shaft (dimensions) Stage

Crank case main bearing bore diameter with bearing shell mm

Crank shaft main bearing journal diameter mm

Normal

50.026 / 50.065

50.0/49.98

Normal 1

49.926/ 49.965

49.900/ 49.880

Repair 1

49.786 / 49.815

49.760/ 49.730

Repair 2

49.526 / 49.565

49.500/ 49.480

Stage

Connecting rod big end bore diameter with bearing shell (mm)

Crank pin journal diameter mm

Normal

45.007 / 45.043

44.995/44.980

Normal 1

44.907 / 44.943

44.895/ 44.880

Repair 1

44.757 / 44.793

44.745 / 44.730

Repair 2

44.507 / 44.543

44.495 / 44.480

Stage

Width of 4th main bearing journal (mm)

Thickness of 4th main bearing thrust washers, mm

Normal

24.052 / 24.000

2.62(2.60-2.65)

Standard 1

24.152 / 24.100

2.57(2.55-2.60)

Repair 1

24.252 / 24.200

2.52(2.50-2.55)

End play of crank shaft

0.06 - 0.226 mm

Fillet radius of main bearing journals

2.5-0.5 mm

Fillet radius of crank pin journals

2.5-0.5 mm

Pre-tension of main bearing shells

ENGINE

0.018-0.040 mm

Hardness of crank shaft main bearing and crank pin journals

50-60 HRC

Width of 1st, 2nd, 3rd and 5th main bearing journals

24.0+0.2 mm

Main bearing parent bore dia in crank case

53.8 +0.019 mm + 0.00 mm

Width of crank pin journals

24.0+0.2 mm

Maximum permissible taper of main bearing parent bore

0.005 mm

Maximum permissible ovality of main bearing parent bore.

0.005 mm

Maximum permissible cylindricity

0.0025 mm

Ovality of main brg. journal

0.005 mm

Max. permissible ovality of crank pin

0.005 mm

Maximum permissible run out of 2nd, 3rd and 4th main bearing journals when supported at 1st and 5th main bearing journals

0.02 mm

Crank shaft journal to main bearing clearence

0.026 / 0.085 mm

Maximum permissible out of parallelism 0.010 mm between crank pin and main bearing journal axis

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97

ENGINE 475 SI MPFI 4th main bearing journal

CRANK SHAFT : ENGINE

Clean and carry out visual inspection of crankshaft for the following l

Overheating of journals, which is indicated by bluish brown colour.

l

Scoring marks on journals.

l

Cranks, which should be checked on magnetic crack detector.

Check crank shaft run out by supporting it on V-block at 1st and 5th main bearing journals. Fig. 149 If run out exceeds permissible limits, straighten crank shaft in cold condition on press carefully. Similarly check lateral and radial run outs of flywheel mounting flange.

Fig. 149

Check crank shaft main bearing and crank pin journal dimension. If necessary, grind crank shaft main bearing and crank pin journals to next under size. MAINTAIN CORRECT FILLET RADII FOR JOURNALS Care must be taken during grinding to ensure that width of journals is not increased. Should it be necessary to grind sides of 4th main bearing journal, grind it to next over size. Re-chamfer oil holes on journals to avoid scoring of new bearing shells. Finish journals by lapping them with 320 grit lapping cloth of suitable width. After grinding recheck main bearing and crank pin journal dimensions.

Fig. 150

Also recheck run out of crank shaft. Thoroughly clean crank shaft with kerosene. Use wire brush for cleaning oil holes. IT IS ESSENTIAL TO RECHECK CRANK SHAFT FOR CRACKS AND BALANCE AFTER GRINDING Apply grease to all machined surfaces, if crank shaft is to be stored. Crank shaft must always be stored in vertical position.

CYLINDER BLOCK Check cylinder block for cracks by pressure testing method. Check crank case mating surface with cylinder head for unevenness with help of straight edge and feeler gauge. Fig. 150 & 151

Fig. 151 98

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ENGINE 475 SI MPFI If necessary grind this surface just to clear unevenness. Ensure that the minimum height of crank case is not less than the specified minimum height.

ENGINE

Thoroughly clean the main bearing caps and corresponding machined surfaces of crank case. Install main bearing caps without bearing shells in their respective positions of crank case. ENSURE THAT THE SERIAL NUMBERS ON CRANK CASE AND MAIN BEARING CAPS ARE MATCHING. ALSO CAPS ARE IN SERIAL ORDER AND NOTCHES FOR BEARING SHELLS ARE ON SAME SIDE. Tighten main bearing cap mounting bolts to specified torque. Fig. 152 Check crank case main bearing parent bore dimensions. Fig. 153 Remove caps. Select main bearing shells according to size of crank shaft main bearing journal diameter, making sure that securing lugs of bearing shells are properly seated in grooves of crank case and main bearing caps.

Fig. 152

Fig. 153 Install main bearing caps with bearing shells in their respective position on crank case. Tighten main bearing cap mounting bolts in specified sequence to specified torque. Fig. 154

Fig. 154

INDEX

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99

ENGINE 475 SI MPFI Measure the main bearing bore.

BOLT LOOSENED

However, it must be physically measured and confirmed. Measure pre tension of main bearing shell with a feeler gauge after loosening main bearing cap mounting bolt on opposite side of bearing shell lug (This is to be done on a flat surface plate as it can not be measured on engine cylinder block because the main bearing caps are guided) Fig. 155. If pre tension is not in range (0.018 - 0.040 mm), change & select new shell. MAIN BEARING SHELLS ARE PRECISION FINISHED AND SHOULD NOT BE BORED OR SCRAPED. Select a new pair of thrust washer according to crank shaft 4th main journal width. Refer Fig. 149

PRETENSION GAP

ÞÞ

ENGINE

BOLT TIGHTENED

IF MAIN BEARING PARENT BORE DIMENSION IS MAINTAINED WITHIN SPECIFIED LIMITS, PROPER MAIN BEARING BORE DIMENSION IS AUTOMATICALLY ACHIEVED.

SURFACE PLATE

Schematic Sketch : Main bearing shell pretension checking

Fig. 155

Cylinder bores Clean cylinder bores thoroughly Check cylinder bore dimension, taper and ovality. Fig. 156a If taper and ovality is found to exceed specified limit or bore is excessively worn out machine cylinder bore as given below to fit the liners. Record the readings in Engine inspection sheet no. 2 given in this manual. Rebore all the cylinders to 78+0.02 mm size and fit the liners as per the procedure.

Fig. 156a

100

INDEX

GROUP INDEX

NEXT

NEXT

PREVIOUS PREVIOUS

ENGINE 475 SI MPFI REMOVAL, INSTALLATION AND MACHINING OF CYLINDER LINERS REMOVAL 1. Keep cylinder block upside down on hydraulic press such that bore from which liner is to be removed lies clear in machine table slot. 2. Ensure that the block is resting squarely on machine bed. 3. Press out liners individually using drift, (Pt. No. 2702 5890 0201 and a suitable distance piece between press ram and the drift. Make sure that the distance piece is also seating squarely between the drift and the ram. INSTALLATION OF LINERS IN CYLINDER BLOCK Thoroughly clean bores of the cylinder block. Thoroughly clean liners. Place cylinder block on hydraulic press ensuring that oil sump mating face is resting evenly and squarely on the horizontal bed. DO NOT SMEAR CYLINDER BORE OF BLOCK OR LINER OUTSIDE SURFACE WITH OIL.

approximately at 100-120 rpm and approx. 50 double strokes per minute. Under these conditions leave about 0.02 mm materials for second stage honing. Anticlock wise direction of rotation of tool will be prefered if possible. Stage II Base honing The honing should be approx. 50-60 rpm & 25 double strokes per minute.The opration should be completed in 5 to 8 double strokes with low pressure of 2.0 to 3.0 kg/cm2. Anticlock wise rotation will be preferred if possible. Note : Adjust honing stick travel project by approx. 20-25 mm from top and bottom of bore during honing. Use plenty of kerosene during honing operation. At bottom 20 mm overtravel, care must be taken that stick holder will not hit to MB faces. Clean cylinder block thoroughly and if engine assembly is not to be taken up immediately, apply grease on machined surface of cylinder block. Special Tools Required : Drift for installation of cylinder liner - 2702 5890 02 01 Drift for removal of cylinder liner - 2702 5890 02 02

Place liner with proper orientation (matching minimum / maximum ovality axis) in the cylinder bore and make it at right angles to cylinder block top surface in longitudinal and crosswise directions using precision tri-square.

78+0.02 22.50+2.50

Press liner using drift 2702 5890 0202. Use a wooden spacer about 100 mm thick between press ram and drift. Pressing force should be within 4 to 6 tonnes. 75+0.01

Similarly, press all other liners. Liners damaged during installation should be removed and replaced with new ones. FINISHING OF CYLINDER BLOCK WITH LINER Process of boring & honing is already explained in manual. Machine all the bores to 74.96 +0.0/-0.045 mm diameter. Note : It is very important that the axes of the bores are parallel to each other and are at right angles to the axis of crankshaft. Therefore, we recommend the use of pillar type boring and honing machines. If portable bar is used, check and clean mating surface have boring bar and cylinder block and centralise the boring bar as accurately as possible in the bore. Finish bore by honing to 75.00 mm diameter. Honing should be done in three stages as follows. Stage I Rough honing Use honing stone of grit 60. The honing should be

INDEX

Fig. 156b

GROUP INDEX

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101

ENGINE

ENGINE 475 SI MPFI Cylinder Block (Dimensions) - in mm C ENGINE

Height of crank case (Dimension A&B) Fig. 157

D

265.8/265.6

Maximum permissible unevenness of crank case mating surface with cylinder head 150x150 : cross wise ‘D’ Fig. 157

0.015

: length wise ‘C’ Fig. 157

0.030

Maximum permissible out of parallelism between crank case top and bottom machined surface Maximum permissible shift in perpendicularity of cylinder bore from crank shaft axis when checked from crank shaft centre line Maximum permissible taper and ovality of cylinder bore

102

INDEX

B

A

0.2

0.25 mm

Fig. 157

0.007

GROUP INDEX

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ENGINE 475 SI MPFI LUBRICATION SYSTEM :

Pump rpm

Minimum flow rate in Ipm

OIL PUMP

4000

28

Unscrew screws holding oil pump to cyl. block and remove the oil pump assembly Check oil pump for flow rate at specified rpm. Check for any leakage at sealing plugs.

2000

14

800

5.6

Check functioning of Pressure relief valve. If the performance of the pump is not satisfactory, then replace the oil pump assembly. Fit oil pump assembly with new gasket. Flow rate measured against back pressure of 3kg/cm2 should be as follows using SAE-30 oil.

ENGINE

Engine oil pressure with coolant temperature of 700 C at idling speed 800+50 rpm - 1 bar at 5000 rpm - 3 bar Oil Pressure Switch NC contact opening pressure : 0.9 /0.6 bar

ENGINE LUBRICATION COMPONENTS

MAINOIL GALLERY

OILFILTER

OILPUMP

GASKET

OILSUMP

STRAINER DRAINPLUG

Fig. 158

INDEX

GROUP INDEX

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103

UPPERCOOLINGLINE

104

INDEX

GROUP INDEX

Fig. 159

NEXT

PREVIOUS THERMOSTATHOUSING

WATER TEMP. SENSOR

BYPASSLINE

CAB HEATER FEEDER HOSE

CYLINDER HEAD VENT LINE

HEATER RETURN HOSE

WATER INLET ELBOW

INTEGRAL HOSE

AUXILIARY WATER TANK

ENGINE

THERMOSTATCOVER

RADIATOR

RADIATOR VENT HOSE

COOLING CIRCUIT

ENGINE 475 SI MPFI

ENGINE 475 SI MPFI COOLING SYSTEM : Fig.159

THEMOSTATE CLOSED

WATER PUMP ENGINE

Check water pump for free rotation. Check water pump for flow rate at specified rpm. Check for coolant leakage through leakage hole. It indicates that the seal is damaged and leaking. Replace the water pump if necessary. Water pump characteristics : ENGINE RPM

PUMP RPM FLOW RATE AT BACK PRESSURE=0.3 BAR (LITRES PER MINUTE)

2000

2100

40

3000

3150

60

4000

4200

80

5000

5250

100

5500

5775

110

Fig. 160 THEMOSTATE OPEN

Thermostat l

Start opening temperature - 87 0C ± 2

l

Full open temperature - 93 0C ± 2

l

By pass port closed at or before

l

Leakage through main valve (including seepage hole) at room temperature and pressure of 1 kg/ cm2 : 150-250 ltrs/hr

l

Maximum leakage through by pass at full open temperature or main flow rate of 130 + 5 lpm : 1.5 lpm

Thermostat is installed in cooling system between cyl. head & radiator inlet tank. The working principle of thermostat : 1.

For cold engine (immediately after starting) : Thermostat does not allow coolant to flow to radiator (Thermostat valve in closed position) instead coolant flows through thermostat by-pass outlet to engine. Thus short circuiting of radiator which helps for attaining engine working temperature in very short period. Fig. 160

2.

As soon as the coolant temperature reaches opening temperature of thermostat, the thermostat valve starts opening gradually and water flow starts to radiator. At the same time thermostat by pass starts closing gradually.

INDEX

Fig. 161 3.

As the engine cooling temperature reaches thermostat full open temperature, thermostat valve opens fully and thermostat by-pass valve closes completely.Under such condition maximum quantity of engine coolant flows to radiator Fig. 161.

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105

ENGINE 475 SI MPFI Satisfactory operation of thermostat is very much essential for : ENGINE

l

Efficient engine operation

l

Longer engine life.

Defective thermostat may cause l

Over cooling due to thermostat valve sticking in full open position

l

Over heating due to thermostat valve sticking in partial/full closed condition

When above defects are observed, thermostat needs checking. Checking of thermostat element 1.

Remove thermostat element from thermostat housing Fig. 162

2.

Mount thermostat element in a suitable fixture and place the fixture in a vessel filled with water.

3.

Fix dial gauge with its spindle on valve surface with a pretension @ 0.5 mm

4.

Heat the vessel and measure the water temperature with proper thermometer

5.

Note down the temperature when dial gauge needle starts moving indicating valve opening.

6.

Note down the water temperature for needle movement of 8mm (valve fully open position)

7.

The opening temperature (Sl.No.5) and fully open temperature (Sl.No.6) as measured should be as mentioned.

If they do not meet the specifications, replace the thermostat element.

Fig. 162

Fig. 163

Cylinder block Assembly : Install main bearing shells, in the block. Install thrust washers in crank case at their respective location on 4th main bearing sides. Apply light coat of engine oil to main bearing shells and main journals. Install crank shaft Fig. 163 Install 4th main bearing cap with thrust washers. Install 1st, 2nd, 3rd and 5th main bearing caps with shells in their respective position on crank case. Tighten main bearing cap mounting bolts evenly and uniformly to specified torque (first 3rd cap, next 4th and 2nd, lastly 5th and 1st) Fig. 164

106

INDEX

Fig. 164

GROUP INDEX

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ENGINE 475 SI MPFI Check that end float of crank shaft is within specified limits. Fig. 165 ENGINE

Fig. 165 Install rear oil seal using drift 2702 5890 0608 in crank case rear cover. Fig. 166 Clean the mating surfaces of crank case & rear cover.

Fig. 166 Fit crank case rear cover with new gasket Fig. 167 Locate flywheel on crank shaft rear flange. Screw-in flywheel mounting screws. Insert flywheel locking pin Tighten flywheel mounting screws to specified torque. Remove flywheel locking pin. Remove the connecting rod bearing cap with shell.

Fig. 167

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107

ENGINE 475 SI MPFI Assemble the connecting rod in piston such that when you hold the piston in your hand, the arrow mark on the piston crown is towards left. ENGINE

Insert the piston pin. Fit piston pin spring clip. Fig. 168 Apply oil on piston, piston rings, cylinder bore and bearing shells. Turn the crank shaft and bring crank pin journal to top most position into which connecting rod with piston is to be fitted. Insert the connecting rod with piston upto piston rings into cylinder bore with arrow on piston crown pointing towards front. Stagger the piston ring gaps such that they are 1200 apart. Clamp piston ring compressor over piston rings such that piston with piston rings can slide inside it. Fig. 169

Fig. 168

Push the piston gradually inside cylinder bore using wooden handle of mallet till connecting rod locates on crank pin journal. Slowly rotate the crank shaft, simultaneously pushing piston till crank pin journal reaches BDC position.

Fig. 169 Install connecting rod bearing cap with bearing shell on connecting rod ensuring that bearing shell lugs are on same side Fig. 170.

VALVE POCKETS

JET

LUGS

Fig. 170 108

INDEX

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ENGINE 475 SI MPFI Tighten connecting rod bearing cap mounting nuts to specified torque. Fig. 171 Assemble other connecting rods with piston in same manner.

ENGINE

Fig. 171 Check end play of connecting rods Fix oil pump gasket Install oil pump Assembly with gasket.

Fig. 172 Tighten the oil pump mtg. screws to specified torque. Fig. 173

Fig. 173

INDEX

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109

ENGINE 475 SI MPFI Fit oil pump strainer with gasket. Fig. 174

ENGINE

Fig. 174 Fit water pump with new gasket. Fig. 175

Fig. 175 Install - Oil sump Fig. 176 - Timing gear rear covers - Timing belt tensioner - Crankshaft gear Install crank shaft pulley assembly (An additional multi groove pulley provided for deluxe version, for AC compressor drive) in position.

Fig. 176 110

INDEX

GROUP INDEX

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ENGINE 475 SI MPFI Lock flywheel with timing pin Fig. 177

ENGINE

Fig. 177 Screw in crankshaft pulley mounting bolt with spacer and tighten it to specified torque. Fig. 178 Fit l

Alternator top mounting bracket

l

Alternator bottom mounting bracket

l

Alternator

Fig. 178 l

NEW oil filter Fig. 179

l

Fit coolant inlet elbow with gasket.

Fig. 179

INDEX

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111

ENGINE 475 SI MPFI Fit clutch disc using mandrel (2702 5890 2501) Fig.180.

ENGINE

Fig. 180 Assemble Clutch pressure plate Fig. 181. FOR ASSEMBLY OF CYLINDER HEAD ON BLOCK, TIMING BELT FITMENT ETC. PLEASE REFER RESPECTIVE SECTIONS OF THIS MANUAL.

2702 5890 250 Mandrel for Clutch Disc

Fig. 181

112

INDEX

GROUP INDEX

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INDEX

CYLINDERHEAD

INTAKEMANIFOLD

AIRTEMPRATURESENSOR

AIR INTAKE SYSTEM

GROUP INDEX

RESONATOR BOX

AIR FILTER

SNORKEL

T - HOSE

ENGINE 475 SI MPFI

ENGINE

Fig. 182

NEXT

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113

ENGINE 475 SI MPFI AIR CLEANER Fig. 182 For regular cleaning as per maintenance schedule : ENGINE

l

Unscrew and remove housing cover, and remove element. Fig. 183

l

Clean it gently by tapping on clean table.

l

Use compressed air, at a very low pressure, for cleaning the element

l

Check the condition of rubber sealing

l

Check element for major rupture or puncture of paper pleats.

l

Replace element if any rupture or puncture is observed.

l

Check condition of air hose / resonator box

l

Check condition of rubber cuff on air filter and replace it if necessary.

l

Always use GENUINE air filter element to ensure long engine life.

l

Install paper filter element

l

Fit housing cover and clamp it firmly with the screws.

114

INDEX

Fig. 183

GROUP INDEX

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ENGINE 475 SI MPFI ACCELERATOR CABLE ENGINE

8

9

11

10

1 2 3 4 5 6 7 8 9 10 11

ASSY.ACC.CABLE-RHD CLIP HOSE GROMMET HEX FL SCREW M6X10 CABLE TIE 4.7X110 BRACKET ACC. CABLE TOP SIDE NUT ACCELERATOR PEDAL ACCELERATOR CABLE PLASTIC END INNER CABLE END

Fig. 184 Removal :

Installation :

1. Loosen the top side nut (8) from threaded end of accelerator cable at throttle body end.

1. Insert accelerator cable plastic end (10) inside the firewall hole.

2. Remove Hex FL screws (5) & remove cable from clip (2).

2. Insert inner cable end (11) in accelerator pedal.

3. Remove inner cable end from throttle body sector after disengaging the threaded end of the cable in throttle body bracket (7). 4. Remove inner cable end (11) from accelerator pedal (9). 5. Remove accelerator cable plastic end (10) through firewall hole.

3. Locate accelerator cable in clip (2). Ensure that rubber sleeve (3) on accelerator cable are located inside the clip. 4. Loosen the top side nut (8) from threaded end of the cable. Engage the threaded end of the cable in body bracket (7). Insert inner cable end in throttle body sector. 5. Ensure tightness in inner cable by adjusting the nuts on threaded end of cable. 6. Ensure that when accelerator cable (9) is fully depressed, full travel of throttle sector is achieved.

INDEX

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115

116

INDEX

ASSY FOOT CONTROL MODULE -RHD ASSY.CONTROL MOUNTING BRACKET (WELDED) ASSY CLUTCH PEDAL LEVER COMPLETE. ASSY ACC PEDAL (RHD) SLEEVE (FOR BRAKE & CLUTCH) CLUTCH PEDAL ASSISTANCE SPRING BRIGHT WASHER 10.5 HEX BOLT M10X125 ASSY BRAKE PEDAL LEVER COMPLETE TORSION SPRING (FOR BRAKE PEDAL RETURN) NYLOC NUT M10 TORSION SPRING FOR ACC.PEDAL RETURN. BUSH CIRCLIP E9X1.1 STOP LIGHT SWITCH CLUTCH PEDAL STOPPER HEX SCREW M8X45 HEX NUT M8 RUBBER COVER (PEDAL PLATE) RUBBER COVER (ACC.PEDAL)

1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART DESCRIPTION

SR. NO.

4.0

®

Fig. 185

ASSY. FOOT CONTROL

®

ENGINE

GROUP INDEX

-Non Reusable Part

- Specified Torque in Kgm

®

ENGINE 475 SI MPFI

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ENGINE 475 SI MPFI ENGINE TESTING After assembly of the engine, mount engine on test bed, prepare engine for starting and testing in the following manner. Connect oil pressure gauge and temperature gauge. Connect coolant hose to and from radiator. Fill coolant in the cooling system. Fit radiator cap. Fill required quantity of recommended running-in oil in the oil sump.

Allow engine to cool down for about 3 hours.Then remove cylinder head cover. Loosen cylinder head mounting bolt by quarter turn and retighten immediately to 7 mkg torque in the correct sequence. Complete cylinder head tightening operation in the same sequence and with the same torque. Start the engine and check for any fuel leakages. Rectify, if necessary.

Mount air cleaner assembly on test bed suitably. Connect air cleaner outlet to engine intake using suitable hoses. Make suitable linkage for controlling accelerator lever. Connect exhaust pipe to exhaust manifold. Connect battery cables to starter motor. Ensure that -ve terminal is earthed. Crank engine with accelerator lever in idling position. Allow oil to be circulated through the system. Check and ensure that oil pressure indicated by gauge is satisfactory. Slightly raise the engine speed and check for any oil, fuel, coolant and air leakages. Rectify if any. Check colour of the exhaust gas. Check for any unusual noise from the engine. Connect engine to dynamometer and run for running in test as per schedule. Engine running in test schedule : Engine Speed (rpm)

Time (minutes)

Torque (mkg)

800 2000 2500 3000 3500 2500

5 5 5 5 5 5

0.0 2.3 4.6 5.8 4.9 8.2

After running in test of the engine, reduce dynamometer load to zero and allow engine to run at idling speed for about 5 minutes and then stop it.

INDEX

GROUP INDEX

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117

ENGINE

ENGINE 475 SI MPFI EVAPORATIVE EMISSION CIRCUIT : ENGINE

Fig. 186 118

INDEX

GROUP INDEX

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ENGINE 475 SI MPFI 8. TROUBLE SHOOTING NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE WIRING HARNESS CAREFULLY. Sr. Problem Observed no. 1.

Engine not cranking

Probable Cause Low battery voltage

ENGINE

Action to be taken Clean and tighten the connectors Jump start using another battery Get battery charged or changed

2.

3.

4.

Engine cranks but doesnot start

Erratic idling

Does not idle

INDEX

Faulty starter

Rectify or replace

Worn out piston rings/seized pistons

Overhaul & replace affected parts

Faulty immobiliser

Check and rectify

Clogged air filter Incorrect valve timing Faulty spark plugs Faulty crank angle signal Faulty water temperature sensor Faulty MAP signal Faulty throttle position signal Faulty ISC valve Clogged injectors

Clean as per the instructions Set valve timing /check & reset Clean, check gap/replace if necessary Check & correct the gap Check & replace if necessary Check & replace if necessary Check & replace if necessary Check & replace if necessary Check & replace if necessary

Faulty fuel regulator

Check & replace if necessary

Clogged fuel filter

Replace

Faulty ignition coil Faulty firing order/ injector (connection) order

Check and replace Check and replace

Faulty E C U

Replace

Faulty inertia switch

Reset if tripped off or replace

Faulty Fuel Pump

Check and replace if necessary

Inlet manifold leakage/ vacuum connections Valve timing incorrect Vehicle speed signal faulty ISC valve faulty Vacuum line to presure regulator connections Faulty firing order/ injector(connection) order Faulty MAP signal Faulty ISC Valve Faulty fuel regulator

GROUP INDEX

Check and rectify Set valve timing /check & reset Check & replace Check & replace Check & tighten/replace Check and rectify Check & replace Check & replace Check & replace

NEXT

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119

ENGINE 475 SI MPFI

ENGINE

Sr. Problem Observed no. 5. Maximum RPM low

Probable Cause

Action to be taken

Battery voltage low

Check and tighten connections Jump start using good battery Get battery charged/changed Clean as per instruction set valve timing /check & reset Clean and check gap/replace if necessary Flush the system and refill Check and rectify the gap 1.5 + 0.5 mm Check and Replace Check and Replace Replace

Clogged air filter Valve timing incorrect Spark plugs defective Adulterated fuel Faulty crank angle signal Clogged injectors Fuel pump faulty Clogged fuel filter Faulty firing order/ injector (connection) order 6.

Poor acceleration/Power

Low battery voltage

Clogged air filter Inlet manifold leakage/ vacuum connections Faulty ISC valve Clogged injectors Faulty fuel regulator Clogged fuel filter Faulty ignition coil Faulty firing order/ injector (connection) order Incorrect tappet clearances Valve timing incorrect Inlet manifold leakage/ vacuum connections Valve timing incorrect Worn out piston rings/seized pistons Spark plugs defective Adultrated fuel Clogged injectors Faulty fuel regulator Fuel pump faulty Clogged fuel filter Faulty firing order/ injector(connection) order

120

INDEX

GROUP INDEX

Check and rectify Check and tighten connections Jump start using good battery Get battery charged/changed Clean as per instructions Check and rectify Check & replace Check & replace Check and replace Replace Check and replace Check and replace Check and reset Set valve timing /check & reset Check and rectify Set valve timing /check & reset Overhaul /replace affected parts Clean and check gap/replace if necessary Flush the system and refill Check and Replace Check and Replace Check and Replace Replace Check and rectify

NEXT

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ENGINE 475 SI MPFI Sr. Problem Observed no.

Probable Cause

Action to be taken

7.

Spark plugs defective Adultrated fuel Vacuum line to presure regulator connections Incorrect valve timing

Clean and check gap/replace if necessary Flush the system and refill

8.

Knocking

Misfiring

Inlet manifold leakage/ vacuum connections Incorrect tappet clearances Valve timing incorrect Spark plugs defective Adultrated fuel Faulty crank angle signal Clogged injectors Faulty firing order/ injector(connection) order

9.

Whitish/Bluish smoke

10. High fuel consumption

Check and Rectify Clean as per instructions Overhaul /replace affected parts Check and Replace Flush the system and refill

Low battery voltage

Check and tighten connections Jump start using good battery Get battery charged/changed Set valve timing /check & reset Check and rectify Check and reset Set valve timing /check & reset Overhaul /replace affected parts Clean and check gap/replace if necessary Flush the system and refill Check and Replace Check and Replace Check and Replace

Adultrated fuel Faulty lambada signal Clogged injectors Faulty fuel regulator Vacuum line to presure regulator connections Faulty firing order/ injector (connection) order

INDEX

Check and Replace Check and rectify Check and reset Set valve timing /check & reset Clean and check gap/replace if necessary Flush the system and refill Check and rectify the gap Check and Replace

Clogged air filter Worn out pistonirings/seized pistons Valve guide seals leaking Adultetated fuel

Inlet manifold leakage/ vacuum connections Incorrect tappet clearances Valve timing incorrect Worn out piston rings/seized pistons Spark plugs defective

11. High oil consumption

Check and tighten/replace Check and adjust.

Clogged Air Filter Worn out piston rings/siezed pistons Valve guide seals leaking

GROUP INDEX

Check and tighten/replacet Check and rectify

Clean/replace Overhaul /replace affected parts Check and Replace

NEXT

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121

ENGINE

FUEL FEED SYSTEM

GROUP INDEX

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FUEL FEED SYSTEM

FUEL FEED SYSTEM

INTRODUCTION :

The fuel system consists of fuel tank, intank fuel pump, fuel filter, fuel lines and fuel rail. The fuel in the tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each injector. The fuel pressure at the injector is always higher than the intake manifold pressure. The fuel is injected into the intake port of the cylinder head when the injector opens according to the injection signal from ECU (Engine Control Unit). The evaporative emission system for tank ventilation is “closed” type. The system prevents fuel vapours formed within the tank and fuel system from entering the atmosphere. It also prevents the release of their load of polluting light hydrocarbons (HC).

INDEX

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i

FUEL FEED SYSTEM CONTENTS Sr. No. 1. 2.

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Description

Page No.

Technical Specification Exploded Views a) Assembly Fuel Tank with Filler pipe b) Schematic circuit for MPFI Fuel Lines Euro II General operation of evaporative emission system Fuel tank Fuel tank purging procedure Electric intank fuel pump Fuel pressure regulator Fuel level guage (tank unit) Fuel level guage (dashboard) Fuel filter Fuel filler cap Fuel hoses and lines Fuel level warning light Evaporative emission control system a) Restrictor b) Vapour separator c) Tank pressure valve d) Carbon canister e) Canister purge valve

INDEX

GROUP INDEX

FUEL FEED SYSTEM

1 2 3 4 5 8 10 11 12 13 14 16 17 18 19 19 19 20 21 23

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iii

FUEL FEED SYSTEM TECHNICAL SPECIFICATIONS 1. Fuel pump pressure(with inbuilt pressure regulator)

:

3 bar

2. Fuel pressure, after ignition key is switched “off”

:

minimum 2.0 bar for 6 minutes

3. Fuel filter type

:

Inline (BOSCH)

4. Fuel specifications

:

Unleaded regular grade petrol conforming to SABS 1598 (or equivalent) and octane rating not less than 91 RON (Research Octane Number). to be used as fuel.

5. Fuel tank capacity

:

37 litres

INDEX

GROUP INDEX

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FUEL FEED SYSTEM

1

2

INDEX

GROUP INDEX

ASSY FUEL TANK COMPLETE (MPFI) ASSY FUEL TANK WELDED (FOR MPFI VERSION) SEALING PLUG AM18X1.5 SEALING WASHER 18X22 IS3175 CU ASSY INTANK FUEL PUMP LOCKING RING PUMP PACKING HEX FLANGE SCREW M6X10 - 8.8 GASKET ASSY TANK UNIT W/O LOW LEVEL SENSOR (INJ)-VDO CR PAN HD SCREW M5X10 SPRING WASHER B5

1 2 3 4 5 6 7 8 9 10 11 12

0.8 to 1.0

PART DESCRIPTION

SR. NO. 13 14 15 16 17 18 19 20 21 22 23 24 25

ASSY FILLER NECK WITH BRACKET (22.7 DIA) ASSY FUEL TANK CAP-NONVENTED ASSY.HOSE PIPE HOSE CLAMP ( 53 DIA ) ASSY BREATHER HOSE HOSE CLAMP ( 23 DIA ) ASSY BRACKET (FUEL FILTER MOUNTING) RUBBER PACKING ASSY.FUEL FILTER (M/S BOSCH ) HEX FLANGE SCREW M6X16 -8.8 ASSY DELIEVERY LINE FROM PUMP TO FILTER ASSY RETURN LINE ON TANK ASSY VAPOUR SEPERATOR

26 27 28 29 30 31 32 33 34 35 36

ASSY NYLON LINE PLUG (FOR VAPOUR LINE) SPRING CLIP (10) ASSY NYLON LINE (VAPOUR SEPARATOR TO TPV) SPRING BAND CLAMP FORM A 12X14D SLEEVE ( VAPOUR SEPARATOR HOSE) CABLE TIE 8 0X300 BLACK WASHER A8 4 IS5370 - ST HEX FL BOLT M8X25 - 8.8 CLAMP(PIPE 8X8) HEX FL SCREW M6X20 - 8.8

0.8 to 1.0

- Specified Torque in Kgm

FUEL FEED SYSTEM

2.2

ASSEMBLY FUEL TANK WITH FILLER PIPE

FUEL FEED SYSTEM

NEXT

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INDEX

PART DESCRIPTION

1 ASSY DELIEVERY LINE FROM FILTER 2 ASSY CLUSTER ON ENGINE (3 BUNDY TUBES) 3 SPRING BAND CLAMP FORM A 12X14D 4 ASSY RETURN LINE (FIREWALL TO UNDERBODY) 5 ASSY PIPE 6 TANK PRESSURE CONTROL VALVE 7 RUBBER HOSE (TPV TO CANISTER) 8 ASSY.ACT.CARBON CANISTER 9 HOSE (BUNDY TO CANISTER) 10 RUBBER HOSE -CANISTER TO CPV(380) 11 CANISTER PURGE VALVE 12 RUBBER HOSE-CPV TO INTAKE MANIFOLD(240) 13 SPRING CLIP (10) 14 CLAMP (PIPE 8X8X4.75X4.75) 15 CLAMPING PLATE (FOR PLASTIC CLAMPS) 16 HEX FL NUT AM6 - 8 17 CLAMP (PIPE 4.75X4.75X8X8) 18 CLAMP(8X8X4.75X4.75) 19 BRACKET 20 CLAMP (PIPE 8X8X4.75X4.75) 21 CLAMPING PLATE 22 CLAMP(PIPE 8X4.75) 23 R CLAMP (PARKING BRAKE CABLE)

SR. NO.

0.8 0.8 0.8

SCHEMATIC CIRCUIT FOR MPFI FUEL LINES EURO II

0.8

0.8

- Specified Torque in Kgm

FUEL FEED SYSTEM

GROUP INDEX

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FUEL FEED SYSTEM

3

FUEL FEED SYSTEM

FUEL FEED SYSTEM

The fuel system consists of :

Warning :

1. 2. 3. 4. 5. 6. 7.

Before performing any operation on fuel system please do following :

Fuel tank assembly Electric intank fuel pump Fuel level gauge (tank unit) Fuel level gauge (dashboard) Fuel filter Fuel filler cap Fuel hoses, fuel lines and fuel rail (i.e. delivery, return and vapour lines) 8. Fuel Pressure regulator The evaporative emission system consists of : a) b) c) d) e)

Tank pressure valve Canister purge valve Carbon canister Resistor Vapour separator

•

Disconnect negative cable terminal at battery (you might have to connect the battery in some cases as explained in next pages).

•

Always wear safety glasses.

•

Release the fuel pressure from the fuel system to reduce the possibility of injury or fire.

•

While removing the fuel tank from the vehicle, keep sparks, cigarettes and open flames away from it.

•

Before repairing fuel tank assembly, clean it thoroughly.

GENERAL OPERATION OF EVAPORATIVE EMISSION SYSTEM: The system operates when outdoor temperature is higher, after the vehicle has been parked / standstill for a long time, the fuel temperature increases and brings about a pressure rise inside the tank. This increase may occur with medium - low fuel levels or with the tank full condition. During tank refilling, the pressure inside is more or less same as atmosphere pressure. The breather port on fuel tank is connected to the breather port on filler neck which allows tank breathing during fuel filling. When the tank is completely filled, there is small pocket of air provided for efficient operation of the evaporative control system when the vehicle is running. When the fuel filler cap is closed, it seals the system, the vapours generated inside the tank (with vehicle moving or while parked) build up due to fuel volatility, and tank internal pressure also builds up until the tank pressure valve opening level is exceeded. When the engine is inoperative, (i.e.while parked), fuel vapour generated inside the fuel tank due to fuel volality are absorbed and stored in the canister. When the engine is running, the fuel vapours absorbed in the canister are purged into intake manifold through canister purge valve operated by the ECU.

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FUEL FEED SYSTEM FUEL TANK : The fuel tank is located under the rear seat of the vehicle. The fuel pump and fuel level gauge are assembled on the upper part of fuel tank. For servicing the fuel level gauge the fuel tank must be removed from the vehicle. Fig 2.

FUEL FEED SYSTEM

Fig 2. Removal : 1. Remove fuel filler cap. 2. Drain the fuel from the fuel tank before removing the tank from the vehicle via drain plug (Fig 3). Do not drain or store fuel in an open container to avoid possibility of fire or explosion. Put lid on container.

Fig 3. 3. Releasing fuel system pressure Since the fuel system remains under pressure when the engine is not running,release the fuel system pressure before disconnecting any fuel lines as per following procedure. a) Start engine. b) Disconnect fuel pump electric connector located under middle floor carpet. (Fig 4.) c) Let engine stall, then turn “OFF” ignition switch. d) Disconnect negative cable at battery.

Fig 4.

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5

FUEL FEED SYSTEM 4. Disconnect the fuel lines (delivery and return) from the fuel pump by loosening spring clamp. (Fig 5.)

FUEL FEED SYSTEM

Fig 5. 5. Disconnect fuel filler hose from fuel hose. (Fig 6.)

Fig 6. 6. Disconnect breather hose and restricter hose from fuel neck.Fig 7.

Fig 7. 6

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FUEL FEED SYSTEM 7. Disconnect fuel inlet and outlet hose of fuel filter by loosening spring clamp. Also disconnect the connection of return line by loosening the clamp. (Fig. 8) Warning : FUEL FEED SYSTEM

A small amount of fuel may be released after fuel lines are disconnected. To avoid the chance of injury, cover the pipe to be disconnected with cotton cloth. Do not use cotton waste. Note : To avoid damage to vapour hoses while disconnecting, slide back the clamps then twist the lines as you pull. 8. Loosen the fuel tank mounting screws and take out the fuel tank down. 9. Remove fuel filter from bracket.

Fig 8.

10. Loosen fuel pump mounting screws. 11. Loosen fuel level gauge mounting screws. Inspection : 1. While removing fuel tank, check all hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Replace if necessary. 2. Check fuel pump and fuel level gauge gaskets for leaks, cracks etc. Replace if necessary. 3. Visually inspect fuel tank for leaks and damage. Replace if necessary.

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7

FUEL FEED SYSTEM FUEL TANK PURGING PROCEDURE :

FUEL FEED SYSTEM

Caution : The purging may not remove all fuel vapours. Therefore any repair on fuel tank using external heat or flame may result in explosion causing personal injury or damage. 1. Remove fuel tank from the vehicle. Refer procedure as mentioned for fuel tank removal. 2. Remove all hoses from fuel tank. 3. Remove fuel pump and fuel level gauge from fuel tank. 4. Shift the tank to flushing area. 5. Fill tank with warm water or normal tap water and agitate rigorously and drain the water through drain plug. Repeat this procedure until inside of tank is clean. Replace the fuel tank if it is rusty from inside.

Fig 9.

6. Completely flush out remaining water after washing. Warning : Do not allow water to remain inside fuel tank af ter washing. This will cause corrosion inside fuel tank. Use shop cotton cloth for tank cleaning. Do not use cotton waste. Assembly : 1. Assemble fuel pump to fuel tank. Tighten the fuel pump screw to tightening torque 0.8 - 1.0 kgm. Replace gaskets for pump and fuel level gauge, if necessary. 2. Assemble fuel level guage to fuel tank. Tighten the screws to tightening torque 0.5 kgm.

Fig 10.

3. Connect the fuel lines (delivery and return) to the fuel pump. 4. Connect fuel breather hose and fuel filler hose to fuel tank. Fig 10. 5. Assemble filter mounting bracket. 6. Assemble fuel tank on the vehicle. Tighten the fuel tank mounting screw to tightening torque 2.2 kgm. 7. Assemble filter. The arrow stamped on the outer case of the filter indicates the fuel flow direction. Fig 11.

Fig 11. 8

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FUEL FEED SYSTEM 8. Connect fuel delivery pipe to filter and return pipe to under chassis fuel hose. Fig 12.

FUEL FEED SYSTEM

Fig 12. 9. Connect fuel pump and fuel level gauge connectors. 10. Fill the tank with fuel. 11. Connect negative cable at battery. 12. With engine “OFF” condition and ignition switch “ON”, check for fuel leakage. 13. Start engine and check each joint of fuel system for leakage. Rectify if necessary.

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9

FUEL FEED SYSTEM ELECTRIC INTANK FUEL PUMP :

FUEL FEED SYSTEM

The electric fuel pump is located inside the fuel tank. It is a positive displacement pump assembly driven by motor to provide continuous flow of fuel to the high pressure fuel system from fuel tank.

On Vehicle Inspection : 1. Check fuel pump for operation as follows : a)

Remove fuel filler cap.

b)

Release the fuel system pressure as mentioned above for ‘removal of tank’.

c)

Turn ignition switch ‘ON’

d)

Check whether fuel pump is running by listening for sound at fuel filter inlet.

e)

If no sound is heard, measure voltage between fuel pump eletrical connector wire to chassis ground. The voltage should be approx. 12V.

f)

If voltage is not correct, check for fuel pump relay and related wiring harness.

g)

If you do not measure 12V, check for continuity between fuel pump connector terminal wires (battery) and (ground).

h)

If there is no continuity, repair ground circuit and again confirm for continuity.

Removal : 2

Fig 13.

Warning :

a) For fuel pump removal fold the rearseat and open the plastic lid located under the floor carpet. b) Disconnect electrical connectors. Release the fuel system pressure as already explained in fuel tank removal. c) Disconnect the fuel lines (delivery and return). d) Loosen fuel pump mountings screws. Take the fuel pump out by pushing the ring aside. e) Check fuel pump for evidence dirt and contamination. If so, clean and check for presence of dirt in fuel tank.

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Unless replacement is necessary, fuel pump, fuel level gauge should not be removed from the tank since the rubber parts i.e. gasket, seals etc. may get exposed to air, light and may become hard. Never apply an excessive force to the fuel pump nipple or lead wire. This may result in bent or poor contact.

Assembly : Assemble the pump in reverse order of removal as explained in 2.e. (above)

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FUEL FEED SYSTEM FUEL PRESSURE REGULATOR This regulator is fitted on the Fuel rail. Fig. 13a A diaphragm operated valve regulates pressure at fuel inlet and returns the excess fuel back to the tank. The diaphragm is operated by differential pressure between fuel rail and intake manifold. Intank fuel pump provides fuel at very high flow rates to common fuel rail where pressure regulator regulates according to the position of diaphragm. This diaphragm is held in an equilibrium position as a result of fuel pressure acting on one side and manifold vacuum acting on the other side of the diaphragm. The excess fuel, after regulation is returned back to fuel tank. This ensures a constant operating pressure of 3 bar across Injector inlet and outlet, at all engine operating conditions.

FUEL FEED SYSTEM

Fig. 13aFuel pressure regulator

Removal: 1. Disconnect the tube from inlet manifold to fuel pressure regulator. 2. Disconnect the fuel hose from fuel filter to fuel pressure regulator. 3. Loosen mounting bolts and remove fuel pressure regulator from fuel rail. Assembly : Assemble the pressure regulator in reverse order of removal as explained above.

Fig. 13b Fuel pressure regulator AIR CHAMBER

VC PIPE

FUEL IN

DIAPHRAGM VALVE

TO FUEL TANK

OUTLET PIPE

Fig. 13c Fuel pressure regulator illustration

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11

FUEL FEED SYSTEM FUEL LEVEL GAUGE (TANK UNIT) :

2PIN CONNECTOR

Removal : Refer procedure as mentioned in Fuel tank removal. FUEL FEED SYSTEM

FULL

WIRE SEAL VIOLET

3/4

BROWN

Inspection : 1. Use an ohmmeter to confirm that the resistance of the fuel level sensor changes with the level of float position.Fig 14,14a &15. 2. The specified resistance values of the fuel gauge are given below :

1/2 BRAZED 1/4

SOLODERED

EMPTY HIGH EMPTY LOW

Fig 14. Tank fuel level in mm

Capacity in lts.

Position of float in tank

Resistance value in Ohm

Tolerance value in Ohm

+8

9.5

1.1

Empty (low)

120

44.5

7.5

Empty (high)

70

±5

64.5

9

1/4

50

±4

109.5

18

1/2

32.5

±3

164.5

29.5

3/4

17

207.5

37

±3 +1

full tank

5

-0

-2

Assembly : When installing fuel tank gauge, ensure that fuel tank gauge unit assembled with O ring in place. IGN

METER METER GAUGE

TERMINAL (Violet) TANK UNIT TERMINAL (BROWN)

Fig 15.

Fig 14a. 12

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FUEL FEED SYSTEM FUEL LEVEL GAUGE (DASHBOARD) : (FIG. 16) Removal : 1. Check fuel level gauge on dashboard for operation as follows a) Pullout the wiring harness connector on tank unit under rear seat carpet. b) Disconnect the connector and check fuel gauge of cluster. Fuel guage shows zero(empty) with ignition ON. c) By shorting the two wires.Brown and voilet of wiring harness connector the fuel guage will show full. CAUTION : • •

If gauge needle shows full, reconnect wires and check for fuel tank gauge. If needle does not show full check fuse wiring connector. If OK, replace gauge and retest.

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FUEL FEED SYSTEM

Fig 16.

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13

FUEL FEED SYSTEM FUEL FILTER :

FUEL FEED SYSTEM

The fuel filter is located under the body near the fuel tank along the pipe carrying the fuel to fuel rail as shown Fig 17, It is made up of an outer case and an integral mount that holds a filter element with high filtering capacity. It filters the fuel being deliver under pressure by the fuel pump. This is essential for ensuring fuel injection operation since the injector is extremely sensitive to foreign particles in the supply circuit. Since it cannot be disassembled, it must be replaced as an assembly at the recommended intervals.

Inspection :

Fig 17.

1. Check fuel filter as per following procedure. a) Release the fuel system pressure as mentioned above for ‘Removal of tank’ b) Disconnect negative battery terminal. c) Jack up the vehicle / hoist the vehicle. d) Install pressure gauge having a range of 0-10 bar at the delivery pipe of fuel filter and return line of pump. e) Connect negative battery terminal. f)

Connect fuel pump connectors.

g) Turn ignition switch ‘ON’ - run engine idle. h) Measure fuel pressure on gauge it should be 3 bar. • If it is not, replace filter and retest. • If it is OK assemble fuel filter.

Removal : 1. Ref. Procedure as mentioned above from (a) to (c). 2. Place fuel container under fuel filter. 3. Disconnect inlet and outlet hoses from fuel filter. Collect fuel emerging during the operation in suitable container.

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FUEL FEED SYSTEM Caution : A small amount of fuel may be released after fuel hose is disconnected. To avoid the chance of accident, cover hose and pipe disconnected with a shop cloth. FUEL FEED SYSTEM

Assembly : 1. Assemble filter. The arrow stamped on the outer case of the filter indicates the fuel flow direction. 2. Tighten the filter clamping screws to tightening torque 0.8 - 1.0 kgm. 3. Connect inlet hose, outlet hose to filter. Ensure that clampings are fitted properly. 4. Connect negative battery terminal. 5. With engine ‘OFF’ condition and ignition switch ‘ON’ check for fuel leakage. 6. Start engine and check each joint of fuel system for leakage. Rectify if necessary.

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15

FUEL FEED SYSTEM FUEL FILLER CAP :

FUEL FEED SYSTEM

The fuel tank filler neck has a non vented (sealed) cap. A ratchet tightening device on the threaded fuel filler cap reduces the chances of overtightening and incorrect installation, which would prevent sealing fuel vapours. After the ‘O’ ring on fuel filler cap and the fuel filler neck flange contacts, the ratchet produces a loud clicking sound, indicating the seal has been set. Removal / Inspection : 1. Remove fuel filler cap. 2. Check O ring for even filler neck imprint. 3. Check O ring for any deterioration or any damage. If found damaged replace fuel filler cap. Note : In case of fuel filler cap, replacement to be done with correct cap. Otherwise it may result in critical malfunction of the system.

TAG THIS IS TO BE ASSEMBLED WITH FILLER NECK

CAP RETAINER SEAL THREADED CAP

TOP VIEW FUEL TANK CAP (NON-VENTED)

Fig 18. 16

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FUEL FEED SYSTEM FUEL HOSES & LINES : The delivery and return lines are made of nylon pipes with clamps at joints. The vapour lines are made of rubber hoses and pipes with clamps at joints.

FUEL FEED SYSTEM

Removal : 1. Ref. Procedure as mentioned for ‘removal of fuel tank’. 2. To avoid damage to the vapour hoses while disconnecting slide back the clamps then twist the lines as you pull. 3. Disconnect clamps by pressing the two tabs. Fig 19.

Fig 19.

Inspection : 1. Visually check all hoses and pipes connected via clamps for leaks, loose connections, deterioration or damage, hose crack etc. Replace if necessary. 2. Make sure that all clamps are secure. 3. If the pipe clamps found deformed, bent or broken, replace with new one. Assembly : 1. Do not tighten the clamps used on breather hose /filler hose excessively to avoid damage to hoses. Use suitable tool for fitment of clamp. 2. Fuel hoses to fuel pipe connections varies for each type of pipe. Necessary care to be taken to connect and clamp each hose correctly. 3. Ensure that clamps are fitted properly on to pipe, filter, pump fittings. 4. Do not kink or twist hose / pipe when they are routed. 5. Install fuel filler hose after fuel tank has been mounted in place on vehicle otherwise this may leads to leakage of fuel around hose connections. 6. Connect negative terminal at battery. 7. Turn ignition switch ON and run engine idle. Check for fuel leakages.

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FUEL FEED SYSTEM FUEL LEVEL WARNING LIGHT (Fig. 20) : 1. Drain fuel tank into an approved container refer procedure as mentioned in fuel tank removal. 2. Ensure that the car is parked on level surface. FUEL FEED SYSTEM

3. Add less than 5 litres of fuel and turn the ignition switch ON.

4. The low fuel warning light should come on within 2 sec. a) If light comes on go to step 5. b) If light does not come ON or only comes ON dimly check wiring. If OK, remove combination meter and check LED. If LED is OK, replace fuel tank gauge. 5. Add fuel so that the total fuel will be more than 5 litre to 7.5 litre and check that the light goes OFF. a) If light does not go OFF, check for short circuit in the wiring harness. If no short circuit, replace fuel tank gauge. b) If light goes OFF, turn the key OFF.Test is complete.

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Fuel Level Warning Light

Fig 20.

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FUEL FEED SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM : RESTRICTOR ON

The car is fitted with an evaporative system to meet all requirements of evaporative emission.

TANK FUEL FEED SYSTEM

The system is designed to prevent fuel vapours formed within the tank and fuel system from escaping into the atmosphere. The evaporative emission system consists of : a) b) c) d) e)

Restrictor Vapour Separator Tank pressure valve Carbon canister Canister Purge valve

FUEL TANK ASSEMBLY

Fig 21.

a) Restrictor : Fig. 21 The restrictor is welded on top portion of the fuel tank assy. The restrictor allows the flow of gasoline vapours only and not liquid fuel in both directions. b) Vapour Separator : Fig. 22 The separator is made of high grade of polypropylene and is mounted near to the filler neck area on the rear wheel arch. A vapour liquid separator allows only liquid free vapour to pass from fuel tank restrictor to the carbon canister through tank pressure valve. The vapours getting condensed / liquid fuel goes to the filler neck.

1 CAN 2 TANK 3F

Removal : 1.

To avoid damage to the vapour hoses while disconnecting slideback the clamps and pull the hoses. 2. Loosen vapour seperator mounting screws.

Fig 22.

Inspection : Check for crack or deformation of vapour separator. Replace if necessary.

3 to 5 mm

Assembly : 1. Vapour hoses connections varies for each type of hose. Necessary care to be taken to connect and clamp each hose correctly.Use suitable tool for fitment of clamp. 2. Do not kink or twist hose when they are routed. 3. For hose connection to vapour separator follow schematic circuit figure. Refer markings on vapour separator.Refer Fig. 22. 4. The first port bearing the word ‘CAN’ to be connected to underbody vapour lines going to tank pressure valve.

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Fig 23. Hose Clamp fitment

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FUEL FEED SYSTEM 5.

The second port is a sealed port.

6.

The third port is to be connected to the restriction on fuel tank.

Warning : FUEL FEED SYSTEM

Unless replacement of vapour seperator is necessary, it should not be removed from the body. Never apply an excessive force to the vapour seperator nipple. This may result in bend/damage. c) Tank Pressure Valve : Fig. 24 & 25 The tank pressure valve is provided to keep the pressure in the fuel tank constant. The valve operates according to the pressure inside tank and engine ON / OFF condition. 1. The tank pressure valve opens out when the engine is ON (since the vacuum from the inlet manifold lifts the valve) and allows vapours from the tank to engine via carbon canister depending upon opening, closing of canister purge valve operated by ECU.

Fig 24.

VACCUM TUBE

2. The tank pressure valve also opens out when the engine is OFF and the pressure inside the tank becomes positive and exceeds on established level of 3.7 – 5 kpa 3. The valve is otherwise closed i.e. when the engine is OFF and the vapour pressure inside tank is less than 3.7 kpa. 4.

When the pressure in the fuel tank becomes negative (vacuum) and reaches it specified value it open the valve to let the air flow in the fuel tank via canister bottom breathing port.

TANK TUBE

CANISTER TUBE

Fig 25.

Inspection : 1. Check tank pressure valve for crack or damage. Replace if necessary. 2. Air should pass through valve smoothly from fuel tank side at moderate pressure. 3. Air also should pass when blown softly from canister side. 4. If air does not pass through valve in step 2 or hard blows required in step 3, replace tank pressure valve. Warning: Do not suck air through tank pressure valve.Fuel vapours inside the valve is harmful.

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FUEL FEED SYSTEM Removal : To avoid damage to the vapour hoses while disconnecting slide back the clamps and pull the hoses. FUEL FEED SYSTEM

Assembly : 1. Vapour hoses connections varies for each type of joint. Necessary care to be taken to connect and clamp each hose correctly. Use suitable tool for fitment of clamp. 2. Do not kink/pinch or twist hose when they are routed. This will reduce the effectiveness of the emission control system and may damage to fuel tank etc. 3. Tank pressure valve must be fitted right way round. The port bearing the word “Tank” (tank end) must be positioned towards the tank. The port bearing the word “CAN” (canister end) must be positioned towards the canister. The vacuum port to be connected to T connector which is connected to intake manifold. (Refer schematic circuit diagram Fig. 25) NOTE : Unless replacement is necessary, it should not be removed from the circuit. Do not apply an excessive force to the tank pressure valve nipple. This may result in bend / damage. d) Carbon canister : Fig. 26 & 27 A canister made of high grade Nylon 66/PA66, containing special dust free activated carbon is used to adsorb fuel vapours. The lower end of the canister is open to atmosphere for ventilation. The end is not really open but there is foam filter. The purpose of the bottom filter is to protect the canister from dust and dirt during operation. When the engine is inoperative (i.e. while parked) fuel vapours generated inside the fuel tank due to fuel volatility are absorbed and stored in the canister through tank pressure valve. When the engine is running, the fuel vapours absorbed in the canister are purged into intake manifold through canister purge valve operated by ECU. The purging takes place due to air drawn through the canister because of pressure differential between manifold vacuum and atmosphere.

Fig 26.

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FUEL FEED SYSTEM Removal:

FUEL FEED SYSTEM

1. Disconnect hose ( from canister to purge valve). 2. When the air is blown into Tank port, there should be no restriction of flow through Purge port and Air port(i.e. canister bottom port). 3. If the operation differs from the above description, canister must be replaced. 4. Connect hoses to canister. 5. Ensure that hoses are clamped securely. Warning : Do not suck air through canister port. Fuel vapours inside canister is harmful.

Purge

Inspection : 1. Remove fuel filler cap. 2. If check result is not satisfactory, check for vaccum hose, purge valve, wire harness etc. Check carbon canister for signs of damage and defects. • If defective, replace canister. • If OK, go to step 3 3. Warm up engine to normal operating temperature. 4. Disconnect “purge” end hose (from the canister to purge valve) 5. a) Place finger against the end of disconnected hoses. Check that vaccum is felt there when engine is running at idle speed. b) Also check that vaccum is felt when engine speed is increased to higher than 2000/3000rpm. 6. Start engine and run it at idle speed. Disconnect vaccum hose(from canister purge valve to T Connector). Block the T connector port from where the hose has been removed, with finger placed against the hose disconnected. Check that vaccum is applied. If it is not applied clean vaccum passage by blowing compressed air.

Fig 27.

Assembly : For hose connection refer schematic circuit diagram.Fig. 1 . The canister port consists of marking “purge” and “tank”.Fig. 27.

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FUEL FEED SYSTEM e) Canister purge Valve : Fig. 28, 28a, 29 & 30 The canister purge valve is controlled by engine management system (EMS). The purging of canister takes place because of pressure differential between manifold vacuum and atmosphere. Fuel vapours are drawn into the intake manifold through canister purge valve operated by ECU. Removal : 1. Disconnect hose from canister purge valve to intake manifold 2. Disconnect the hose from canister to purge valve from canister “purge” end. Inspection : 1. With ignition switch OFF, disconnect connectors from canister purge valve. 2. Check reisitance between two terminals of canister purge valve. Resistance 26 + 4 ohm at 20oC. If resistance is as specified, proceed to next operation, check. If not, replace. 3. Blow air into hose removed from T connector.Refer Fig 39. 4. Verify that no air flows through the valve when the engine is stopped with purge valve connectors disconnected. 5. Air will pass through freely when the 12V battery voltage is applied to valve connector. It indicates that the valve is functioning properly. If no air flows, replace the valve. 6. Reinstall valve connector. 7. Reconnect vacuum hoses. Warning : Do not suck air through purge valve. Fuel vapours inside valve is harmful.

Fig. 28 Location of purge valve

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FUEL FEED SYSTEM

Fig 28a.

HOSE CONNECTION NON RETURN VALVE LEAF SPRING SEALING ELEMENT SOLENOID ARMATURE SEALING SEAT SOLENOID COIL HOSE CONNECTION

Fig 29.

Fig 30.

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EXHAUST

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EXHAUST SYSTEM

EXHAUST SYSTEM

INTRODUCTION : The exhaust system consists of exhaust manifold, assembly front pipe with Lambda sensor, spherical seal, assembly catalytic convertor with assembly pre silencer, assembly rear pipe with main silencer and rubber hangers. The catalytic convertor added in the system to lower the levels of hydrocarbon (HC), carbon monoxide (CO) and nitorgen oxide (NOx) from exhaust gas into atmosphere with minimum loss of power with good NVH characteristics and long life.

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EXHAUST SYSTEM CONTENTS Sr. No.

Description

1.

Tightening Torque

2.

Exploded View :

Page No. 1

a. Exhaust System

2

3.

General Precautions

3

4.

Exhaust Pipe

4

5.

Safety precautions for catalytic convertor

5

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EXHAUST SYSTEM

iii

EXHAUST SYSTEM TIGHTENING TORQUES OF EXHAUST PIPE ENDS : 1)

Exhaust manifold to front pipe

=

3.2 kgm

2)

Spherical joint of exhaust pipe

=

4.5 kgm

3)

Pre Silencer joint

=

2.3 kgm EXHAUST SYSTEM

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1

EXHAUST SYSTEM

EXHAUST SYSTEM

1

ASSY GASKET -EXHAUST MANIFOLD-MPFI

2

ASSY FRONT EXH PIPE WITH FLEX BELLOW

3

HEX FL NUT BM8-TS17430-8-SS8451-8C

4

SPHERICAL SEAL

5

PRESSURE SPRING(SPHERICAL JOINT)

6

HEXAGONAL BOLT (SPHERICAL JOINT)

7

HEX FL NUT AM10 TS17430-8-SS8451-8C

8

ASSY.CATALYTIC CONVERTER (M/S WALKER)

9

RUBBER HANGER

10

HEX FL BOLT M8X28 TS17130-8.8-SS8451-8C

11

GASKET- EXHAUST PIPE.

12

HEX FL NUT AM8 TS17430-8-SS8451-8C

13

ASSY PRE SILENCER WITH HEAT SHIELD COMP

14

REAR EXHAUST PIPE

15

LAMBDA SENSOR - M/S BOSCH

® 2.3

2.3

®

3.2

®

4.5

®

- Specified Torque in Kgm

-Non Reusable Part

2

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EXHAUST SYSTEM GENERAL PRECAUTIONS : To avoid the danger of being burnt, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust system as follows : • •

•

EXHAUST SYSTEM

Check rubber mountings for damage, deterioration and out of position. Keep a sufficient clearance between exhaust system components and underbody or adjacent parts.

Check exhaust system for leakage, loose connection, dent and damage.

If bolts or nuts are loosened, tighten them to specified torque.

•

Check nearby body areas for damaged, missing or mispositioned part, open seam, hole, loose connection or any other defect which could permit exhaust fumes to seep into vehicle.

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3

EXHAUST SYSTEM ON – VEHICLE SERVICE EXHAUST MANIFOLD • Check gasket and seal for deterioration or damage. Replace them as necessary.

EXHAUST SYSTEM

EXHAUST PIPE For replacement of exhaust pipe, be sure to hoist vehicle and observe WARNING under “Maintenance” and following. CAUTION : An exhaust pipe and catalytic converter should not be exposed to any impulse. Be careful not to drop it or hit it against something. • •

Tighten bolts and nuts to specified torque when reassembling. After installation, start engine and check each joint of exhaust system for leakage.

4

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EXHAUST SYSTEM SAFETY PRECAUTIONS FOR CATALYTIC CONVERTOR : The catalytic convertor is fitted on your car to reduce exhaust pollution. The catalytic convertor will quickly heat up after starting to ensure that it operates correctly during the warm up phase of the engine. On a car with a catalytic convertor, the fuel tank filler neck is of reduced diameter compatible with standard unleaded petrol supply nozzle.

CARE AND MAINTENANCE : •

•

Use Unleaded petrol only, since use of Leaded petrol will damage (poison) the Catalytic Convertor permanently. In the event of following symptoms, drive the car at slow speed without rapid acceleration:

a) Engine misfires or runs irregularly, following a cold start. b) A significant loss of power is noticed. c) In case “Check Engine” lamp remains ON even after engine has been started.

EXHAUST SYSTEM

•

Switching “OFF” the ignition when driving down the hill.(This will not save the fuel).

•

Fuel tank getting almost empty.

•

Idling the engine with any of the Spark Plug Cable disconnected, manually, during diagnostic test. (Use appropriate test equipment).

•

Pre- Coating/Painting of Catalytic Convertor.

Parking Warning : Avoid parking the vehicle over inflammable materials,such as dry leaves, grass, etc. as the exhaust system is hot enough to initiate “FIRE”.

If the vehicle is continuously run with misfirng, it may cause overheating of shell, carpet etc. resulting into fire. Avoid : •

Push start or tow-starting the vehicle. (Use jump leads).

•

Long (not more than 10 seconds) repeat (not more than 3 times) starting of the vehicle. Investigate the cause for difficulty in starting and rectify the same.

•

Long idling (to warm-up). If the engine is running rough, after a cold start.

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5

CLUTCH

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CLUTCH

CLUTCH

INTRODUCTION :

The clutch in Indica is a single disc dry friction type with a diameter of 190 mm. It is of diaphragm type and is mechanically actuated by a cable connecting clutch pedal and the clutch release lever. No clutch pedal free play adjustment is required although clutch pedal height from floor has to be adjusted as the clutch lining wears.The clutch pedal height from the floor keeps on increasing as the clutch lining wears.

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i

CLUTCH CONTENTS Sr. No.

Description

Page No.

1.

Technical specifications

1

2.

Tightening Torques

3

3.

List of Special Tools

3

4.

Theory of Diaphragm spring clutch

4

5.

Constructional details

5

6.

Factors affecting clutch wear

5

7.

Preliminary Inspection of clutch

6

8.

Clutch cable Removal, Inspection & Installation

7

9.

Removal of clutch from the car

8

10.

Inspection of components

9

11.

Installation of clutch on the car

9

12.

Procedure for clutch adjustment

10

13.

Trouble shooting

11

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CLUTCH

iii

CLUTCH Technical Specifications : Type Cover Assembly

Single plate dry friction Diaphragm spring type

Disc Assembly

Predamper X (D) type Non asbestos (F491) facings

Release bearing Assembly

Self Centering Type

Clutch Disc : Fig. 1

1.

Outside Diameter

190 mm

2.

Inside Diameter

134 mm

3.

Thickness of Clutch disc with new lining under 320 kg load

4.

7 + 0.3 mm

Max. Permissible out of Perpendicularity of each lining surface of clutch disc

5.

Max. Permissible imbalance of clutch disc

6.

Cushioning of Clutch disc

7.

Total Friction Area (Both sides)

INDEX

CLUTCH

0.4 mm at 186 mm dia. 15 gm-cm 0.6 to 0.85 mm 285 sq.cm

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1

CLUTCH

7+0.3

N

EC

TI

DAMPENING SPRINGS *

[Minor dia]

TIO TA O R

R DI

ON

18.2+0.5 O 18.33 mm

CLUTCH

134 O

190 O

25+0.5

DAMPENING SPRINGS

* THE CHARACTERISTICS OF DAMPENING SPRINGS FOR DIESEL AND PETROL CLUTCH DISCS ARE DIFFERENT.

Fig. 1 Clutch disc - Petrol Engine

2

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27.1 O

HEIGHT

6.51

34 O FINGER

TRAVEL

WEAR

CLUTCH

18.7+3.02 CLUTCH

TRAVEL

RELEASE

8+1

132 +1 O 190 -1.5 O

Fig. 2 Clutch Pressure Plate : Fig. 2

1.

5. 6.

Max. Height of Pressure plate housing from mounting face Height of Diaphragm spring (finger) from cover mounting surface Max. Permissible imbalance of Pressure plate assembly Max. Permissible face run out of release bearing contact surface of diaphragm Clamp load (Minimum on unloading curve) Max. release load (New clutch)

7.

Release travel

8. 9.

Max. Wear travel Min. Pressure plate lift for release travel of 8 mm

2. 3. 4.

24 mm 18.7 ± 3.02 mm 150 gm-mm 0.8 mm at 34 mm dia. 320 kg 95 kg 8 +1 mm 6.51 mm 1.4 mm

Tightening Torques : Clutch Housing to Cylinder block

-

4 to 5 mkg.

Clutch Pressure plate mounting bolts

-

2.4 mkg.

-

2702 5890 2501

List of Special Tools : Mandrel for aligning clutch disc

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3

CLUTCH Theory of Diaphragm spring clutch l

When engaged, the clutch allows the engine driveline to rotate together as one solid member

l

When disengaged, the engine from the driveline allowing it to remain running while the vehicle is stopped.

l

The clutch can be used to interrupt and reconnect the flow of engine power to allow the changing of gears.

CLUTCH

Cover Assembly Non Asbestos Facing Pressure Plate Disc Assembly

Diaphragm Spring

Pre Damper Spring

Fork Seating Location

Main Damper Spring

Clutch Release Bearing

Flywheel Face

Fig. 3 Clutch System - Sectional View 4

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CLUTCH 4

10

7 9

8

6

5

11

1

4

13 12 2 14

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14)

BACK COVER ASSY. CLUTCH RELEASE YOKE BUSH (LOWER) TA65 MOUNTING BOLTS COVER (INSPECTION WINDOW) BUSH (UPPER) CLUTCH RELEASE LEVER HEX. FLANGED SCREW HEX. FLANGED NUT ASSY. BRACKET (ON TRANS AXLE) CLUTCH RELEASE BEARING CLUTCH DISC ASSEMBLY COVER ASSEMBLY FLANGED HEX SCREW

CLUTCH

3

Fig. 4 1.

CONSTRUCTIONAL DETAILS Fig. 4

i. Clutch riding

Clutch is the mechanism interposed between engine and the Transaxle which enables engine power as well as torque of the engine to be transmitted at will to the transaxle through friction drive. When clutch pedal is depressed the clutch is disengaged therefore motion and power flow from engine to Transaxle and hence to road wheels is disconnected.

Using clutch pedal as foot rest by keeping foot constantly on pedal while driving will cause partial clutch disengagement. It will result in slipping of the clutch disc and premature failure of the clutch.

It is a single disc dry friction type clutch having 190 mm dia. clutch disc. Clutch pressure plate assembly is diaphragm spring type. Clutch actuation is through mechanical linkages (cable). 2.

FACTORS AFFECTING CLUTCH WEAR The clutch is designed to give maximum life under most severe conditions when handled carefully. However, while in operation, clutch lining is subjected to wear. Apart from this the extent of wear also depends on following.

2a. DRIVING Following driving conditions will affect the performance of the clutch.

INDEX

ii. Permitting the clutch to slip too long Half clutch driving and thereby permitting the clutch purposely to slip too long will have the same result as above. iii. Permitting the clutch to jerk Sudden clutch engagement at higher engine speed specially while moving out the stuck car will cause severe instantaneous clutch loading, resulting in clutch slippage and burning of the lining locally. Starting the car in first gear under such conditions will avoid such problem. Always start the car in first gear. iv. Restarting on gradient : While restarting the car on gradient, make use of parking brake. Half clutch driving while restarting on the gradient will cause premature damage to clutch.

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5

CLUTCH 2b. OPERATING CONDITIONS Cars operating on shorter runs, city operations, off highway and operations in hilly terrains are obviously subjected to more number of clutch operations and thereby higher clutch wear.

3.

PRELIMINARY INSPECTION OF CLUTCH Clutch needs replacement mainly on account of clutch slippage or imperfect engagement and disengagement. This may be due to worn out/ damaged clutch parts. It is desirable to carry out the following preliminary checks before removal of the clutch for replacement of the parts. Before carrying out the tests, check the clutch cable for damage and also check for proper position of the clutch pedal.

CLUTCH

3a. CLUTCH SLIPPAGE TEST Clutch slippage can be confirmed by any of the following two methods : i)

Drive the car in 1st or 2nd gear at maximum speed corresponding to that gear. Keeping the accelerator pedal pressed with your right foot, apply brake gradually with your left foot. If the engine stalls, it means that clutch does not slip.

ii)

Drive loaded car in 3rd gear on level ground and let the speed drop down to approximately 15 kmph. Now press the accelerator pedal fully.With slipping clutch, the car speed will not pick up and also clutch burning smell will be noticed. If this does not occur and the car picks up speed, it indicates that clutch does not slip.

3b. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST During the clutch slippage test, when the car is in motion, depress clutch pedal fully without changing the accelerator pedal position. If the engine speed increases immediately, perfect clutch disengagement is indicated. Further, release the clutch pedal suddenly. If the car moves forward with a little jerk, perfect clutch engagement is indicated. CAUTION : This test should be carried out with utmost care because sudden release of the clutch might cause heavy jerk and damage to the clutch lining.

6

INDEX

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CLUTCH 4.

CLUTCH CABLE

Control Mounting Bracket

Clutch Pedal Clutch cable holding clip

Clutch Cable Piot CLUTCH

Clutch Cable Silicon Rubber Sleeve Exhaust Pipe

50

Centre of vehicle

120

Plastic straps

Release lever Joint pin Cable holding clamp On fire wall stud

Cable nut

Fig. 5

4a Removal

b) the cable is having a worn end.

1.

Remove the clutch cable nut and disconnect the joint pin from inner cable. Fig. 5

c) the boots are broken.

2.

Disconnect the cable from hook at clutch pedal top. Fig. 5

3.

Remove the clip holding clutch cable on firewall inside cabin.

4.

Remove cable holding clamp at LH side of fire wall in engine compartment.

5.

Remove the plastic straps fitted on steering rack housing and take out the cable.

4c Installation 1

Grease the joint pin and cable end hook.

2

Fix properly the clip for holding clutch cable on firewall inside cabin.

3

Hook the cable end with pedal from inside the cabin.

4

Join the inner cable with joint pin in release arm.

5

Tie the clutch cable with plastic straps on steering rack housing.

6

Ensure the heat resistant sleeve is in front of the exhaust front pipe.

4b Inspection Replace the cable if a) there are any bends or kinks.

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7

CLUTCH

4

10

7 9

8

6

5

CLUTCH

11

1

4

13 12 2 14

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14)

BACK COVER ASSY. CLUTCH RELEASE YOKE BUSH (LOWER) TA65 MOUNTING BOLTS COVER (INSPECTION WINDOW) BUSH (UPPER) CLUTCH RELEASE LEVER HEX. FLANGED SCREW HEX. FLANGED NUT ASSY. BRACKET (ON TRANS AXLE) CLUTCH RELEASE BEARING CLUTCH DISC ASSEMBLY COVER ASSEMBLY FLANGED HEX SCREW

3

Fig. 6 7

Fix LH side cable holding clamp on firewall. Ensure that cable is free in the clamp.

l

Unscrew the mounting bolts evenly (alternately and crosswise) in small steps Fig. 7

8

Adjust the pedal height according to specifications after the clutch cable nut is fastened on to the cable.

l

Remove clutch pressure plate assembly and clutch disc along with the mandrel.

9

Finally check the clutch for proper functioning.

5

REMOVAL OF CLUTCH FROM THE CAR :

l

Place chokes on wheels to prevent movement of car.

l

Disconnect battery and electrical connections of the starter motor.

l

Loosen mounting bolts and remove starter motor. Disconnect and remove transaxle along with housing from engine (for procedure refer transaxle group)

l

Remove clutch release bearing with sleeve (7) Fig. 6

l

Support clutch pressure plate and clutch disc with mandrel.

MANDREL PART NO. 2702 5890 2501

Fig. 7 8

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CLUTCH 6

INSPECTION OF COMPONENTS

i.

Check clutch disc hub splines for damage and wear.

ii.

Check torsion damper mechanism springs for distortion, damage etc. For this purpose, hold drive shaft in vice. Insert clutch disc and slide it as far back as possible. Rotate disc by hand. Rattling noise and excessive play indicates damaged torsional damping mechanism and such disc must be replaced.

clutch disc and centralize clutch disc on flywheel by locating the mandrel at the flywheel end . NOTE :

iii.

Check disc facing for wear, cracks, contact pattern, burning marks and oil contamination. Facings with any of the above defects or worn out beyond permissible limits must be replaced.

Do not mix clutch mounting bolts with other fasteners. Do not use longer or shorter screws. Longer screws may not tighten the clutch at all. Shorter screws will not provide enough threads to achieve desired tightening. l

While tightening the clutch mounting screws check aligning mandrel for continuous free sliding to ensure concentric installation of clutch disc which will avoid trouble during the installation of the transaxle.

NOTE : 1. It is recommended to replace a defective disc having any of the above mentioned defects with a new genuine clutch disc. We do not recommend removal and replacing of clutch facing. 2.

We do not recommend overhauling of the clutch pressure plate assembly. However, before refitment, the assembly should be checked for specifications and should conform to the data of clutch pressure plate assembly given on page 3.

3.

Use correct clutch discs for the Petrol & Diesel versions Identification : The hub length in clutch disc for Petrol is more than that of Diesel.

4.

Use Disc & Pressure plate of the same make.

Ensure that the clutch facing material is not contaminated with oil or grease as this shall result in clutch slipping.

7.

INSTALLATION OF CLUTCH ON THE CAR :

Proceed in reverse order of removal of clutch. However, following care must be taken during installation. Clean friction face of flywheel and check for cracks, scoring, burn marks or unevenness. If necessary, machine flywheel friction face just to clear the defect. Lightly apply grease (3% MoS2) on the disc splines. Install disc and pressure plate assembly. Press the aligning mandrel through the pressure plate assembly and

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9

CLUTCH

CLUTCH 8. PROCEDURE FOR CLUTCH ADJUSTMENT : Hook at clutch pedal top (Apply grease) 2 1 3

Clip (to hold clutch cable on fire wall)

Tension spring

Inner cable

Adjusting Nut

CLUTCH

Cable holding clamp On fire wall stud

Steering rack housing Cable ties

Fig. 8 Note : There is no free play in the system and hence no clutch pedal free play adjustment is required. However, for ensuring the proper functioning of the clutch the following procedures should be used. 1.

Clutch pedal height should be same as the brake pedal height. (Brake pedal height is automatically ensured by protrusion of booster push rod (refer Brake pedal adjustment from Brake Group)).

2.

The clutch pedal height from the floor keeps on increasing as the clutch lining wears.

3.

Clutch pedal height can be adjusted by setting the nut provided on the clutch release lever. The release lever is located on transaxle housing. Turn the nut by hands so as to get clutch pedal height same as brake pedal height, and cable is sufficiently stretched. Press the clutch pedal 2/3 times and confirm the height.

10

INDEX

4.

It should be possible to lift the clutch pedal by hand easily without much force. The pedal should have movement of 40 to 50 mm. If pedal lifting force is high, (more than 0.9 kg.) then shift the position of tension spring hook on holes 1, 2 and 3 for reducing tension Fig. 8

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CLUTCH 9 SR. NO. 1.

TROUBLE SHOOTING IN THE VEHICLE

THE COMOPONENT

CAUSE

New Clutch : Difficulty in changing gear Difficulty in changing Burrs thrown up around Due to poor alignment of the gear, following splines causing stiff gearbox on reassembly. replacement of clutch movement on input shaft. The driven plate was improperly aligned. Aggressive location of input shaft into hub.

2.

The centre hub of the driven plate has ripped out and possibly one or more of the springs have been pushed out.

The weight of the gearbox has been hung on the centre plate. This has distorted the driven plate resulting in failure within a short period of use.

Ensure that the gearbox shaft and gearbox are not hung on the clutch driven plate by using a pit jack or trolley jack to support the gearbox on reassembly. Very aggressive clutch control. Do not “boy race” ie.“Racing starts” or when Educate the driver. towing a heavily laden trailer.

Slipping Clutch Clutch slip. The control The clutch friction There is an oil leak from the system is in good material is contaminated engine or gearbox. condition and correctly with oil. adjusted.

4.

Carefully check the engine and gearbox oil seals. Replace seals if oil is present in bell housing.

Juddering During Pulling Away Clutch judder on initial take up of torque.

5.

Care with the centering of driven plate; use an appropriate clutch aligning tool. Do not force the gearbox but rotate the flywheel or gearbox shaft to line up with splines.

Loss of Drive : With recently fitted clutch Loss of drive and loud clatter, only covered a few hundred kilometres.

3.

REMEDY

Oil or grease found on Excess grease applied the middle of the clutch to input shaft splines. driven plate.

Only use the correct amount and the correct type of grease.

Loss of Drive Loss of drive

INDEX

The friction material has Drive error - e.g. accidentally come off from both changing from 5th to 2nd sides (centrifuged). gear at 85 miles per hour. The facings have centrifugated. The shattered linings are lodged into cover assembly and loose in the bell housing. Some parts of the driven plate could be broken.

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11

CLUTCH

CLUTCH SR. NO. 6.

IN THE VEHICLE

THE COMOPONENT

CAUSE

REMEDY

Vibrations Through the Pedal When Starting to Declutch Pedal vibration when The fingers of the The gearbox input shaft has Carefully guide in the starting to declutch. diaphragm are out of line struck the fingers of the gearbox to avoid any knocks and show signs of diaphragm on fitting. on fitting. damage.

7.

Metallic Shound with Pedal Fully Depressed Metallic sounding noise affected by engine speed with pedal fully depressed

CLUTCH

8.

The tips of the diaphragm fingers are worn away by the release bearing. The bearing can appear to be in good condition.

The pre-load on the release bearing is too low or not existent.The pre-load spring is unhooked.

During clutch installation thoroughly inspect all linkages and joints. Ensure that the clutch cable is smooth and free throughout its movement. Always refer to vehicle workshop manual for correct adjustment. The pre-load should be minimum of 50 Newtons to a maximum of 80 Newtons.

A location lug on the release bearing has broken.

A lug has broken. An other fault in the mechanical operation of the clutch has caused the lug to break. For example, the fork is out of shape or wrongly positioned at the time of assembly.

Check the fork and the guide sleeve and replace if signs of wear are present. Ensure components are lubricated. Carefully check the clutch cable.

The bearing has seized or was noisy from the start. Or the bearing has overheated, burning off the grease caused by incorrect pre-load.

Systematically check the clutch cable, linkages, joints fork bearings, pre-load spring .

Noisy Clutch The clutch is noisy and the pedal can be slack.

10.

Systematically check the condition of the cable, linkage and automatic adjuster. Always refer to vehicle workshop manual for correct adjustment.

Excessively Heavy Pedal The pedal is hard to depress. This stiffness increases over time.

9.

Signs of rubbing on the Incorrect clutch adjustment diaphragm fingers, in the excess travel. Automatic area of contact with the adjuster is faulty. release bearings.

Horse Noise on Decltuching A harsh whistling noise The movement of the can be heard either on release bearing is hard declutching or all the when rotated by hand. time. It varies according to the pressure applied to the pedal.

12

INDEX

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CLUTCH SR. NO. 11.

IN THE VEHICLE

The levers are badly Incorrect clutch adjustment damaged and the release causing bearing failure. bearing has seized.

Regularly check the clutch adjustment. Always refer to the vehicle workshop manual for correct method of clutch adjustment.

The pressure plate shows Driver resting foot on pedals. burn marks. Incorrect clutch adjustment.

Regularly correct clutch adjustment. Always refer to the vehicle workshop manual for correct method of clutch adjustment. Educate the driver.

Juddering After Changing the Clutch The clutch judders.

14.

REMEDY

Slipping and Juddering The clutch slips and eventually judders.

13.

CAUSE

Permanent Loud Noise Permanent, loud noise.

12.

THE COMOPONENT

Circular grooves can be The clutch has been replaced seen on the friction when the flywheel has been material on the flywheel previously scored. side.

Systemically check the condition of the flywheel. Skim flywheel if necessary.

Pedal Stiff Stiff pedal with the risk The guide tube is of prolonged slipping corroded and worn. after pulling away. Clutch wear is abnormal taking into account the amount of mileage.

INDEX

The release bearing jams on the guide.

GROUP INDEX

If there are any signs of irregular wear replace guide tube. Avoid excessive lubrication which could contaminate the friction material.

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13

CLUTCH

TRANSAXLE

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TRANSAXLE

TRANSAXLE

INTRODUCTION :

The Indica MPFI - Euro II has a transversely mounted engine and transaxle. This layout of engine is typical of front wheel driven cars. The propeller shafts and centre joints are eliminated and the gear box and differential are integrated into a single housing termed as Transaxle. The drive is transmitted to front wheels from differential side gears through constant velocity shafts. Since the final drive axis and crankshaft axis are parallel, there are no crown wheel and tail pinion. Instead the final reduction is done by a pair of helical gears. All the forward gears are synchromesh and reverse gear is sliding mesh. The gear shifting conforms to international H pattern, 5th and reverse being in line. All layshaft gears are free on it without needle bearings. There is no pilot bearing for the input shaft and there are no control dimensions to be maintained on input shaft and layshaft. Pinion is integral with the input shaft and all the gears on the input shaft are located by circlips. Speedo cable drive is located on differential housing.

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i

TRANSAXLE CONTENTS Sr. No.

Description

Page No.

1.

Technical Specifications

1

2.

Tightening Torques

2

3.

List of special Tools

3

4.

Exploded View of Gear Shift Linkage

4

5.

Exploded View of Housing and Differential

5

5.

Exploded View of Input shaft and Layshaft

6

7.

Exploded View of Shifter shaft arrangement

7

8.

Removal of Transaxle from the car

8

9.

Installation of Transaxle on the car

9

10.

Disassembly of Transaxle

10

11.

Assembly of Transaxle.

17

12.

Sub-assemblies :

TRANSAXLE

Disassembly, Inspection and Assembly of : i.

Layshaft

22

ii.

Input shaft

30

iii.

Differential Assembly

31

iv.

Identification of components

35

v.

Sub-Assembly of Gears/Synchro pack

37

vi.

Assembly Bracket Selection and Shifting

39

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iii

TRANSAXLE TECHNICAL SPECIFICATIONS : Type

:

Synchromesh on all forward gears and sliding mesh for reverse gear.

Oil capacity

:

3.3 Liters

Type of oil

:

SYNGEAR EP 75W 90 GL4

Model

:

TA 65-5 / 3-42 (5 speed with over drive)

Gear Ratios

:

Indica 75PS LEi & LSi

Indica 85PS LX & LXi

1st - 3.42

1st - 3.42

2nd - 1.95

2nd - 1.95

3rd - 1.36

3rd - 1.36

4th - 0.95

4th - 0.95

5th - 0.77

5th - 0.714

REV. - 3.58

REV. - 3.58

Final drive ratios:

4.06:1

4.64:1

Gear shift

Floor mounted with international “H” pattern with first and reverse inline.

:

TRANSAXLE

There is an interlock provided to prevent engagement of reverse gear directly from fifth gear

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1

TRANSAXLE TIGHTENING TORQUES : Sr. No.

Description

Torque (kg-m)

1.

Engine ‘A’ mount nut

1.5

2.

Engine ‘A’ mount bracket to block

4.5

3.

Engine ‘B’ mount nut

2.5

4.

Engine ‘C’ mount nut

1.00

5.

Engine ‘C’ mount to body shell

8.00

6.

Starter motor mounting

2.4

7.

Fuel Line Clamps

1.5

8.

Transaxle mounting bolt

9.

Gearshift Linkage to transaxle end

2.5

10.

Gearshift Linkage to body shell

2.5

11.

Transaxle intermediate plate mounting bolt.

12.

Selection/shifting bracket assy. screws

0.85 to 1.05

13.

Layshaft and input shaft nuts

12.3 to 16.7

14.

Detent plate mounting screws

0.85 to 1.15

15.

Rear cover mounting screws

16.

Drain plug & filler plug

TRANSAXLE

2

INDEX

4

3.2 to 3.8

2.1 to 2.5 3 to 4.1

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TRANSAXLE LIST OF SPECIAL TOOLS : Sr. No.

Description

Part No.

1.

Mandrel for clutch disc alignment

2702 5890 2501

2.

Drift for drive shaft oil seal

2702 5890 2601

3.

Drift for input shaft bearing (front)

2702 5890 2602

4.

Drift for installation of layshaft bearing front

2702 5890 2603

5.

Puller for differential side bearing (Transaxle)

2702 5890 2604

6.

Drift for removal of cylinderical roller bearing from layshaft front

2702 5890 2605

7.

Holder for removing input shaft rear bearing

2702 5890 2606

8.

Holder for removing layshaft rear bearing

2702 5890 2607

9.

Drift for differential bearing inner race

2702 5890 2608

10.

Fixture for holding gear on differential casing

2702 5890 2609

11.

Mounting plate - transaxle on work stand

2702 5890 2610

12.

Adaptor for locking input shaft

2702 5890 2611

13.

Rest pad

2702 5890 2612

14.

Drift for a) Lay shaft deep groove ball bearing b) Rear hub outer bearing seating on spindle

2641 5890 2601

15.

Drift for input shaft rear bearing, lay shaft rear bearing

2651 5890 3308

16.

Puller for differential side bearing

2651 5890 3506

17.

Puller for deep groove ball bearing (Front) Input shaft

2657 5890 2801

18.

Drift for differental bearing outer race and speedo gear

2654 5890 3507

19.

Puller for deep groove ball bearing (Rear)

2654 5890 3508

20.

Work stand

2573 5890 3701

INDEX

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TRANSAXLE

3

TRANSAXLE EXPLODED VIEW GEAR SHIFT LINKAGE

ASSY KNOB WITH BELLOW & BASE PLATE

RUBBER BELLOW (G.S.LEVER) 2.3 RUBBER BELLOW (CUP) ASSY BRACKET INNER SPACER

BUSH (G.S.LEVER BALL SEAT)

RUBBER BUSH (EXT ARM)

8.0 ASSY GEAR SHIFT LEVER

SPACER PIN

COLLAR BUSH

ASSY EXTENSION ARM

ASSY YOKE

RUBBER BOOT (G.S.LEVER GUIDE)

ASSY BKT

ASSY PLATE (BELLOW/SUPPORT HOLDER) 2.3

2.3 0.95 PIN

ASSY HANGER

COLLAR BUSH

2.3

ASSY YOKE 4.6 2.1-2.9 2.5-4.0

PIN

2.3 ASSY SHIFT LINK ASSY YOKE (SHIFT LINK) COLLAR BUSH

2.3

-- SPECIFIED TORQUE IN Kgm

4

INDEX

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TRANSAXLE HOUSING AND DIFFERENTIAL

ASSY DRIVE SHAFT (LH)

OIL SEAL (DRIVE SHAFT) ASSY REAR COVER

2.1-2.5

RUBBER SEAL 21. - 2.5 BREATHER

3.0-4.1

REV. LIGHT SWITCH 1.6-1.9

LOCK PLATE DETENT SPRING AND BALL GASKET

NEEDLE BUSH (SKEWED) REV. IDLER GEAR

DETENT PLATE

REV. IDLER SHAFT

1.8-1.15

3.2-3.8

INTERLOCK PIECE

DOWEL SLEEVE TAPER ROLLER BRG

STOPPER BKT (REV. IDLER) SPIDER

DIFFERENTIAL HOUSING SPEEDO PINION SPEEDO ADAPTOR

EXT CIRCLIP BEVEL PINION GEAR FINAL DRIVE

O-RING OIL SEAL

8.0-9.0

0.85-1.15

SIDE BEVEL GEAR

INTEGRAL OIL SEAL SPEEDO GEAR TAPER ROLLER BEARING SHIM (DIFF. BEARING) RUBBER BELLOW

0.85-1.15

INPUT SHAFT COVER ASSY DRIVE SHAFT (RH)

-- SPECIFIED TORQUE IN Kgm

INDEX

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5

TRANSAXLE INPUT SHAFT AND LAYSHAFT 12.3-16.7

LOCK PLATE (5th SPEED GEAR) SHIFTER SLEEVE (5th SPEED)

ENGAGING GEAR (5th SPEED) SYNCHROCONE (3rd/4th/5th)

SUB ASSY 5th GEAR LAYSHAFT

BUSH (5th GEAR LAYSHAFT)

NEEDLE CAGE (5th GEAR LAYSHAFT)

BALL BRG WITH SNAP RING

SUB ASSY 4th GEAR LAYSHAFT

SYNCHROCONE (3rd/4th/5th)

SHIFTER SLEEVE (3rd/4th)

TRANSAXLE

ENGAGING GEAR (3rd/4th) 3rd GEAR LAYSHAFT

SYNCHROCONE (3rd/4th/5th) CIRCLIP

SYNCHROCONE (1st/2nd)

2nd GEAR LAYSHAFT REV GEAR / SHIFTER SLEEVE (1st/2nd)

ENGAGING GEAR (1st/2nd)

SYNCHROCONE (1st/2nd)

CIRCLIP

1st GEAR LAYSHAFT 12.3-16.7 CYLINDRICAL ROLLER BRG

5th GEAR INPUT SHAFT BALL BEARING (REAR END)

LAYSHAFT

INPUT SHAFT

CAP BALL BEARING (FRT. END)

-- SPECIFIED TORQUE IN Kgm

6

INDEX

NOTE : ALL CIRCLIPS TO BE USED IN SELECTION

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TRANSAXLE SHIFTER SHAFT ARRANGEMENT SHIFTER SHAFT (3rd/4th)

SHIFTER FORK (3rd/4th) DOUBLE DOWEL SLEEVE

SPIRAL DOWEL

SHIFTER DOG

TRANSAXLE

SHIFTER SHAFT (1st/2nd)

SPIRAL DOWEL

SPIRAL DOWEL

SHIFTER FORK (1st/2nd)

SHIFTER DOG (3rd/4th) 0.85-1.05 SHIFTER SHAFT PIN SPIRAL DOWEL

SPRING (1st/2nd)

SHIFTER DOG (5th/REV)

CUP (BKT SEL./SHIFT)

ASSY FINGER (SEL./SHIFT.) PLATE (REV. LOCK)

0.85-1.05

SPRING (5th/REV.)

SUB ASSY BRACKET (SEL/SHIFTING) SHAFT (SEL./SHIFTING)

ASSY REV. LEVER PIN

LEVER (SE./SHIFTING) 2.5-4 2.1-2.9

0.85-1.05

-- SPECIFIED TORQUE IN Kgm

INDEX

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7

TRANSAXLE

TRANSAXLE REMOVAL OF TRANSAXLE FROM THE CAR : 1. 2. 3. 4. 5. 7. 8. 9. 10. 11.

12. 13.

Park the vehicle properly, and place chocks on rear wheels. Disconnect the battery terminals and remove the battery. Drain the Transaxle oil. Jack up and remove front wheels and support the vehicle properly. Remove the starter motor. Remove the air filter assembly. Remove tie member front suspension. Fig. 1 Disconnect power steering pressure line. Remove ball joint (steering rack) from steering knuckle from both sides. Disassemble ball joint assembly from steering knuckle by loosening clamping bolt. Disconnect gear shifter linkage. Remove dust cover of flywheel (on lowerside of engine) Remove clutch housing cover and remove stifner bracket bolts. Loosen mounting bolts of clutch housing. Fig.2

Fig. 1

Fig. 2 14. Remove fuel line supporting bracket from clutch housing. 15. Disconnect clutch release cable from clutch release lever. 16. Support engine suitably. 17. Disconnect ‘C’ mount bracket. 18. Disconnect speedo cable, vehicle speeed sensor from speedo adaptor. Fig. 3 19. Disconnect electrical connections of Reverse Light switch. Ensure to release wiring harness from below clutch cable and clutch actuating lever. 20. Swing out both drive shafts from transaxle together with brake assembly and place it suitably along side. Do not pull drive shaft excessively as the plunge joint will come out of housing and

8

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Fig. 3

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TRANSAXLE

21. 22. 23. 24. 25. 26. 27.

damage the boot. Pry plunge joint housing for taking out joint out of splines.Do not place the CV drive shaft on rough/uncleaned surfaces. This might damage the drive shaft boot. Loosen and remove B Mount nut. Remove ‘B’mount rubber pad. Lower the assembly (engine and transaxle). Remove B mount bracket from transaxle housing. Remove clutch housing mounting bolts and take out the transaxle. Remove clutch release bearing from input shaft. Fig.4 Lift and support the engine assembly properly.

INSTALLATION OF TRANSAXLE ON THE CAR Tie actuating lever of clutch in clutch disengaged position. Place clutch release bearing (replace by new one if required) on input shaft and locate it properly. 2. Remove the support and lower the engine assembly slightly and align transaxle assembly with engine assembly 3. Fit clutch housing on to engine and locate bolts and tighten them. Fig. 5 4. Fix ‘B’ mount bracket on transaxle. 5. Lift the transaxle assembly and engine assembly together. 6. Locate and fix ‘B’ mount rubber pad on bracket below the battery tray. Fig. 6 7. Fix the ‘B’ mount nut and tighten it to specified torque. 8. Torque transaxle housing mounting bolts to specified torque. 9. Fix ‘C’ mount bracket to transaxle housing and remove engine support. 10. Align and insert both the drive shaft assemblies into transaxle carefully. CARE SHOULD BE TAKEN NOT TO DAMAGE DRIVE SHAFT OIL SEAL (DO NOT USE HAMMER). Ensure that splined end of plunge joint is inserted fully in differential gear.

Fig. 4

TRANSAXLE

1.

Fig. 5

‘ C ’ MOUNT

11. Assemble ball joints on lower link (both RH & LH). 12. Connect ball joint (steering rack) on steering knuckle.

FRONT ‘B’ MOUNT

‘A’ MOUNT

Fig. 6

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9

TRANSAXLE

TRANSAXLE 13. Connect clutch release cable to clutch release lever and adjust (see Clutch group for cable adjustment procedure). Route the harness carefully under the lever. 14. Fix fuel line support bracket on clutch housing and tighten the mounting bolts to specified torque. 15. Fix clutch housing inspection cover. 16. Connect gear shift linkages.Ensure molykote grease is applied on pin joints. 17. Fix starter motor. 18. Connect Speedo-cable and vehicle speed sensor. 19. Connect reverse light switch connection. 20. Place the battery tray and mount battery on it. 21. Connect electrical connection of starter motor.

Fig. 7

22. Fix air filter. 23. Fit wheels and hand tighten the bolts and remove the jack support, and chocks from rear wheels. 24. Tighten wheel mounting bolts to specified torque. 25. Fill transaxle oil. 26. Fix fuel filter assembly 27. Connect battery terminals. 28. Fix power steering pressure line. 29. Fix tie member front suspension. TRANSAXLE TA 65 DISASSEMBLY: 1.

Ensure that oil is drained completely from the transaxle before mounting on the work stand.

2.

Fix the mounting plate (2702 5890 2610) on workstand 2573 5890 3701 by using hex bolt in 3 holes of 14mm dia. on the mounting plate.

3.

Mount transaxle face on mounting plate and fix it by three hex bolts of M8 size and remove assembly reverse light switch. Fig. 7

Fig. 8

Remove the ‘B’ mount bracket if required. 4.

Turn the table by 900 deg.

5.

Lock input shaft by adapter 2702 5890 2611 Fig. 8

6.

Turn back the table by 900 deg.

7.

Remove assembly rear cover. Fig. 9 Fig. 9

10

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TRANSAXLE 8.

Remove the spiral pin of the shifter fork (5th speed) Fig. 10

Fig. 10 9.

TRANSAXLE

Unscrew the locknut on lay shaft. Fig. 11

10. Unlock & remove locknut on Input shaft. Fig. 11 11. Engage any of the gears for locking the, lay shaft.

Fig. 11 12. Remove lock plate (5th speed gear) Fig. 12

Fig. 12

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11

TRANSAXLE 13. Remove 5th gear shifter sleeve from lay shaft along with 5th speed shifter fork 14. Remove engaging gear (5th speed) along with 5th gear and synchrocone, taking care that carrier assembly does not slip off. Fig. 13

Fig. 13

TRANSAXLE

15. Remove needle bearing. Fig. 14 16. Remove the bush. 17. Remove spacer(layshaft)

NEEDLE BEARING

BUSH

Fig. 14 18. Remove the conical washer and 5th gear (input shaft) Fig. 15

Fig. 15 12

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TRANSAXLE 19. Remove lock plate (lay shaft bearing) from housing rear half by unscrewing T40 torx head screws Fig. 16. (Use new torx head screws during reassembly) 20. Remove lock plate input shaft bearing from housing (rear half) by unscrewing the screws.

Fig. 16

TRANSAXLE

21. Remove hex screw M6 x 16 (2 Nos.) on detent plate and remove gasket detent plate springs (3Nos.) and steel ball (8dia) (3Nos) Fig.17 Take note of the sequence of springs (1 R/5 spring hard, two springs soft for 1/2 and 3/4) 22. Remove the hex. flanged bolts M8 x 95(2Nos) and hex. flanged bolts (14 Nos.) M8 x 40. Remove the bracket for retaining clutch return spring on rear half of housing. 23. Remove the gear box housing (rear half) by gently tapping with a mallet.

Fig. 17 24. Remove reverse idler shaft and reverse idler gear Fig. 18.

Fig. 18

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13

TRANSAXLE 25. Remove double dowel pins of shifter fork (1st and 2nd) Fig.19 26. Remove spiral pin of shifter dog (Rev) Fig. 20.

Fig. 19

TRANSAXLE

27. Remove spiral pin of shifter dog (3rd & 4th) 28. Remove spiral pin of shifter dog (1st & 2nd) Fig.20 29. Remove shifter shaft (3rd & 4th), shifter shaft (5th & reverse) and shifter shaft (1st & 2nd). 30. Remove shifter fork (3rd and 4th) & also lock plate on shifter selection bracket (for 4 speed)

Fig. 20 31. PLEASE DO NOT TRY TO REMOVE SHIFTER FORK (1st and 2nd) 32. Remove selection shifter bracket assembly by removing four mounting screws M6. 33. Now remove shifter fork (1st and 2nd) Fig. 21

Fig. 21 14

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TRANSAXLE 34. Remove the inter lock pieces (2nos) Fig. 22 35. Remove adapter part No. 2702 5890 2611 for locking input shaft. Tap input shaft assembly gently from spline end. Simultaneously, also pry out the lay shaft assembly gently so that both, lay shaft assembly and input shaft assembly come out of intermediate plate simultaneously.

Fig. 22

TRANSAXLE

36. Remove the intermediate plate mtg. screws, M10x30 (10Nos.) and M10X20(1No.) Fig. 23 37. Remove the stopper bracket (Reverse idler) 38. Pry out gently the intermediate plate from housing (front half). CAUTION : THE MOUNTING SCREW FOR INTERMEDIATE PLATE NEAR THE REVERSE IDLER SHAFT HOLE IS OF SIZE M10X20.

Fig. 23 39. Unlock the lock nut M10 and unscrew and remove the locking screw on lever (selection/shifting) Fig. 24 40. Remove the differential assembly from the housing front. 41. Pull out assembly shaft (selector/shifting) from lever (selection/shifting) and bellow holder with oil seal from housing front half. 42. Pry out the oil seal of shaft (selector/shifting) from bellow holder and replace it with a new one while assembling. DO NOT USE THE OLD OIL SEAL.

Fig. 24

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15

TRANSAXLE 43. Remove rubber bellow and replace it if damaged. 44. Remove the assembly hex screw (speedo lock plate) Fig. 25 along with lock plate (speedo gear). 45. Remove speedo adaptor with speedo pinion and ‘O’ ring Fig. 25 inset. 46. Replace oil seal (speedo shaft) if damaged. 47. Replace ‘O’ ring if damaged.

Fig. 25

TRANSAXLE

48. Remove input shaft cover by removing M6X10 (3 Nos.) mounting screws. Fig. 26 49. Pry out the oil seal from the cover (if damaged) and replace it with new one.

Fig. 26 50. Remove hex flanged screw holding release lever on to release yoke & take out release lever from release yoke Fig. 27 51. Remove the plastic bushes at both ends of clutch release fork and remove the clutch release shaft from inside. 52. Remove oil seals of drive shaft from both housing (front and rear half). Replace it with a new one while assembling. 53. Remove bearing outer races of differential side bearing along with shims. Ensure that outer races are not interchanged. SHIMS SHOULD NOT BE REUSED.

Fig. 27 16

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TRANSAXLE 1

Apply anabond 112 on threads of all fasteners

2.

Apply RTV silicon liquid gasket anabond 676 on housing interface.

3.

The chips collected by magnetic drain plug, are to be removed at the time of every oil change.

4.

Keep inner and outer races of taper roller bearing in sets.

5.

Use sealing anaerobic compound for all oil seals outer diameter.

6.

For oil seals of input drive shaft & bellows use anabond 112.

C

NOTE :

ASSEMBLY 1.

Fit clutch release fork shaft. Fit plastic bushes.

TRANSAXLE

2.

Fix delrin bush and rubber bush into assembly shaft (selector/shifting). Ensure that delrin bush is at the centre of the hole of the selector shifter shaft boss.

B

3.

Fit rubber bellow on assembly shaft (selector/ shifting).

A

Fit lever on clutch release shaft and lock it by grooved pin.

4.

Fit new oil seal in new bellow holder (if damaged) of press pt. of assembly shaft (selector/shifting) into housing front half.

5.

Assemble shaft through oil seal and fix the lever (selector/shifting) by lock nut and lock screw. Ensure that the locking screw gets locked in shaft (selector/shifter) centre hole.

6.

Differential bearing preload adjustment procedure. Fig. 28 a)

Measure dimension ‘A’ (Distance between top mating surface of transaxle front half and the outer differential bearing seat) say 103.7mm in housing and dimension ‘B’ (Distance between mating surface of transaxle rear half and the inner differential bearing seat) say 19mm in housing for bore 65.088 mm dia.

b)

Place outer races on both differential side bearings and measure distance between outer surfaces of these outer races (dimension ‘C’).

c)

Select shim thickness = (A+B)-C

Fig. 28

to (A+B)-C + 0.05

and install the shims against front half taper roller bearing outer race.

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17

TRANSAXLE 7.

Fix the outer race of differential side bearing in the housing (front half) by using drift part no. 2654 5890 3507. Fig. 29

Fig. 29

TRANSAXLE

Fit oil seal in Housing front half using drift part No. 2702 5890 2601 Fig. 30 8.

Place assembly differential in front half housing. Ensure that the dowel sleeve should be there on front half before the intermediate plate assembly.

Fig. 30 9.

Assemble intermediate plate along with stopper plate (reverse idler gear by means of mounting bolts).Tighten the bolts to 3.2 to 3.8 mkg torque. Fig. 31

CAUTION : BOLT NEAR THE IDLER SHAFT HOLE OF STOPPER PLATE IS SHORTER, M10X20.

Fig. 31 18

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TRANSAXLE 10. Place layshaft assembly & input shaft assembly together (front half). Tap lay shaft & input shaft GENTLY and SIMULTANEOUSLY. Do not press fully (till there is a gap of around 2 mm between lower face of first gear lay shaft and intermediate plate mounting bolt head). Fig. 32

Fig. 32

TRANSAXLE

11. Place interlock pieces (2 Nos.). CAUTION : ENSURE THAT THE LUG POSITIONS WHILE ASSEMBLING IN THE INTERMEDIATE PLATE. FIG. 33

Fig. 33 12. Ensure that the shifter fork is assembled with ribbed face upwards on shifter sleeve 1/2. Fig. 34

Fig. 34

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19

TRANSAXLE

TRANSAXLE 13. Fix sub-assembly bracket (Selection/Shifting) by 4 mounting screws. Fig. 35 14. Place shifter fork 3/4 on shifter sleeve 3/4 by keeping ribbed face upward. 15. Place shifter shaft 1/2 into shifter fork hole, and lock it by spiral pin. CAUTION : WHILE PLACING ALL THREE SHIFTER SHAFTS, ENSURE THAT THREE NOTCHES ON IT ARE UPWARDS AND FACING THE BRACKET AND THE SHAFTS ARE LOCATED PROPERLY IN THE INTERLOCK PIECES. Fig. 36 16. Assemble shifter dog (1/2) on shifter shaft by keeping its dog slot downward and lock it on shifter shaft by spiral pin.

Fig. 35

17. Assemble shifter shaft 3/4 through shifter fork and shifter dog below it with its dog slot and lock it with shifter fork and shifter dog by spiral pins.

B A - 1/2 SHIFTER SHAFT B - 3/4 SHIFTER SHAFT

18. Locate the reverse shifter dog slot into pin on bkt. and place shifter shaft 5/R, locate and lock, the shifter dog on shifter shaft with spiral pin.

C - 5/R SHIFTER SHAFT A

19. Assemble reverse idler shaft with assembly reverse idler gear, and new spring & spacer. CAUTION : THE SLOT IN REVERSE IDLER SHAFT IS TO BE LOCKED IN GROOVE IN FRONT GEAR BOX HOUSING.

C

Fix the lever (on assembly bracket) into the slot of Reverse Idler Gear. 20. Ensure that all the spiral pins are pressed properly. Assemble the Housing (rear half) on lay shaft, input shaft and shifter shaft and tap it gently and uniformly so that it gets located on lay shaft and input shaft bearing.

C

B

NOTE :

A

Care to be taken to locate the three shifter shafts in the housing rear half.

Fig.36 20

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TRANSAXLE NOTE : Apply liquid gasket (Anabond 90 or 3 bond 12S001) with proper bead size on front half/ interface. 21. Fix the housing (rear half) and tighten the flanged mounting bolts to specified torque. Fig. 37 22. Place lock plates of lay shaft bearing and input shaft bearing and fix them by allen screws. Tap the shaft in either direction if required. 23. Place spacer on lay shaft. 24. Put input shaft 5th gear on input shaft. CAUTION : Ensure ground face (5th gear I/S) towards the bearing face.

Fig. 37

TRANSAXLE

25. Put conical washer and lock nut on input shaft. 26. Place 5th gear assembly (lay shaft) with bush and needle cage and synchro pack (5/R) along with shifter fork (5th gear) on shifter sleeve. Locate shifter shaft hole on shifter fork to shifter shaft. 27. Lock the shifter fork on shifter shaft by spiral pin. 28. Place lock plate on lay shaft 5th gear assembly 29. Fix lock nut on lay shaft. 30. Put 3 steel balls and 3 springs in detent holes and gasket (detent plate) and fix detent plate. Fig. 38. Take care that the blue coloured spring is for 5/R. Fig. 38 31. Lock the input shaft from below. Engage any one of the gears. 32. Tighten the lock nuts on both lay shaft and input shaft by giving torque of 12.3-16.7 mkg Fig. 39

Fig. 39

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21

TRANSAXLE

TRANSAXLE Stake the collar of both lock nuts on layshaft and input shaft. Fig. 40 33. Check the correct positioning of shifter shaft by moving the gear shifter shaft assembly in neutral. 34. Assemble speedo pinion with speedo adaptor. Fix assembly speedo pinion. Fix assembly hex. screw (speedo) lock plate) along with lock plate (speedo gear). 35. Place assembly rear cover with rubber seal on housing (rear half) and fix it by assembly hex. screws (3Nos.).

é

é

CAUTION : ENSURE THAT TUBULAR PORTION OF THE RUBBER SEAL IS SEATED PROPERLY (WITHOUT ANY PINCHING ONTO THE CHANNEL IN THE REAR COVER). Fig. 41 36. Tighten the screws to specified torque. Fig.41a CAUTION : USE PROPER GASKET AND SEALANT Clean the front half and rear half interfaces/ so that no cured and dried liquid gasket remained are left on the machined surfaces. 36. Unlock the input shaft from below. 37. Fix reverse light switch on housing (rear half), magnetic drain and filter plugs with new washers. 38. Fix the C-mount bracket on the gear box front housing. 39. Fix the B-mount bracket in the correct orientation. 40. Unscrew 3 mounting bolts (M8) and dismount the transaxle assembly from adaptor plate on workstand. DISASSEMBLY OF LAYSHAFT 1. Remove Deep groove Ball bearing from lay shaft by using holder 2702 5890 2607 with puller 2654 5890 3508 Fig. 42

Fig. 40

Fig. 41

Fig. 41a

Fig. 42

22

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TRANSAXLE 2.

Remove spacer Fig. 43

Fig. 43 3.

Remove sub-assembly 4th gear (lay shaft) Fig. 44

4.

Remove Synchropack assembly (3/4 speed) CAREFULLY so that springs, carriers and balls do not jump out. Fig. 45

Synchropack -

5.

TRANSAXLE

Shifter sleeve, engaging gear, synchrocone, spring, ball, carrier (sleeve in case of 1st gear).

Pry out circlip from lay shaft Fig. 46 Fig. 44

Fig. 46

Fig. 45

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23

TRANSAXLE 6.

Remove 3rd gear lay shaft Fig. 47

Fig. 47

TRANSAXLE

7.

Pry out circlip from lay shaft Fig. 48

Fig. 48 8.

Remove 2nd gear lay shaft Fig. 49

Fig. 49 24

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TRANSAXLE 9.

Remove synchro pack (1/2 speed) CAREFULLY so that springs, carriers and balls do not jump out. Fig. 50

Fig. 50

TRANSAXLE

10. Pry out circlip from lay shaft Fig. 51

Fig. 51 11. Remove 1st gear lay shaft Fig. 52

Fig. 52

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25

TRANSAXLE 12. Pry out circlip from lay shaft. 13. Place the lay shaft upside down and remove cylindrical roller bearing using drift Part No. 2702 5890 2605. Fig. 53

Fig. 53

TRANSAXLE

LAY SHAFT ASSEMBLY ASSEMBLY : 1.

Press cyl. roller bearing on lay shaft by using drift Part No. 2702 5890 2603, Fig. 54

2.

Fit Circlip. It should snugly fit.

NOTE : Circlips are available in different thicknesses. 2.25mm, 2.3mm, 2.35mm, 2.4mm.

Fig. 54 3.

Place first gear (lay shaft) on lay shaft by keeping dog teeth upward.

4.

Place synchrocone (1/2 speed) Fig. 55

Fig. 55 26

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TRANSAXLE 5.

Install preselected circlip. Fig. 56 Circlip thickness should be so selected that there is no axial play of gear.

Fig. 56 6.

Place engaging gear (1/2 speed) with circlip races downward and with slot on engaging gear on corresponding lug on synchrocone. Fig. 57

7.

Place springs (3 nos.) plungers (3nos.) into the hole in engaging gear (1/2 speed).

8.

Place sleeve carrier and steel ball on it and slide reverse gear/shifter sleeve (1/2 speed) on it with fork slot in upward position.

TRANSAXLE

Fig. 57 9.

Place synchrocone (1/2 speed) and locate its lugs into the slot of engaging gear. Fig. 58

Fig. 58

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27

TRANSAXLE 10. Place 2nd gear with its dog teeth downward. Fig. 59

Fig. 59

TRANSAXLE

11. Install preselected thickness circlip on it.Fig. 60 12. Place 3rd gear lay shaft with its dog teeth upwards.

Fig. 60 13. Fit preselected circlip. Fig. 61 There should not be any axial play of gear. 14. Place synchrocone (3rd gear)

Fig. 61 28

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TRANSAXLE 15. Place engaging gear with circlip recess downward and with slot on engaging gear on corresponding lug on synchrocone. Place springs (3 nos.) carrier (3/4/5) (3 nos.) and steel balls (3 nos.) and slide shifter sleeve (3/4/5 speed) on it. Ensure that the slot for fork pad on shifter sleeve (3/4/5) will be in downward position. Fig. 62

Fig. 62

TRANSAXLE

16. Place synchrocone (4th gear) and locate its lug into slots of engaging gear. 17. Place 4th gear Fig. 63 18. Place spacer

Fig. 63 19. Press deep groove ball bearing with taper groove for lock plate side upwards on lay shaft using drift part no. 2641 5890 2601. Fig. 64 20. Press the cap on Lay shaft oil hole bore (below the final drive pinion)

Fig. 64

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29

TRANSAXLE INPUT SHAFT SUB ASSEMBLY DISASSEMBLY: 1.

Remove deep groove ball bearing (rear) by using holder part no. 2702 5890 2606 with puller part no. 2654 5890 3508 Fig. 65

Fig. 65

TRANSAXLE

2.

Remove deep groove ball bearing(front) by using puller part no. 2657 5890 2801. Fig. 66

Fig. 66 ASSEMBLY : 1.

Place and fit deep groove ball bearing (rear) on input shaft using drift part no. 2651 5890 3308 with taper groove for Lock Plate in upward direction.

2.

Place Inputshaft upside down and press deep groove ball bearing (front) by drift part no. 2702 5890 2602. Fig. 67

Fig. 67 30

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TRANSAXLE DIFFERENTIAL ASSEMBLY : DISASSEMBLY: 1.

Remove taper roller bearings by using puller part no. 2702 5890 2604, and rest pad part no. 2702 5890 2612N Fig. 67

2.

Remove speedo gear using by puller part no. 2651 5890 3506 and rest pad part no. 2702 5890 2612N.

Fig. 68 3.

TRANSAXLE

Remove two (1.5 Thick) circlips locking the spider. Fig. 69

CAUTION:DO NOT REUSE THE 1.5 THICK CIRCLIPS 4.

Push out spider from differential housing

5.

Rotate bevel pinions by 900 and remove the side bevel gears.

Fig. 69 6.

Remove bevel pinions with washers. Fig. 70

7.

Hold fixtures for gear on differential assembly part no. 2702 5890 2609 in soft jaw vice.

Fig. 70

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31

TRANSAXLE 8.

Mount differential housing on fixture part no. 2702 5890 2609 and lock it. Fig. 71

Fig. 71

TRANSAXLE

9.

Unscrew and remove the collared bolts (10 Nos.) Fig. 72

ASSEMBLY : 1.

Hold fixture for gear on differential casing on soft jaw vice.

2.

Mount differential housing on fixture part no. 2702 5890 2609 and lock it.

Fig. 72 3.

Place gear final drive on differential housing. Tighten the collared bolts (10 nos.) to specified torque of 8 to 9 mkg. Fig. 73

4.

Place bevel pinion on differential housing spherical radius.

Fig. 73 32

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TRANSAXLE 5.

Place bevel pinion in similar manner as explaned in Sl. No. 4 Fig. 74

6.

Place both side bevel gears with washer exactly opposite to each other and rotate by 900 so as to align the holes on side bevel gears with holes in the housing.

Fig. 74

TRANSAXLE

Push the spider into the holes. Fig. 75 7.

Check the free play of differential gears. It should be 0-0.1 mm.

8.

If the value of play is not within specifications, add or remove washers.

9.

Assemble the two 15x1.5 thick circlips into the groove near the ends of spider.

Fig. 75 To check backlash, hold the two different pinions and one side gear and check freeplay or remaining side gear teeth flank as shown in Fig. 76

Fig. 76

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33

TRANSAXLE 10. Fix speedo gear with recess inside using drift part No. 2654 5890 3507 Fig. 77

Fig. 77

TRANSAXLE

11. Press taper roller bearings using drift part no. 2702 5890 2608 on either side of differential housing Fig. 78

Fig. 78

34

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TRANSAXLE IDENTIFICATION : 1.

Engaging Gears : i)

5th engaging gear is having smaller dia inner spline for fitment on layshaft.

ii)

3rd & 4th engaging gear is similar in size with 5th engaging gear but having bigger inner splines to fit on layshaft.

iii) 1st & 2nd engaging gear is having inner spline dia similar to 3rd/4th engaging gear but outer dia is bigger to engage with 1st/2nd shifter sleeve. 2.

Shifter Forks : i)

ii)

5th gear shifter fork has three prominent ribs and dowel hole is approx. in the centre of the boss. Fig. 79

Fig. 79

TRANSAXLE

3rd/4th gear shifter fork has a prominent rib and has extended guide for locating the shaft. Fig. 80

Fig. 80 iii) 1st/2nd gear shifter fork has the smaller two ribs and locating hole is at an extreme corner of the boss. Fig. 81

Fig. 81

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35

TRANSAXLE 3.

Shifter Shafts : Fig. 82 a) 1st/2nd shifter shaft is the smallest of all with one notch for interlock piece. b) 3rd/4th shifter shaft is intermediate in length with two notches at the bottom for two interlock pieces. c) 5th/Rev. shifter shaft is the longest of all.

Fig. 82

TRANSAXLE

4.

Shifter Sleeve : i) 5th/3rd/4th shifter sleeves are identical and are interchangeable. Fig. 83

Fig. 83 ii) 1st/2nd shifter sleeve is integral with reverse gear. Fig. 84 5.

Synchrocone : i) 5th/4th/3rd synchrocones are having smaller inner dia and are identical. ii) 1st/2nd synchrocones are having bigger inner dia and are interchangeable.

Fig. 84 36

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TRANSAXLE SUB-ASSEMBLIES : 1.

5th Synchropack Assembly i) Place needle roller bearing and bush in 5th gear. Fig. 85 ii) Assemble the carrier 3/4/5 springs, balls engaging gear and shifter sleeve.

Fig. 85

TRANSAXLE

NOTE : The engaging gear can be put in either way. iii)

Place synchrocone on 5th gear layshaft.

iv)

Place synchropack assembly with shifter sleeve on 5th gear. Fig. 86 Ensure that slot or fork pad on shifter sleeve 3/4/ 5 be in downward position.

Fig. 86 2.

3rd/4th Synchropack Assembly : i) Place the engaging gear such that the groove for circlip is downwards ii) Place the shifter sleeve on engaging gear 3rd/ 4th such that the smaller groove is upwards and assemble the carriers, springs and balls Fig. 87 & 88

Fig. 87

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37

TRANSAXLE 3.

1st/2nd synchropack Assembly i) Place the engaging gear 1st/2nd such that the groove for circlip is downwards.Fig. 89

Fig. 88

TRANSAXLE

Fig. 89 ii) Place shifter sleeve such that the fork slot is in upward position and assemble the carriers, springs, balls and sleeves. Fig. 90

Fig. 90 38

INDEX

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TRANSAXLE 4.

Assembly Bracket selection and shifting : Fig. 91 & 92

Disassembly : i)

Loosen the M6 Nut.

ii)

Remove the pin and finger along with two springs

iii)

Separate out 1/2 spring (torsion cum compression), Rev. lock plate 5/R compression spring & cup.

Fig. 91 iv)

TRANSAXLE

Press out pin (rev. lock plate) from finger. Assembly : Fig. 91 & 92 Assemble in reverse order of disassembly.

CAUTION : Ensure correct fitment & orientation of spring lugs (1/ 2 torsion / compression) Ensure correct fitment of torsion spring for Rev. gear lever. Apply Locktite 262 on threads of hex F1 nut BM6 & tightening torque 0.85 to 1.05 mkg.

Fig. 92

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39

DRIVESHAFT

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DRIVESHAFT

INTRODUCTION : Driveshaft assemblies are flexible assemblies, which transmit engine power to independently suspended wheels. They consist of an inner and outer constant velocity joint connected by an axle shaft. The inner joint is completely flexible and can move in and out. The outer joint is also flexible, but cannot move in and out.

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1

DRIVE SHAFT

DRIVESHAFT CONTENTS Sr. No.

Description

Page No.

1.

Special Tools

5

2.

Exploded View

6

3.

Driveshaft Parts

8

4.

Disassembly and Assembly of Driveshaft

9

5.

Replacement of Rubber Damper on RH Drive Shaft

20

6.

Driveshafts handling

21

7.

General Guidelines for Testing Driveshaft Noise

22

DRIVE SHAFT

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3

DRIVESHAFT SPECIAL TOOL : SWAGE TOOL : 2779 5890 2001 DRIVESHAFTS PARTS OUTBOARD JOINT

INBOARD JOINT

SMALL SEAL RETAINING CLAMP

AXLE SHAFT LARGE SEAL CV BOOT SEAL RETAINING (OUTBOARD SEAL) CLAMP(CV SIDE)

TRIPOT SEAL (INBOARD SEAL)

LARGE SEAL RETAINING CLAMP (TRIPOT SIDE)

Fig.1 LH Driveshaft assembly (NON ABS TYPE) CV JOINT RETAINER RING

BALL

CV BOOT SEAL

TRIPOT OUTER HOUSING

SPIDER ASSEMBLY

AXLE SHAFT

RUBBER DAMPER C.V. DEFLECTOR RING

LARGE SEAL RETAINING CLAMP SMALL SEAL (CV SIDE) RETAINING CLAMP

TRIPOT SEAL

‘A’ = 418+50

RETAINER RING

TRIPOT RETAINER RING

LARGE SEAL RETAINING CLAMP

Fig.2 RH Driveshaft assembly (NON ABS TYPE)

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5

DRIVE SHAFT

DRIVESHAFT EXPLODED VIEW ABS RING DEFLECTOR RING

CV JOINT INNER CV OUTER RACE CV JOINT CAGE

RETAINING RING

CV BALLS

CV BIG CLAMP

CV JOINT BOOT CLAMP

DRIVE SHAFT

CV SMALL CLAMP

AXLE BAR DAMPER

TRIPOT SMALL CLAMP

ASM SPIDER

TRIPOT BOOT

TRIPOT BIG CLAMP RETAINING RING MALE TRIPOT HOUSING

RETAINING RING

RETAINING RING

-- NON-REUSABLE PART

Fig. 3 RH Driveshaft exploded view (ABS TYPE) 6

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DRIVESHAFT

DRIVE SHAFT

Fig.4 RH Driveshaft (ABS TYPE)

RUBBER DAMPER

ABS RING

CLAMP

DEFLECTOR RING

FOR RH ONLY

Fig.5 View of Rubber Damper

INDEX

Fig.6 View of Toner and Deflector ring

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7

DRIVESHAFT DRIVESHAFT PARTS : SEALS : Driveshaft assemblies use inboard and outboard joint seals. The inboard and outboard seals are made of thermoplastic material. The thermoplastic material performs well against normal handling and operational wear conditions. However, it is not strong enough to withstand abusive handling or damage due to objects such as sharp tools or the sharp edges of any other surrounding component in the vehicle. The functions of the seal are as below :

•

To protect the internal parts of the inboard and outboard joint by protecting the grease from surrounding detrimental atmospheric conditions such as stones, dirt, water, salt, etc.

•

Facilitate angular and axial movement as applicable for inboard and outboard joints.

DRIVE SHAFT

treatment. The main function of the inboard joint is to allow the halfshaft assembly to compensate for suspension movement in the vehicle by allowing the shaft to move axially or stroke in the inboard housing. AXLE SHAFT : The axle shaft simply connects the inboard joint and the outboard joint. It is made out of special steel heat treated to give optimum strength and fatigue performance. The function of the axle shaft is to transmit torque and rotation to the wheel from the transmission. Note : The rubber damper is fitted on RH driveshaft only for petrol versions.

CLAMPS : These are made of stainless steel. The clamps provide a leak proof connection at housing and axle shaft for the inboard and outboard joints. OUTER JOINT (OUT BOARD JOINT) : The outer joints use the Constant Velocity (CV) joint design, which is the standard outboard joint for front wheel drive cars. It is a fixed centre ball type joint. The outer housing is made using special steels by cold forming process followed by heat treatment. The coldformed surfaces give superior wear resistance and increased joint life. The main function of the outboard joint is to allow the vehicle’s wheels to turn during steering operation or have a steer capability. INNER JOINT (IN BOARD JOINT) : This is a Constant Velocity universal joint radically self supported and permitting axial movement consisting of a housing directly connected to the axle shaft through three equally spaced transmission mounted balls. These are made of special steels through complex forming process followed by heat

8

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DRIVESHAFT I. DISASSEMBLY PROCEDURE : 1.

Hold the centre of the axle shaft in the vice as shown in Fig.7 and clean the shaft thoroughly, using cleaning solvent. Important : Do not damage the sealing surface of outer housing.

Fig.7 2.

Remove the small seal retaining clamp from the axle shaft with a side cutter or by tapping the clamp ear junction by screw-driver with rounded edge as shown in the Fig.8. Discard the small retaining clamp.

DRIVE SHAFT

Important : The screw-driver should not damage the seal.

Fig.8 3.

Remove the larger retaining clamp from the inboard joint by tapping junction which is shown in Fig.9 by using screw driver as shown in Fig. 9.

Fig. 9

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9

DRIVESHAFT 4.

Separate the housing assembly from the seal at large diameter as shown in Fig. 10. Slide the seal away from the joint along axle shaft.

Fig. 10

DRIVE SHAFT

5.

Remove the spider assembly retainer ring by using plier as shown in Fig. 11 and discard the retaining ring.

Fig. 11 6.

Remove the tripot spider assembly from the axle shaft as shown in Fig.12. If required tap the spider assembly gently using a nylon mallet.

Fig. 12 10

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DRIVESHAFT 7.

Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.

• The tripot balls • Needle rollers • Housing Dry all the parts. Inspect these parts for damage or wear.( If any of the parts are damaged, the entire sub-assembly along with the outer housing needs to be replaced.) After this remove the seal from the axle shaft as shown in Fig. 13 Fig. 13

DRIVE SHAFT

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11

DRIVESHAFT II. ASSEMBLY PROCEDURE : 1.

Install the new small seal retaining clamp on the neck of the seal. Do not crimp the small seal retaining clamp. Slide the tripot seal into the axle shaft, passing over the seal grooves of the axle shaft towards the CV end of the axle as shown in Fig. 14

Fig. 14 2. DRIVE SHAFT

Place the tripot spider assembly on to the drive axle shaft. Assemble the spider assembly to the axle shaft and tap gently if required. Insert the new retainer ring using the plier as shown in Fig. 15 Important : Ensure that the ring is fully seated in the groove on the axle.

Fig. 15 3.

Transfer approximately half of the grease from the service kit into the seal and another half grease into the tripot housing. Slide the housing over the spider assembly on the shaft. Engage the tripot seal with the tripot outer as shown in Fig.16 Important: The end of the tripot seal must be next to the seal stop on the housing.

Fig. 16 12

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DRIVESHAFT 4.

Slide the tripot seal smaller end to the corresponding groove on the axle shaft and crimp the small seal retaining clamp (new one) using pincer crimping tool as shown in Fig. 17 and maintain max 2.6 mm. ear gap as shown below.

Crimping tool

(spider Assembly at approximately middle of the tripot bowl)

2.6 mm

Fig. 17 5.

Slide the new large seal retaining clamp over the housing in the free condition of the boot & housing as shown in Fig. 18. Insert the swage tool part no: 2779 5890 2001 over the clamp as shown in Fig. 18.

DRIVE SHAFT

SWAGE TOOL

Fig. 18 6.

Align the seal bigger dia on the housing and position the big seal retaining clamp in its place and swage the large seal-retaining clamp using spanner as shown in Fig. 19. Please tighten alternatively between two bolts (i.e. don’t tighten one bolt alone completely at a time).

Fig. 19

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13

DRIVESHAFT DISASSEMBLY PROCEDURE : 1.

Clean the shaft thoroughly using cleaning solvent and hold the shaft at the middle of the axle shaft in the vice as shown in Fig.20

Fig. 20

DRIVE SHAFT

2.

Remove the large seal retaining clamp from the CV joint with a side cutter or a screw-driver with rounded tip as shown in Fig.21 and discard. Important: Ensure that there is no cut on the boot seal during this operation.

Fig. 21 3.

Remove the small seal retaining clamp from the axle shaft with a side cutter or screwdriver with rounded tip as shown in Fig.22 and discard. Slide the seal away from the joint along the axle shaft.

Fig. 22 14

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DRIVESHAFT 4.

Wipe the grease from the face of CV joint inner race. Angulate the CV joint on the axle shaft and expose the retainer ring. By holding the retainer ring in closed position using a plier tap the CV joint outer race at the larger diameter until the joint separates out, as shown in Fig.23.

5.

Remove the retaining ring from the CV Outer housing and discard the retaining ring

6.

Remove the CV Joint seal from the axle shaft.

This ring

Fig. 23 7.

Clamp the CV assembly on a vice and place a brass drift/screw-driver against the CV joint cage and tap gently on the brass drift/screw-driver with a hammer in order to tilt the cage. Remove the first chrome alloy ball when the CV joint cage tilts. Tilt the CV joint cage in the opposite direction to remove the opposing chrome alloy ball. Repeat this process to remove all six of the balls as shown in Fig.24.

DRIVE SHAFT

Fig. 24 8.

Pivot the CV joint cage and the inner race 900 to the centreline of the outer race. At the same time, align the cage windows with the lands of the outer race as shown in Fig.25. Lift out the cage and the inner race.

Fig. 25

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15

DRIVESHAFT 9.

Remove the inner race from the cage by rotating the inner race upward as shown in Fig. 26

10. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. Dry all the parts. Check the CV joint assembly for unusual wear, cracks, or other damage. If any of the parts are damaged entire sub-assembly is to be replaced. Clean the axle shaft. Use a wire brush to remove any rust in the seal mounting area (grooves).

Fig. 26 DRIVE SHAFT

16

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DRIVESHAFT ASSEMBLY PROCEDURE : 1.

Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race.

2.

Hold the inner race 900 to the centreline of the cage with the lands of the inner race aligned with the windows of cage as shown in Fig. 27. Insert the inner race into the cage.

Fig. 27 3.

Hold the cage and inner race 900 to the centreline of the outer race. Align the cage windows with the lands of the outer race.

DRIVE SHAFT

Important: Ensure that the retaining ring side of the inner race faces the axle shaft. Install the cage and the inner race into outer race as shown in Fig. 28

Fig. 28 4.

Place a brass drift/screw-driver against the CV joint cage, tap gently on the brass drift/screwdriver with a mallet in order to tilt the cage as shown in Fig. 29 Install the first chrome alloy ball when the CV joint cage tilts. Repeat this procedure to install all six of the balls as shown in Fig. 29

Fig. 29

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17

DRIVESHAFT 8.

Fill the CV joint with half of the grease supplied in the service kit and install the new CV joint retainer ring in the groove of the CV inner race.

9.

Clean the axle shaft using a wire brush to remove any rust in the seal mounting area (grooves).

7.

Install the new small retaining clamp on the neck of the seal and do not crimp. Slide the CV joint seal onto the axle shaft towards tripot end. Position the small seal retaining clamp on the boot seal as shown in Fig. 30

Fig. 30 DRIVE SHAFT

8.

Align the inner race spline and the axle spline in 1800 position as shown in Fig. 31 and press the CV joint assembly in to the axle bar until the joint could not move further in the axle bar. Gently tap the CV outer axially with a mallet if required. This ensures that the retaining ring is engaged in the inner race.

Fig. 31

18

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DRIVESHAFT 9.

Slide the boot seal into the seal groove on the axle shaft and check the clamp position to ensure that it is positioned correctly around the entire circumference, then crimp the small retainer clamp by using the crimping pincer tool as shown in Fig. 32. Maintain the ear gap of 2.6 mm as shown below.

2.6 mm

Fig. 32 10. Place the remaining grease from the service kit inside the seal and slide the larger diameter of the seal with the larger seal retaining clamp in place over the outside of CV joint as shown in Fig. 33

DRIVE SHAFT

Important : The CV seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly equalise pressure.

Fig. 33 11. Crimp the seal retaining clamp using pincer tool as shown in Fig. 34 and maintain ear gap of 2.6 mm as shown.

Ear Gap 2.6 mm. Max

Fig. 34

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19

DRIVESHAFT

CV JOINT RETAINER RING

BALL

CV BOOT SEAL

SPIDER ASSEMBLY

TRIPOT OUTER HOUSING

AXLE SHAFT

C.V. DEFLECTOR RING

RUBBER DAMPER LARGE SEAL RETAINING CLAMP SMALL SEAL (CV SIDE) RETAINING CLAMP

DRIVE SHAFT

‘A’ = 418 +50

TRIPOT SEAL

RETAINER RING

TRIPOT RETAINER RING

LARGE SEAL RETAINING CLAMP

Fig. 35 RH DRIVER SHAFT ASSEMBLY (NON ABS TYPE)

REPLACEMENT OF RUBBER DAMPER ON RH DRIVESHAFT : Only for Petrol vehicle : Check if there is any damage on rubber damper. To replace the Damper : a)

Dismantle the outboard CV joint, as described earlier.

b)

Remove the clamp retaining the damper in the same manner as small seal retaining clamp is removed. Discard the clamp.

c)

Slide a new damper in the direction shown in Fig. 35 along with new clamp.

d)

Reassemble the C. V. joint.

e)

Clamp the damper at distance A = 418 +50mm

20

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DRIVESHAFT DRIVESHAFT HANDLING : Half shafts must be stored in their original shipping containers or Delphi approved fixtures until assembled into vehicle. It is important to take all precautions to avoid stacking halfshafts on top of each other. The seals and deflecting rings are extremely delicate and any cut, nick, or abrasion may reduce the performance of the driveshaft. Note : Protect this surface from nicks and scratches. Damage to this surface may reduce the performance of the mating seal.

Note: If Out board joint must be angulated to fit the half shaft assembly into the vehicle, all precautions should be taken to avoid damaging the surface of the threads and splines. During installation

Note : Protect deflector ring from impacts, which could cause dents. A dented/Damaged deflector ring may result in an interference condition and affect the seal

Note : Take all precautions to avoid any contact between the inboard and outboard seals and any surface which may cause a cut, nick or abrasion. The seals are extremely delicate and critical to the performance to the halfshaft. Do not allow the seals to contact other halfshafts, workbenches, the vehicle frame, lower control arm, or any other chassis component. If grease leakage is observed from either seal, the halfshaft should be removed from the vehicle, handled with care, and returned to authorised dealer for analysis

DRIVE SHAFT

Note : Eared clamp must be in position and crimped. Take precaution to avoid any contact between the ear of the clamp and any object, which may bend/crush, the “ear”. A damaged “ear” will decrease the clamping load, which may cause grease leakage and/ or intrusion of water/debris.

Note : Clamps should be in position and tight. If clamps are loose, don’t install into vehicle.

Note : Take precaution to avoid any contact between the inboard seal and the tooling used to insert the assembly into the transmission. Contact between the seal and the tooling will cause a seal peak abrasion which may reduce the life of the seal and lead to dissatisfied customer.

Note : To prevent damage to the internal components of the inboard joint, take all precautions to avoid over extending the joints. CROSS SECTION SHOWN IS NON ABS TYPE LH DRIVERSHAFT

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21

DRIVESHAFT GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE : •

Ensure that the DRIVER is alone in the vehicle while conducting the test.

•

All the windows of the vehicle should be fully rolled-up to reduce the disturbances caused by external noises.

•

Drive on a smooth stretch of road and pay particular attention to various noises emanating from the front portion of the vehicle. Observe the changes in noise levels through speeds between 10 and 60 kmph (6 and 36 mph).

•

It should be noted here that the driver may encounter difficulty in distinguishing between similar sounding noises resulting from either the drive shaft or the under-body (for example noise from Strut & Caliper).

•

Therefore, it is advised that the car be driven on uneven and bumpy surfaces as well, to observe the noises which may then be attributable to the under-body.

•

Focus on that side of the car being considered for the drive shaft complaint.

•

Tests for CV (wheel side) and Inboard (engine side) joints are different and need to be conducted separately.

DRIVE SHAFT

Extreme RIGHT Turn

Extreme LEFT Turn Fig. 36

TESTING FOR NOISE : Checking for wheel side (CV) joint noise: (This noise will appear to emanate closer to the wheel, rather than the engine). 1.

Shift to the 2nd gear and maintain a steady speed between 20 and 30 kmph (12 and 18 mph).

2.

Drive the car to form a figure of “8” as shown in the Fig. 124 alongside. Identify an audible and persistent “Cluck” – like noise during either an extreme left or extreme right turn

3.

The “Cluck-ing” noise on a particular turn can be confirmed by repeating the turn.

22

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DRIVESHAFT Checking for engine side joint noise : (This noise will appear closer to the engine, than the wheel). 1.

Shift to the 4th gear and maintain a steady speed between 40 and 60 kmph (24 and 36 mph).

2.

Lower the car speed by gently applying the brakes while ensuring that the tyres do not screech and the car does not dive forward sharply.

3.

Identify an audible ”Dug” sounding noise as the car decelerates. As the car slows down, it can be observed that the sound would become louder and occur after longer intervals.

Other useful observation will include : SYMPTOMS

• Noise accompanied by vibration of the brake pedal & not from the drive shaft.

INDEX

DIAGNOSIS

DRIVE SHAFT

A.

Vibration could be from the calipers and

B.

If there is NO vibration on the pedal, the noise could be from the drive shaft.

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23

SUSPENSION LEi & LSi

LX & LXi

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SUSPENSION LEi & LSi

INTRODUCTION :

The front and Rear suspension of Indica are Independent type Suspension i. e. each wheel is a separately suspended unit connected to body in such a way that the rise and fall of one wheel does not affect the other wheel directly. This helps each wheel to maintain a level position regardless of influences on the other wheel. The Front suspension is Mc pherson strut type and the Rear suspension is of Independent semi-trailing arm type with hydraulic shock absorber and coil spring mounted co-axially.

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i

SUSPENSION

SUSPENSION LEi & LSi CONTENTS Sr. No.

Description

Page No.

I)

FRONT SUSPENSION :

1)

Tightening Torques

1

2)

List of Special Tools

1

3)

Exploded Views

2

4)

Removal & Installation of Anti-roll bar

6

5)

a)

Removal & Installation of strut assembly

7

b)

Disassembly & Assembly of strut

8

a)

Removal & Installation of wheel hub

10

b)

Sub-assembly of knuckle/Hub

13

a)

Removal & Installation of lower link assembly

14

b)

Removal & Fitment of Rubber bushes

14

6)

7)

8)

Procedure for checking the ball joint play on front suspension lower arm ball joints

II)

REAR SUSPENSION :

1)

Repairs/Adjustment data

16

2)

Tightening Torques

16

3)

Lubricants Specification

16

4)

List of Special Tools

17

5)

Exploded Views

18

6)

Removal of Rear Hub

20

a)

Hub-dismantling & Assembly

21

b)

Assembly of Hub on trailing arm Spindle

23

7)

15

Removal & Installation of shock absorber assembly

26

a)

26

Disassembly & Assembly of shock absorber

8)

Disassembly/Assembly of Trailing Arm

28

9)

Inspection of shock absorber / strut on the car

29

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SUSPENSION

iii

SUSPENSION LEi & LSi FRONT SUSPENSION (LEi & LSi - 75 PS) TIGHTENING TORQUE (kg-m) 1.

Strut assembly upper mounting nuts

2.3

2.

Strut mounting bolts on knuckle

3.

Knuckle bottom ball joint clamping hex bolt

4.

Drive shaft nut

5.

Lower link mounting on body hex bolt

6.

Clamp hex screw on antiroll bar

4.5

7.

Lower link front mounting pin with tie member

10

8.

Strut top nut

9.

Ball joint to lower link

8 5.5 26 +2 8

4 to 6 4.6

SUSPENSION

LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1.

Rest pad for removing inner race of bearing from hub.

2702 5890 2612

2.

Holder for hub assembly.

2702 5890 3301

3.

Puller for pulling out the front hub.

2702 5890 3302

4.

Clamp for removing inner race for hub.

2779 5890 3303

5.

Striker for pulling out the hub.

2702 5890 3304

6.

Drift for installing the brg. in knuckle.

2779 5890 3301

7.

Puller for removing ball joint.

2702 5890 4602

8.

Spring compression tool.

2702 5890 3202

9.

Dolly for fitting front rubber bush in lower link.

2702 5890 0107

10.

Puller for removing inner race from hub.

2654 5890 3508

11.

Offset spanner.

2702 5890 3201

12.

Puller for knuckle bearing

2779 5890 3302

13.

Drift for fitting knuckle assembly on hub

2576 5890 4401

14.

Handle for drift

2640 5890 3511

INDEX

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1

SUSPENSION LEi & LSi ASSY. FRONT STRUT

SUSPENSION

SR. NO.

PART DESCRIPTION

1

ASSY FRONT STRUT COMP.LH/RH

2

ASSY STRUT ELEMENT LH /RH

3

DUST COVER

4

FRONT BUMP STOPPER -POLYURETHANE

5

SPRING FRONT SUSPENSION

6

RUBBER SEAT

7

ASSY SPRING SEAT TOP

8

SPACER RUBBER SEAL

10

THURST BALL BEARING(FRT.STRUT)

11

LOCATOR (FRONT STRUT BEARING)

12

BOTTOM PLATE(THRUST BRG.)

13

ASSY. TOP CUP

14

BRIGHT WASHER 8.4

15

NYLOC NUT M8

16

TOP STOPPER

17

SPRING WASHER B12

18

HEX NUT M12X1.5

19

COVER STRUT TOP CUP

20

STRUT MTG PIN (ECCENTRIC)

21

HEX FLANGE BOLT M12x1.25x33 HEX FLANGE BOLT

23

HEX FLANGE NUT AM10

®

2.3

®

9

22

®

®

® ®

24

HEAT SHIELD (LOWER BALL JOINT)

25

NYLOC NUT M12

8.0

® 8.0

4.5

®

-Non Reusable Part - Specified Torque in Kgm

2

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INDEX

GROUP INDEX

PART DESCRIPTION

ASSY LOWER LINK COMPLETE - (P/STG)

LOWER LINK,FRONT

ASSY.PIVOT BUSH (INNER)

ASSY. RUBBER BUSH (REAR)

ASSY. CLAMP (LOWER LINK REAR MTG. BKT.)

ASSY. LOWER BALL JOINT

SR. NO.

1

2

3

4

5

6

8.0

WASHER MOUNTING PIN SPRING WASHER B14 IS3063 SS8451-8C HEX NUT M14X1.5 IS13722-8-SS8451-8C HEX FL SCREW M12

10 11 12 13

HEX NUT M10 IS1364P3-8-SS8451-8C

9

HEX FL BOLT M10X30 TS17130-8.8-SS8451-8C

®

8

1.2

8.0

®

7

4.6

8.0

ASSY. LOWER LINK

14

®

Tie Member

NEXT

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- Specified Torque in Kgm

-Non Reusable Part

SUSPENSION LEi & LSi

SUSPENSION

3

®

4

INDEX

GROUP INDEX FRONT HOLLOW ANTIROLL BAR(TC SPRING) NYLOC NUT M10 ASSY RUBBER MOUNTING. CUP (FRONT ANTIROLL BAR)

1 2 3 4

CUP (FRONT ANTIROLL BAR)

PART DESCRIPTION

SR. NO.

- Specified Torque in Kgm

®

RUBBER BUSH (ANTIROLL BAR MTG)

®

4.5

6

®

5

®

-Non Reusable Part

8.0

SUSPENSION

FRONT ANTI ROOL BAR MOUNTING

12

11

10

9

8

7

WASHER A10.5

SPECIAL HEX.FL.SCREW

CLAMP

BEARING BLOCK (ANTI ROLL BAR)

SLEEVE (ANTI ROLL BAR)

HEX BOLT M10X130

SUSPENSION LEi & LSi

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SUSPENSION LEi & LSi FRONT AXLE

®

®

26.0

SUSPENSION

®

SR. NO.

PART DESCRIPTION

1

STEERING KNUCKLE

2

ANG. CONTACT BRG (HUB END) SKF

3

INTERNAL CIRCLIP 72X2.5N

4

FRONT HUB

5

FRONT BRAKE DISC (20 THK.)

-Non Reusable Part

6

DISC SCREW

- Specified Torque in Kgm

7

WASHER

8

LOCK NUT

Fig. 15

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5

SUSPENSION LEi & LSi REMOVAL AND INSTALLATION OF ANTI ROLL BAR REMOVAL 1.

Disconnect battery terminals.

2.

Apply parking brake and place wheel chokes at rear

3.

Remove anti roll bar nuts, washers and rubber cushions Fig.1

4.

Remove anti roll bar mounting brackets Fig.2

5.

Remove anti roll bar.

Fig. 1 INSTALLATION Fig. 3 1.

For Installation proceed in reverse order of removal

1a.

Apply silicon grease molycoate - 33 (medium) on antiroll bar over bearing width before fitment.

2.

Assemble antiroll bar components but do not tighten. Centralise anti-roll bar as shown in fig. 3. Ensure the crank position is on the bottom side.

SUSPENSION

Fig. 2

BEARING BLOCK AND MOUNTING BRACKET

ANTI ROLL BAR

CRANK

Fig. 3 6

INDEX

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SUSPENSION LEi & LSi 3.

4.

Tighten rubber cushion bolt assembly on lower link, maintaining bolt projection above the nyloc nut between 9-10 mm Fig. 4.

9 +1mm ANTI ROLL BAR

Apply silicon grease molycoate-33 (medium) on anti roll bar over bearing width before fitment.

Fig. 4

REMOVAL & INSTALLATION OF STRUT ASSEMBLY REMOVAL 1.

Remove wheel rim cover (if fitted) Loosen wheel bolts Fig. 5.

2.

Jack up the car allowing the front suspension to hang freely.

3.

Unscrew wheel mounting bolts and remove the wheel.

4.

Remove brake hose from the clamp on strut bracket.

SUSPENSION

Fig. 5 5.

Unscrew mounting bolts on strut bottom bracket Fig.6.

Fig. 6

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7

SUSPENSION

SUSPENSION LEi & LSi 6.

Open the engine bonnet, unscrew and remove nuts of upper support using offset spanner 2702 5890 32 01. Fig. 7

7.

Keep relays mounting bracket on LH side and auxilliary tank bracket on its position.

8.

Remove strut assembly from bottom.

INSTALLATION 1.

Install strut assembly in reverse order of removal.

2.

Fit bolts & nuts only as shown in Fig. 8.

NOTE : First tighten top mounting bolt no.1 and then the bottom mounting bolt no. 2. 3.

Tighten all bolts and nuts to specified torque.

4.

Apply ADH thread locker wicking grade ANABOND 124 at nut end & bolt thread. Ensure that the threads are free from oil/grease.

DOWEL PIN

OFFSET SPANNER PART NO. 2702 5890 3201

Fig. 7

FRONT OF VEHICLE

CAUTION : 1.

Ensure that brake hose does not twist during installation.

2.

Strut colour having the same colour code mark on the spring should be assembled on the left hand and right hand side.

TOP ECCENTRIC BOLT

DIS-ASSEMBLY AND ASSEMBLY OF STRUT

BOTTOM BOLT

DIS-ASSEMBLY : 1.

Compress the spring with spring compression tool part No. 2702 5890 3202 until the spring tension is released (i. e. becomes free in its seating place). Unscrew nut (1) and dismantle the parts Fig.9.

Fig. 8

Hold top stopper by spanner (A/F 60 mm) to stop piston rotation during loosening of nut.

À Fig. 9 8

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SUSPENSION LEi & LSi ASSEMBLY (Fig. 11) : Check the condition of the components and replace if necessary. It is recommended that all the rubber components should be replaced during the overhauling. 1.

Compress the spring with spring compression tool part No. 2702 5890 3202 to reduce length as done during dis-assembly as shown in Fig. 10.

Fig. 10

SUSPENSION

Fig. 11

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9

SUSPENSION LEi & LSi 2.

Insert the compressed spring on the strut (ensure that the spring end is located in the lower seat of strut). Fig 12

3.

Pull strut rod up as far as possible.

4.

Insert bump stopper.

5.

Fit spring rubber seat and assembled spring seat torque along with dust cover (if fitted) on the spring properly locating it with spring end.

6.

Install cover with rubber bellow

7.

Fit locater bush/spacer and locate the spring seat (cover)

8.

Grease the thrust bearing with recommended grease and fit the bearing over the locater.

9.

Fit bottom plate.

10.

Fit assembly top cup.

11.

Fit spacer.

12.

Fit top stopper.

13.

Fit spring washer & tighten hex nut to 4-6 mkg torque. Fig 13

SUSPENSION

SPRING SEAT LOWER

SPRING SEAT UPPER

LUG

LUG

Fig. 12

Note : The top cap should be free to rotate after assembly.The maximum torque to rotate the cap should not exceed 0.5 kgcm. 14.

Remove spring compressing special tool carefully.

Note : It is a good practice to replace bump stopper at every 30000 km / 18750 miles. REMOVAL & INSTALLATION OF WHEEL HUB REMOVAL : 1.

Apply parking brake and place wheel chokes at rear.

1a.

Drain out oil from transaxle (if required)

2.

Loosen the wheel mounting bolts. Fig. 14

3.

Jack up car till the front wheels are off the ground.

4.

Unscrew the wheel mounting bolts and remove the wheel.

Fig. 13

Fig. 14 10

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SUSPENSION LEi & LSi 5.

Unscrew and remove tie rod ball joint nut Fig. 16.

5a.

Remove tie rod ball joint using puller part no. 2702 5890 4602 Fig.17.

6.

Support the lower link from bottom.

7.

Hold hub assembly with holder part No 2702 5890 3301 Fig. 18.

8.

Unstake and unscrew drive shaft nut and take out the thrust washer.

9.

Remove holder from the hub assembly.

10.

Unscrew the calliper mounting bolts and remove the calliper assembly alongwith the brake hose (Do not disconnect the brake hose).

11.

Unscrew the disc screws and remove the disc Fig. 19

Fig. 17

SUSPENSION

Fig. 18

Fig. 16

Fig. 19

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11

SUSPENSION LEi & LSi 12.

Pull out the hub with the help of puller part No. 2702 5890 3302 and striker part No. 2702 5890 3304. Fig. 20

13.

Remove puller from the hub.

14.

Remove strut mounting bottom bolts from the knuckle assembly by supporting the drive shaft. Fig. 21

15.

Remove bottom ball joint from lower arm.

16.

Remove knuckle.

16a. Remove the drive shaft. (if required). 17.

Using clamp part No. 2702 5890 3303, puller part No 2654 5890 3508 and rest part No. 2702 5890 2612 remove inner race of bearing from the hub Fig. 22.

18.

Remove circlip from knuckle Fig. 23.

19.

Pull out knuckle bearing using puller part No. 2702 5890 3306. Fig. 24

Fig. 21

SUSPENSION

PULLER PART NO. 2654 5890 3508 REST PAD PART NO. 2654 5890 2612 CLAMP PART NO. 2654 5890 3303

Fig. 22

Fig. 20

Fig. 23

12

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SUSPENSION LEi & LSi INSTALLATION : Note : High / Low point matching on Hub & Disc Observe the condition of disc surface. If the disc surface is smooth ensure that punch mark (Low Point) on disc and hub (High Point) are aligned and assembled. If the disc surface is uneven showing rough marks, grooves - machine it to the specified limit, measure the run out on dia 220 w.r.t. hub and disc resting face. Punch mark around bolt hole where runout on dia 220 is at low point. While assembly align low point on disc and high point on hub. Assemble with countersunk screws. 1.

Proceed in reverse order of removal.

2.

Tighten drive shaft nut 26 +2 mkg torque and lock by staking. Fig. 25

3.

Ensure that oil seal in trans axle is not damaged while fitting drive shaft.

4.

Fill transaxle with recommended oil if you have removed dry shaft during disassembly.

Fig. 24

SUSPENSION

PRECAUTION : (Use a new hub bearing and new circlip, Oil the bearing housing in knuckle carrier and hub itself. Old bearing, even if serviceable can not be reused.)

SUB ASSEMBLY-KNUCKLE/HUB Clean all the parts thoroughly and replace damage/ worn out parts. 1.

With the help of drift part No 2779 5890 3301 and 2640 5890 3511 fit bearing in the knuckle. Fig. 26

2.

Fit circlip.

3.

Place the knuckle assembly over the hub. Using drift part No. 2702 5890 3305 press the knuckle assembly on the hub.

Fig. 25 PRESS

Fig. 26

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13

SUSPENSION

SUSPENSION LEi & LSi REMOVAL AND INSTALLATION OF LOWER LINK ASSEMBLY (Front wheel, Knuckle assembly and anti-roll bar already removed) 1. Unscrew rear mounting bracket bolt and remove the bracket Fig. 27. 1a. Unscrew nut connecting lower link pin and the tie member and remove tie member. 2. Unscrew 3 bolts on lower link front bracket spindle Fig. 28. 3. Unscrew mounting screws of the rear rubber bush clamp. 4. Remove lower link assembly along with rear mounting rubber bush and front bracket Fig. 29. INSTALLATION 1. Proceed in the reverse order of removal. 2. Replace rubber bushes, worn damage parts. 3. Tighten the rear mounting bracket bolt to 8 mkg torque. 4. Insert the tie member and tighten the nuts. Ensure that the tie member offset is away from the transaxle flange i.e towards front of the vehicle (Fig. 28a). 5. Ensure that heat shield is assembled properly on ball joint.

Fig. 28

REMOVAL AND FITMENT OF RUBBER BUSHES 1. 2. 3.

4.

Remove front bracket and bush from the lower link. Remove rear rubber bush from Lower link. Fit front rubber bush of lower link using dolly part No. 2702 5890 0107. Apply soap water to bush, inside surface of tool and bore of assembly lower link before fitment. Fit Rubber bush on the rear spindle of the Lower link.

Fig. 28a DOLLY PART. NO. 2702 5890 0107 RUBBER BUSH LOWER LINK

Fig. 27

Fig. 29

14

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SUSPENSION LEi & LSi PROCEDURE FOR CHECKING THE BALL JOINT PLAY ON FRONT SUSPENSION LOWER ARM BALL JOINTS It is recommended that the axial play on the ball joints should be checked as per the procedure given below before removal of the ball joints. Note : Please check tightening torque of all nut & bolts on the ball joint mounting bracket and ball pin nut before checking the ball joint play. The front lower arm ball joints play should be checked at every 10,000 kms as per the procedure given below. Procedure : a)

b)

Apply the parking brakes and remove front wheel by jacking up the car with the help of a floor jack or by lifting it on a two pole hoist

Fig. 29a

Mount the dial gauge with magnetic stand on the brake disc as shown in Fig. 29a

Important : Note that the Dial Indicator plunger axis should be perpendicular to the ball joint bottom face for the correct reading. c)

The tip of the dial gauge should be in contact with the lower arm ball joint bottom plate. ( With preloading of about 1mm on the dial gauge).

d)

Place another jack under the lower arm by gently lifting up the lower arm. The jack is to be placed under the lower arm as shown in Fig. 29b.

e)

f)

As the jack is lifted slowly spring in the ball joint gets fully closed (solid) at a load of about 100 kg. and then the dial gauge needle will start moving and indicate the play in the ball joint. Keep on increasing the load by lifting up the lower arm till the needle stops moving further. Note the reading. This should not be more than 0.5 mm. Do not further load the ball joint after the needle movement stops.

g)

If the reading found is in excess, replace ball joint.

SUSPENSION

Fig. 29b

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15

SUSPENSION

SUSPENSION LEi & LSi REAR SUSPENSION (LEi & LSi - 75 PS) REPAIRS/ADJUSTMENT DATA 1.

Hub bearing axial play

0.01-0.03 mm

2.

Axial play adjusting shim thickness available in steps of

0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.4,0.5 & 1.0 mm

TIGHTENING TORQUES

(kg-m)

1.

Wheel mounting bolt

8

2.

Shock absorber nyloc nut top

3.5 to 4

3.

Assy, Shock absorber mounting top hex flange nuts on the shell

4.5

4.

Shock absorber bottom nyloc nut

6

5.

Assembly inner bracket to cab hex screw (Semi trailing arm)

8

6.

Semi trailing arm mounting nut (inner and outer pivots)

8

7.

Castle nut on hub

10-12

8.

Anchor plate mounting hex screw

4.5

LUBRICANTS 1.

Hub grease specifications

Grease - Lithium IPOL IPLEXLC Grease-2

2.

Quantity of grease (both hubs)

110 gms.

16

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SUSPENSION LEi & LSi LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1.

Drift for installing inner race of outer brg.

2702 5890 2602

2.

Spring compressor

2702 5890 3202

3.

Holder for taking out the hub assembly from spindle.

2702 5890 3301

4.

Puller for taking out the hub assembly from spindle.

2702 5890 3501

5.

Puller for removing outer race of inner taper roller bearing.

2702 5890 3502

6.

Puller for removing outer race of outer tapper roller brg.

2702 5890 3503

7.

Drift for installing outer race of inner taper roller brg.

2702 5890 3504

8.

Drift for fitting oil seal.

2702 5890 3505

9.

Dolly for fitting rubber bush (inner)

2702 5890 0108

10.

Dolly for fitting rubber bush (outer)

2702 5890 0109

11.

Drift for installing outer race of outer taper roller brg

2651 5890 4602

SUSPENSION

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17

18

INDEX

GROUP INDEX

ASSY.SEMI TRAILING ARM WITH BUSHES ASSY. SEMI TRILING ARM- (WITH ABS) ASSY.SEMI TRAILING ARM - LH/RH SPINDLE SPACER (FOR OIL SEAL) ASSY.PIVOT BUSH (INNER) ASSY PIVOT BUSH (SEMITRAILING ARM) ASSY.INNER BRACKET- SEMI TRAILING ARM ASSY.OUTER BRACKET SEMI TRAILING ARM HEX FLANGE BOLT M12x1.25x33 ASSY REAR S/A COMP ASSY REAR SHOCK ABSORBER SPRING REAR SUSPENSION

③

1 2 2 3 4 5 6 7 8 9 10 11 12

③

PART DESCRIPTION

③ ③

SR. NO.

4.5

4.5

③

8.0

8.0

③

REAR SPRING DUST COVER (REAR SHOCK ABSORBER) REAR BUMP STOPPER (POLYURETHANE) / (POLYURETHANE FOAM) ASSY.BUMP STOPPER CUP SPRING TOP RUBBER BOTTOM RUBBER(SHOCK ABSORBER TOP MTG.) ASSY.STRUT MOUNTING BRACKET_TOP TOP RUBBER

6.0

③ 15 16 17 18 19

12 13 14

③

SUSPENSION

REAR SUSPENSION

20 21 22 23 24 25 26 27

③

8.0

8.0

- Specified Torque in Kgm

-Non Reusable Part

(SHOCK ABSORBER TOP MOUNTING) LOCK WASHER NYLOC NUT M10 HEX FL NUT AM10 RUBBER COVER (REAR SHOCK ABSORBER) HEX FL BOLT M10X70 NYLOC NUT M10 HEX BOLT M12 X 1.5 X 90 NYLOC NUT M12 X 1.5

③

SUSPENSION LEi & LSi

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INDEX

GROUP INDEX

SR. NO.

1 2 3 4 5 6 6 6

® ®

ASSY.REAR HUB COMPLETE HUB CUM BRAKE DRUM (REAR) (180 DIA.) TAPER ROLLER BEARING-OUTER OUTER BEARING SPACER TUBE (BETWEEN BRGS OF REAR HUB) SHIM (1.00 THK) SHIM (0.50 THK) SHIM (0.40 THK)

PART DESCRIPTION

10-12

®

6 6 6 6 6 6 7 8

®

SHIM (0.30 THK) SHIM (0.25 THK) SHIM (0.20 THK) SHIM (0.15 THK) SHIM (0.100 THK) SHIM (0.05 THK) DOUBLE-LIP OIL SEAL THRUST WASHER

9 10 11 12 13 14 15

4.5

4.5

ASSEMBLY REAR HUB - Specified Torque in Kgm

-Non Reusable Part

THIN CASTLE NUT M16X1.5 SPLIT PIN 4X32 IS549 SS8451-8C HUB COVER SPACER PLATE HEX SCREW M10X28 SPRING WASHER B10 HEX NUT M10

®

SUSPENSION LEi & LSi

SUSPENSION

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19

SUSPENSION LEi & LSi REMOVAL OF REAR HUB 1.

Place wheel chokes at front wheels.

2.

Loosen rear wheel mounting bolts Fig. 30.

3.

Jack up the car.

4.

Support the trailing arm and remove the wheel.

5.

Take out hub cap.

6.

Remove split pin on the castle nut.

7.

Unscrew castle nut and take out thrust washer Fig. 31.

8.

Mount puller part No. 2702 5890 3501 over the holder part No. 2702 5890 3301 on the hub and take out the hub assembly from the spindle Fig. 32.

9.

Fig. 31

If required, Disconnect brake bundy tube from wheel cylinder Fig. 33, disconnect parking brake from anchor plate. Unscrew anchor plate mounting bolts and remove the anchor plate.

SUSPENSION

Fig. 32

Fig. 30

Fig. 33

20

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SUSPENSION LEi & LSi REAR HUB-DISMANTLING AND ASSEMBLY DISMANTLING 1.

Pry out rear oil seal.

2.

Take out inner race of inner taper roller bearing.

3.

Remove spacer tube along with the shims.

4.

Remove inner taper roller bearing outer race, using puller part No. 2702 5890 3502 Fig. 34.

5.

Remove outer race of outer taper roller bearing using puller part No. 2702 5890 3503 Fig. 35.

6.

Remove old grease completely from hub bearing etc.

SUSPENSION

REMOVAL OF INNER BEARING OUTER RACE

PULLER PART NO. 2702 5890 3502

Fig. 34

REMOVAL OF OUTER BEARING OUTER RACE

PULLER PART NO. 2702 5890 3503

Fig. 35

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21

SUSPENSION

SUSPENSION LEi & LSi INSPECTION 1.

Check the taper roller bearings and the bearing seating in the hub and check the spindle.

2.

Check the contact surface for the radial seal on the spacer.

3.

Check the trust washer if necessary replace it.

4.

Generally bearing can be reused if the running surface and rollers show no visible damage or wear. For perfect judgement bearings should be cleaned in gasoline or trichloro-ethylene until all contamination’s are washed out of bearings. Bearing does not bind when rotated manually if it is free of any contamination. For judging silent running of bearings apply few drops of engine oil to clean bearing and rotate.

5.

Fig. 36

Bearings should not be cleaned with kerosene / cotton waste.

ASSEMBLY Absolute cleanliness is required during bearing assembly in order to avoid entry of dirt, dust and foreign particle. 1.

Clean hub, bearings, spacer tube, shims, thrust washer, and spindle diameter with gasoline.

2.

Fit inner taper roller bearing outer race, using drift part No. 2702 5890 35 04.

3.

Pack roller cage of inner bearing race with recommended wheel bearing grease. Grease quantity 5gm.

4.

Fit inner race of inner taper roller bearing.

5.

Fit outer race of outer Taper roller bearing using drift Pt No. 2651 5890 46 02. Fig. 36

6.

Press new oil seal with drift part no. 2702 5890 35 05 Fig. 37a. Coat the contact surface of oil seal lip with recommended grease. The oil seal should be pressed in the hub such that sealing lip and the spring faces towards the bearing Fig. 37. Whenever bearings are removed / replaced use new oil seal and new grease.

Fig. 37

Fig. 37a 22

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SUSPENSION LEi & LSi

1 15

3

4

14

5 12

7 6 8

11 13

9

10

1. Assembly Brake Drum 2. Spacer plate 3. Inner Taper Roller Bearing 4. Spacer Tube 5. Outer Taper Roller Bearing 6. Shims 7. Castle Nut 8. Hub Cap 9. Split Pin 10. Thrust Washer 11. Spacer for Oil Seal 12. Oil Seal 13. Spindle 14. Semi Trailing arm 15. Anchor Plate

SUSPENSION

2

Fig. 38 ASSEMBLY OF REAR HUB ON STUB AXLE SPINDLE Fig. 38. 1. 2.

If removed, fit anchor plate assembly, connect Parking brake cable, connect hoses. Fit hub assembly on the spindle. Make sure that oil seal lip is not getting damaged during assembly.

3.

Assemble the spacer tube on the spindle.

4.

Fill the space between two taper roller bearings with 20 gm quantity of recommended grease.

may result in loss of lubricating power. Insufficient grease may prevent perfect lubrication of bearings. 5.

Insert a shim of 1.5 mm thickness over the spacer tube. For shim selection see page no. 20.

6.

Pack roller cage of outer bearing race with recommended wheel bearing grease. Grease quantity 5gm.

Note : Recommended wheel bearing grease and its quantity must be maintained. If grease in excess, excessive heat can be generated and

INDEX

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23

SUSPENSION LEi & LSi 7.

Install inner race of outer bearing using drift part No. 2702 5890 26 02 Fig. 39 & 40

8.

Install thrust washer.

9.

Screw in castle nut and tighten to 10 to 12 kg-m torque Fig. 41 When tightening the castle nut, turn the rear hub constantly in either direction and tap with a soft hammer to ensure correct seating of bearings.

10. Pull/Push the hub for checking bearing play. Turn the hub several times prior to any measurement of play. Fit the dial gauge on the hub using magnetic stand. The dial should have a pretension of about 2 mm. Measure the hub play on the dial gauge stem on the spindle Fig. 41a The recommended hub play is between 0.01 0.06 mm. To achieve this hub play, shim may be added or removed. For increasing the hub play shims to be added and for reducing the hub play shims may be removed. Before checking bearing play ensure that the parking brake lever is in released condition.

SUSPENSION

Fig. 40

Fig. 41

Fig. 39

Fig. 41a

24

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SUSPENSION LEi & LSi PROCEDURE FOR SELECTION OF SHIM THICKNESS : For example, if the measured hub play with 1.5 mm shim as selected earlier (ref. point 5 as above) is 0.5 mm. Then correct size of shim for maintaining hub play of 0.03 mm will be as follows1.5 mm

shim (as selected earlier)

-0.5 mm

(play observed)

+0.03

(required hub play)

=1.03 mm (Correct shim thickness required instead of 1.5 mm shim thickness as selected earlier) 11. Insert the new spilt pin in the castle nut and lock the nut by bending the split pin. In case the spilt pin hole in the spindle does not align with the hole in the castle nut loosen / tighten castle nut just enough so that spilt pin can be inserted. Check the hub play once again it should be within 0.01 to 0.06 mm. 12. Fill the hub cap with recommended grease. Grease quantity 25 gm and fit the cap. While fitting the hub cap, hammer lightly at several locations on the collar of cap until collar comes closely into contact with hub.

SUSPENSION

13. Fit the wheel and tighten the wheel mounting bolts to recommended torque.

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25

SUSPENSION LEi & LSi REMOVAL OF SHOCK ABSORBER ASSEMBLY 1.

Place wheel chokes at front wheels.

2.

Loosen rear wheel mounting bolts.

3.

Jack up the car, allowing rear suspension to hang freely.

4.

Support the trailing arm.

5.

Unscrew wheel mounting bolts and remove the wheel.

6.

Unscrew and remove bottom mounting bolt of shock absorber Fig. 42.

7.

Unscrew upper mounting flange nuts of the shock absorber (which are accessible from luggage compartment) and remove shock absorber assembly Fig. 43.

Fig. 42

INSTALLATION OF SHOCK ABSORBER ASSEMBLY 1.

Proceed in reverse order of removal.

2.

Tighten upper mounting flange nut to 4.5 kg-m torque.

3.

Tighten bottom mounting bolt to 6 kg-m torque.

SUSPENSION

DIS-ASSEMBLY AND ASSEMBLY OF SHOCK ABSORBER DIS-ASSEMBLY :1.

Compress the spring with spring compression tool part No. 2702 5890 3202 until the spring length is reduced such that load on upper and lower cups is released. Unscrew nut(1) and dismantle the parts Fig. 44.

Fig. 43

À

Fig. 44 26

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SUSPENSION LEi & LSi ASSEMBLY : Fig. 46 Check the condition of the components and replace if necessary. It is recommended that all the rubber components be replaced during the overhauling. 1.

Compress the spring with spring compression tool part No. 2702 5890 3202 to release length as done during dis-assembly. Fig. 45 Insert the compressed spring on the Shock absorber (ensure that the spring end is located in the spring cup bottom of Shock absorber)

3.

Pull shock absorber rod up as far as possible.

4.

Insert rear bump stopper.

5.

Fit dust cover on assembly bump stopper cup.

Fig. 45

1 5

SUSPENSION

4

3

6

2

9 7

1.

LOCK WASHER

2.

ASSEMBLY BUMP STOPPER CUP

3.

ASSEMBLY STRUT TOP BRACKET

4.

BOTTOM RUBBER (SHOCK ABSORBER MOUNTING)

5.

TOP RUBBER (SHOCK ABSORBER MOUNTING)

6.

RUBBER SEAT

7.

OUTER COIL SPRING

8.

BUMP STOPPER

9.

DUST COVER

8

Fig. 46

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27

SUSPENSION LEi & LSi 6.

Install assembly bump stopper cup along with dust cover over the rear bump stopper.

7.

Fit spring rubber seat on the spring properly locating it with spring end.

8.

Install bottom rubber and shock absorber mounting bracket top.

9.

Fit assembly sub mounting bracket.

10.

Fit top rubber.

11.

Insert lock washer over the Shock absorber rod.

12.

Tighten nyloc nut to 4-4.5 mkg torque. Fig. 47

13.

Remove spring compressing tool carefully.

DIS-ASSEMBLY/ASSEMBLY OF TRAILING ARM (HUB REMOVED)

Fig. 47

DIS-ASSEMBLY 1.

Unscrew nyloc nut from front and rear mounting pins Fig. 48 & 49.

2.

Remove mounting pins and take out the arm assembly from the brackets.

3.

Remove the rubber bushes from the trailing arm Fig. 50.

SUSPENSION

ASSEMBLY

Fig. 48

1.

Fit rubber bushes in trailing arm by using dolly part No. 2702 5890 0108 (for inner bush) and 2702 5890 0109 (for outer bush).

2.

Locate the trailing arm on the brackets and fit the pins.

3.

Tighten nyloc nut both front and rear to 8 mkg torque.

Fig. 49

DOLLY PART. NO. 2702 5890 0108 / 2702 5890 0109 RUBBER BUSH TRAILING ARM

Fig. 50 28

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SUSPENSION LEi & LSi INSPECTION OF SHOCK ABSORBER / STRUT ON THE CAR

Checks to be carried out after removal of shockabsorber & strut.

Noise due to loose brake hose

1.

Look for signs for breakage such as piston rod bent or heavy dents on the body. These are results of accident or abuse of suspension parts.

2.

Discoloration & light scratch marks on working area of piston rod is normal and doesnot need replacement, unless leakage is noticed & confirmed.

3.

Look for signs of suspected oil leakage such as oil patches or wet mud cakes on the damper body. The presence of oil patch or mud cake can also be result of oily sprayfrom road or accidental spillage of oil during servicing.

4.

Examine damper area near the seal. Presence of oil here is sign of oil leakage.

1.

Ensure that the brake hose is tightened fully, loose brake hose will give noise.

Noise due to fouling parts : 1.

Ensure that the Strut components are not fouling with any other parts near by.

2.

Ensure that the spring end is sitting securely on the spring seat at the correct place Fig. 51.

3.

Ensure the correct torque on the two bolts is correct : 8 kgf-m of the strut mounting at the bottom bracket. It may be noisy if there is any play in the bolts.

INDICA rear suspension 1.

Ensure that the torque for shock absorber lower mounting bolt is correct : 8 mkg. if loose, there will be a distinct noise. Ensure that the strut components are not fouling with any other parts nearby any fouling part is bound to give a noise.

2.

Ensure that the shock absorber upper mounting bolt torque is correct: 4.5 mkg.

3.

Ensure that the strut spring end is sitting securely on the spring seat at the correct place.

4.

Ensure the alignment of the bottom eye of the shock absorber is proper before tightening, top bolts. If alignment is improper, and the top bolts are tightened first there may be a noise in the rear shock.

SUSPENSION

SPRING SEAT LOWER

SPRING SEAT UPPER

LUG

LUG

Fig. 51

INDEX

GROUP INDEX

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29

SUSPENSION (LX & LXi)

INTRODUCTION : The front and Rear suspension of Indica are Independent type Suspension i. e. each wheel is a separately suspended unit connected to body in such a way that the rise and fall of one wheel does not affect the other wheel directly. This helps each wheel to maintain a level position regardless of influences on the other wheel. The Front suspension is Mc pherson strut type and the Rear suspension is of Independent semi-trailing arm type with hydraulic shock absorber and coil spring mounted co-axially.

INDEX

GROUP INDEX

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i

SUSPENSION

SUSPENSION (LX & LXi) CONTENTS Sr. No.

Description

Page No.

I)

FRONT SUSPENSION (LX & LXi) :

1)

Tightening Torques

1

2)

List of Special Tools

1

3)

Exploded Views: a)

Front Strut & Lower Link Components

2

b)

Front Antiroll Bar Mounting

3

4)

Front Suspension

4

5)

Removal & Installation of Anti-roll bar

5

6)

a)

Removal & Installation of strut assembly

6

b)

Disassembly & Assembly of strut

7

7)

Front Axle - Non ABS

10

8)

a)

Removal & Installation of wheel hub

11

b)

Sub-assembly of knuckle/Hub

14

a)

Removal & Installation of lower link assembly

14

b)

Removal & Fitment of Rubber bushes

15

9) 10)

Procedure for checking the ball joint play on front suspension lower arm ball joints

II)

REAR SUSPENSION (LX & LXi) :

1)

Repairs/Adjustment data

18

2)

Tightening Torques

18

3)

Lubricants Specification

18

4)

List of Special Tools

19

5)

Exploded view

6)

7)

17

a)

Rear Suspension

20

b)

Assembly Rear Hub - ABS

21

Removal of Rear Hub

22

a)

Rear Hub-dismantling & Assembly

23

b)

Assembly of Rear Hub on semi-trailing arm Spindle

25

Removal & Installation of shock absorber assembly

27

a)

27

Disassembly & Assembly of shock absorber

8)

Disassembly/Assembly of Trailing Arm

30

9)

Inspection of shock absorber / strut on the car

31

INDEX

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SUSPENSION

iii

SUSPENSION LX & LXi FRONT SUSPENSION (LX & LXi - 85 PS) TIGHTENING TORQUE Fasteners

Torque in Kg-m

1.

Strut assembly upper mounting nuts

2.3

2.

Strut mounting bolts on knuckle

3.

Knuckle bottom ball joint clamping flange bolt

4.

Drive shaft nut

5.

Lower link mounting on body hex bolt

6.

Clamp hex screw on antiroll bar

4.5

7.

Lower link front mounting pin & tie member clamping nut

12

8.

Strut top nut

4 to 6

9.

Ball joint to lower link

4.6

8 5.5 26 +3 8

LIST OF SPECIAL TOOLS

SUSPENSION

Sr. No.

Description

Part No.

1.

Reset pad removing inner race of bearing from hub

2702 5890 2612

2.

Holder for hub assembly

2702 5890 3301

3.

Puller for pulling out the front hub

2702 5890 3302

4.

Clamp for removing inner race for hub

2779 5890 3303

5.

Striker for pulling out the hub

2702 5890 3304

6.

Drift for installing the bearing in knuckle

2779 5890 3301

7.

Drift for fitting knuckle assembly on hub

2576 5890 4401

8.

Puller for removing ball joint

2702 5890 4602

9.

Spring compression tool

2702 5890 3202

10.

Dolly for fitting front rubber bush in lower link

2702 5890 0107

11.

Puller for removing inner race from hub

2654 5890 3508

12.

Offset Spanner

2702 5890 3201

13.

Puller for knuckle bearing

2779 5890 3302

14.

Handle for drift

2640 5890 3511

INDEX

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1

SUSPENSION LX & LXi SR. NO. 1 2 3 4 5 6 7 8 9 10 11 12 12 12 12 12 12 12 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

FRONT STRUT & LOWER LINK

4.0 - 6.0 2.5

® 2.5

® ®

®

SUSPENSION

ASSY FRONT STRUT COMP ASSY FRT DAMPER SPRING SEAT RUBBER (BOTTOM) DUST COVER FRONT BUMP STOPPER -POLYURETHANE SPRING FRONT SUSPENSION SPRING SEAT TOP (RUBBER) ASSY SPRING SEAT SPACER-FRONT STRUT TOP CUP-THRUST BRG. THRUST BALL BEARING ASSY TOP CUP (FORGED FOR THRUST BRG) SHIM 0.1 THK SHIM 0.15 THK SHIM 0.2THK SHIM 0.25 THK SHIM 0.3 THK SHIM 0.35 THK SHIM 0.5 THK SHIM 1.0 THK SUPPORT-THRUST BRG SPACER-(THRUST BRG) TOP STOPPER SPRING WASHER B12 HEX NUT M12X1.5 COVER STRUT TOP CUP NYLOC NUT M8 STRUT MOUNTING PIN (ECCENTRIC) SP HEX FL BOLT (M12 X 1.25 X 60) HEX FL.NUT AM12X1.25 ASSY LOWER LINK COMPLETE LH LOWER LINK ASSY PIVOT BUSH (FRONT SUSPENSION) ASSEMBLY RUBBER BUSH (REAR) ASSY CLAMP ASSY.LOWER BALL JOINT (FRT.SUSP.)-RANE HEX FL BOLT M10X35 SPRING WASHER B10 HEX NUT M10 35 SPRING WASHER B16 WASHER 36 HEX NUT M16X1.5 MOUNTING PIN 37 HEX FL SCREW M12 WASHER 38 HEX FL SCREW M12 39 HEAT SHIELD (LOWER BALL JOINT) 40 HEX FLANGE BOLT 41 NYLOC NUT M10 42 TIE MEMBER FRONT SUSPENSION

®

®

PART DESCRIPTION

8.0

®

4.6

5.5

®

8.0

8.0

8.0

12.0

- Specified Torque in Kgm

2

INDEX

®

- Non Reusable Part

GROUP INDEX

NEXT

PREVIOUS

INDEX

GROUP INDEX

®

NEXT

PREVIOUS

- Non Reusable Part

- Specified Torque in Kgm

4.6

®

®

®

8.0

® 4.5

ANTI ROLL BAR MOUNTING

SR. NO. 1 2 3 4 5 6 7 8 9 10 11

ANTI ROLL BAR (FRONT SUSPENSION) BALL JOINT ASSY,FRONT ARB ASSY RUBBER MOUNTING. CUP (FRONT ANTIROLL BAR) RUBBER BUSH (ANTIROLL BAR MTG) CUP (FRONT ANTIROLL BAR) NYLOC NUT M12X1.5 NYLOC NUT M10 BEARING BLOCK (ANTI ROLL BAR-28 DIA.) CLAMP (ANTIROLL BAR MTG BRACKET) SPECIAL HEX.FL.SCREW

PART DESCRIPTION

SUSPENSION LX & LXi

SUSPENSION

3

FRONT SUSPENSION

SUSPENSION LX & LXi

SUSPENSION

4

INDEX

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SUSPENSION LX & LXi REMOVA L AND INSTALLATION OF ANTIROLL BAR REMOVAL 1.

Disconnect battery terminals.

2.

Apply parking brake and place wheel chocks at rear.

3.

Remove antiroll bar nuts, washers and rubber cushions (Fig. 1). Do not remove nyloc nut connecting antiroll bar and ball joint pin.

4.

Remove antiroll bar mounting brackets and bearing block.

5.

Remove antiroll bar. Fig. 1

INSTALLATION : (Fig. 2) 1.

For installation proceed in reverse order of removal.

2.

Apply silicon grease molycoate - 33 (medium) on antiroll bar over bearing width before fitment.

3.

Assemble antiroll bar components but do not tighten. Ensure the crank is on the bottom side. Align paint mark with bush face to centralise ARB as shown in (Fig. 2).

SUSPENSION

Fig. 2 4.

Assemble ball joint, rubber bush, cup and spacer as shown in (Fig. 3). Ensure ball joint face is parallel to mounting face of ARB. Tighten ball joint to ARB.

5.

By holding the hex on the shank of the ball joint with a spanner, keep on tightening the lower nyloc nut till the threads protrude about 6 to 7 mm outside the nut (Fig. 3).

ARB FACE

IN ASSEMBLED CONDITION THIS FACE TO BE MAINTAINED PARALLEL TO ARB FACE

HEX ON THE SHANK

NYLOC NUT

6 to 7 mm

Fig. 3

INDEX

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5

SUSPENSION LX & LXi REMOVA L AND INSTALLATION OF STRUT ASSEMBLY REMOVAL : 1.

Remove wheel rim cover (if fitted).

2.

Loosen wheel bolts (Fig. 4).

3.

Jack up the car allowing the front suspension to hang freely.

Fig. 4 4.

Unscrew wheel mounting bolts and remove the wheel.

5.

Remove brake hose from the clamp on strut bracket.

6.

Remove ABS wheel speed sensor harness mounting bolt (if equipped).

7.

Unscrew mounting bolts on strut mounting bracket (Fig. 5).

SUSPENSION

Fig. 5 8.

Open the engine bonnet, unscrew and remove nuts of upper support using offset spanner 2702 5890 3201 (Fig. 6).

9.

Keep relays mounting bracket on LH side and auxiliary tank bracket on its position.

10. Remove strut assembly from bottom.

OFFSET SPANNER PART NO. 2702 5890 3201

Fig. 6 6

INDEX

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SUSPENSION LX & LXi INSTALLATION : 1.

Install strut assembly in reverse order of removal.

2.

Fit bolts and nuts only as shown in Fig. 7.

APPLY THREAD LOCKER FRONT OF VEHICLE ANABOND - 124

NOTE : First tighten top eccentric bolt and then the bottom mounting bolt. 3.

Tighten all bolts and nuts to specified torque.

4.

Apply ADH thread locker wicking grade ANABOND 124 at nut end & bolt thread. Ensure that the threads are free from oil/grease.

TOP ECCENTRIC BOLT

BOTTOM BOLT

CAUTION : 1.

Ensure that brake hose does not twist during installation.

2.

Strut having the same colour code mark on the spring should be assembled on the left hand and right hand side.

Fig. 7

DISASSEMBLY AND ASSEMBLY OF STRUT

SUSPENSION

DISASSEMBLY : 1.

Compress the spring with spring compression tool part No. 2702 5890 3202 until the spring tension is released (i.e. becomes free in its seating place). Unscrew nut (1) and dismantle the parts. (Fig. 8). Hold top stopper by spanner (A/F 60 mm) to stop piston rotation during loosening of nut.

1 Fig. 8

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7

SUSPENSION LX & LXi 15

14

13

12

11 10 9 8 7 6

1.

FRONT STRUT DAMPER

2.

DUST COVER

3.

BUMP STOPPER

4.

SPRING FRONT STRUT

5.

SPRING SEAT RUBBER

6.

ASSEMBLY SPRING SEAT

5

7.

SPACER - FRT STRUT TOP

17 4

8.

ASSEMBLY TOP CUP

9.

THRUST BALL BEARING

3 2

SUSPENSION

1 16

10.

SHIMS

11.

SUPPORT THRUST BEARING

12.

SPACER

13.

TOP STOPPER

14.

HEX NUT & SPRING WASHER

15.

NYLOC NUT & BRIGHT WASHER

16.

SPRING SEAT BOTTOM

17.

RUBBER SLEEVE

Fig. 9 ASSEMBLY (Fig. 9) : Check the condition of the components and replace if necessary. 1.

Compress the spring with spring compression tool part No. 2702 5890 3202 to reduce length as done during dis-assembly as shown in Fig. 10.

Fig. 10 8

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SUSPENSION LX & LXi 2.

Insert the compressed spring on the strut (ensure that the spring end is located in the lower rubber seat of strut) Fig. 11.

3.

Pull strut rod up as far as possible.

4.

Insert bump stopper

5.

Fit top spring rubber seat and assemble spring seat top along with dust cover on the spring properly locating it with spring end.

6.

Fit spacer and locate the assy spring seat.

7.

Grease the thrust bearing with recommended grease & fit the bearing as shown in Fig. 9.

8.

SPRING SEAT LOWER

SPRING SEAT UPPER

LUG

LUG

Fit assy top cup and support Fig. 11

9.

Fit spacer.

10. Fit top stopper 11. Fit spring washer and tighten hex nut to 4 to 6 kg.m torque. Set axial clearance for front struts 0.05 to 0.1mm by selecting proper shims. Use 60 A/F spanner to hold top stopper during tightening of nut (Fig. 12).

SUSPENSION

Note : The top cap should be free to rotate after assembly. The maximum torque to rotate the cap should not exceed 0.5 kgcm. 12. Remove spring compressing special tool carefully. Note : It is a good practice to replace bump stopper at every 30000 km / 18750 miles.

INDEX

Fig. 12

GROUP INDEX

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9

SUSPENSION LX & LXi FRONT AXLE - NON ABS FRONT BRAKE DISC

DOWEL

STEERING KNUCKLE FRONT HUB

26.0

SUSPENSION

®

®

ANGULAR CONTACT BEARING

INTERNAL CIRCLIP

-- SPECIFIED TORQUE IN Kgm

®

-Non Reusable Part

Fig. 13 10

INDEX

GROUP INDEX

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PREVIOUS

SUSPENSION LX & LXi REMOVA L AND INSTALLATION OF WHEEL HUB : REMOVAL : 1.

Apply parking brake and place wheel chocks at rear.

2.

Remove wheel rim cover.

3.

Loosen the wheel mounting bolts.

4.

Jack up car till the front wheels are off the ground.

5.

Unscrew the wheel mounting bolts and remove the wheel. Fig. 14

6.

Unscrew and remove tie rod ball joint nut (Fig. 14).

SUSPENSION

Fig. 15 7.

Remove tie rod ball joint using puller part No. 2702 5890 4602 (Fig. 15).

8.

Support the lower link from bottom.

9.

Hold hub assembly with holder part No. 2702 5890 3301(Fig. 16).

Fig. 16

INDEX

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11

SUSPENSION

SUSPENSION LX & LXi 10. Unstake and unscrew drive shaft nut and take out the thrust washer. 11. Remove holder from the hub assembly. 12. Unscrew the caliper mounting bolts and remove the caliper assembly along with the brake hose (Do not disconnect the brake hose). 13. Disconnect the connector. Unscrew the sensor mounting screw & remove the sensor (if equipped).

Fig. 17 14. Unscrew the dowels and remove the disc (Fig. 17) 15. Pull out the hub with the help of puller part No. 2702 5890 3302 and striker part No. 2702 5890 3304 (Fig. 18). 16. Remove puller from the hub.

Fig. 18 17. Remove strut mounting bottom bolts from the knuckle assembly by supporting the drive shaft (Fig. 19). 18. Remove bottom ball joint from lower arm. 19. Remove knuckle

Fig. 19 12

INDEX

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SUSPENSION LX & LXi 20. Using clamp part No. 2779 5890 3303 puller part No. 2654 5890 3508 and rest part No. 2702 5890 2612 remove inner race of bearing from the hub (Fig. 20).

PULLER REST PAD CLAMP

Fig. 20 21. Remove circlip from knuckle (Fig. 21). 22. Pull out knuckle bearing using puller part No. 2779 5890 3302 (Fig. 22).

SUSPENSION

Fig. 21 INSTALLATION : 1.

Proceed in reverse order of removal.

Note :High / Low point matching on Hub & Disc Observe the condition of disc surface. If the disc surface is smooth ensure that punch mark (Low Point) on disc and hub (High Point) are aligned and assembled. If the disc surface is uneven showing rough marks, grooves - machine it to the specified limit, measure the run out on dia 220 w.r.t. hub and disc resting face. Punch mark around bolt hole where runout on dia 220 is at low point. While assembly align low point on disc and high point on hub. Assemble with dowel. Fig. 22

INDEX

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13

SUSPENSION

SUSPENSION LX & LXi 2.

Tighten drive shaft nut 26 to 29 mkg torque and lock by staking (Fig. 23).

3.

Ensure that oil seal in transaxle is not damaged while fitting drive shaft.

4.

Ensure to refit sensor and reconnect the connector. (if equipped)

PRECAUTION : Use a new hub bearing and new circlip, oil the bearing housing in knuckle carrier and hub itself. Old bearing, even if serviceable can not be reused.

Fig. 23

SUB ASSEMBLY - KNUCKLE / HUB : Clean all the parts thoroughly and replace damage / worn out parts. 1.

With the help of drift part No. 2779 5890 3301 and 2640 5890 3511 fit bearing in the knuckle (Fig. 24)

2.

Fit circlip

3.

Place the knuckle assembly over the hub. Using drift part No. 2576 5890 4401 press the knuckle assembly on the hub.

REMOVA L AND INSTALLATION OF LOWER LINK ASSEMBLY : 1.

Remove front wheel & disconnect anti roll bar at lower link end.

2.

Unscrew nut connecting lower link ballpin and knuckle.

3.

Unscrew rear mounting bracket bolt and remove the bracket (Fig. 25).

4.

Unscrew nut connecting lower link pin and the tie member and remove tie-member.

5.

Unscrew 3 bolts on lower link front bracket spindle (Fig. 26).

Fig. 24

5a. Unscrew mounting bolt of rear bush clamp.

Fig. 25 14

INDEX

GROUP INDEX

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SUSPENSION LX & LXi 6.

Remove lower link assembly along with rear mounting rubber bush and front bracket.

INSTALLATION : 1.

Proceed in the reverse order of fitment.

Fig. 26 2.

Replace rubber bushes, worn damaged parts

3.

Tighten the front and rear mounting bracket bolts with proper torque.

4.

Insert the tie member and tighten the nuts. Ensure that the tie member offset is away from the transaxle flange i.e. towards front of the vehicle (Fig. 27).

5.

Ensure that heat shield is assembled properly on ball joint.

SUSPENSION

Fig. 27

40

REMOVAL AND FITMENT OF RUBBER BUSHES : 1. Remove front and rear bushes with bracket. 2.

Fit front bush on lower link using dolly part No. 2702 5890 0107. Apply soap water before fitment.(fig.28,fig.28a)

3. Fit rear bush on lower link, ensure bush inclination/orientation as shown in fig.28,fig.28a. Note : It is a good practice to replace a ball joint and suspension bushes at every 30000 km/18750 miles.

INDEX

PRESS

PIVOT BUSH

ASSEMBLY LOWER LINK

Fig. 28

GROUP INDEX

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15

SUSPENSION LX & LXi

PRESS

SUSPENSION

PIVOT BUSH

ASSEMBLY LOWER LINK

Fig. 28a 16

INDEX

GROUP INDEX

NEXT

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SUSPENSION LX & LXi PROCEDURE FOR CHECKING THE BALL JOINT PLAY ON FRONT SUSPENSION LOWER ARM BALL JOINTS It is recommended that the axial play on the ball joints should be checked as per the procedure given below before removal of the ball joints. Note : Please check tightening torque of all nut & bolts on the ball joint mounting bracket and ball pin nut before checking the ball joint play. The front lower arm ball joints play should be checked at every 10,000 kms as per the procedure given below. Procedure : a)

Apply the parking brakes and remove front wheel by jacking up the car with the help of a floor jack or by lifting it on a two pole hoist

b)

Mount the dial gauge with magnetic stand on the brake disc as shown in Fig. 29a

Fig. 29a

SUSPENSION

Important : Note that the Dial Indicator plunger axis should be perpendicular to the ball joint bottom face for the correct reading. c)

The tip of the dial gauge should be in contact with the lower arm ball joint bottom plate. (With preloading of about 1mm on the dial gauge).

d)

Place another jack under the lower arm by gently lifting up the lower arm. The jack is to be placed under the lower arm as shown in Fig. 29b.

e)

As the jack is lifted slowly spring in the ball joint gets fully closed (solid) at a load of about 100 kg. and then the dial gauge needle will start moving and indicate the play in the ball joint.

f)

Keep on increasing the load by lifting up the lower arm till the needle stops moving further. Note the reading. This should not be more than 0.5 mm. Do not further load the ball joint after the needle movement stops.

g)

If the reading found is in excess, replace ball joint.

Fig. 29b

INDEX

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17

SUSPENSION

SUSPENSION (LX & LXi) REAR SUSPENSION (LX & LXi - 85 PS) REPAIRS/ADJUSTMENT DATA 1.

Hub bearing axial play

0.01-0.03 mm

2.

Axial play adjusting shim thickness available in steps of

0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.4,0.5 & 1.0 mm

TIGHTENING TORQUES

(kg-m)

1.

Wheel mounting bolt

8

2.

Shock absorber nyloc nut top

4 to 4.5

3.

Assy, Shock absorber mounting top hex flange nuts on the shell

4.5

4.

Shock absorber bottom nyloc nut

6

5.

Assembly inner and outer bracket to cab hex screw (Semi trailing arm)

8

6.

Semi trailing arm mounting nut (inner and outer pivots)

8

7.

Castle nut on hub

10-12

8.

Anchor plate mounting hex screw

4.5

LUBRICANTS SPECIFICATIONS 1.

Hub grease specifications

Grease Lithium IPOL IPLEXLC Grease-2

2.

Quantity of grease (both hubs)

110 gms.

18

INDEX

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SUSPENSION (LX & LXi) LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1.

Drift for installing inner race of outer brg.

2702 5890 2602

2.

Spring compressor

2702 5890 3202

3.

Holder for taking out the hub assembly from spindle.

2702 5890 3301

4.

Puller for taking out the hub assembly from spindle.

2702 5890 3501

5.

Puller for removing outer race of inner taper roller bearing.

2702 5890 3502

6.

Puller for removing outer race of outer tapper roller brg.

2702 5890 3503

7.

Drift for installing outer race of inner taper roller brg.

2702 5890 3504

8.

Drift for fitting oil seal.

2702 5890 3505

9.

Dolly for fitting rubber bush (inner)

2702 5890 0108

10.

Dolly for fitting rubber bush (outer)

2702 5890 0109

11.

Drift for installing outer race of outer taper roller brg

2651 5890 4602

SUSPENSION

INDEX

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19

20

INDEX

GROUP INDEX

ASSY.SEMI TRAILING ARM WITH BUSHES ASSY. SEMI TRILING ARM- (WITH ABS) ASSY.SEMI TRAILING ARM - LH/RH SPINDLE SPACER (FOR OIL SEAL) ASSY.PIVOT BUSH (INNER) ASSY PIVOT BUSH (SEMITRAILING ARM) ASSY.INNER BRACKET- SEMI TRAILING ARM ASSY.OUTER BRACKET SEMI TRAILING ARM HEX FLANGE BOLT M12x1.25x33 ASSY REAR S/A COMP ASSY REAR SHOCK ABSORBER SPRING REAR SUSPENSION

®

1 2 2 3 4 5 6 7 8 9 10 11 12

®

PART DESCRIPTION

® ®

SR. NO.

4.5

4.5

®

8.0

8.0

®

REAR SPRING DUST COVER (REAR SHOCK ABSORBER) REAR BUMP STOPPER (POLYURETHANE) / (POLYURETHANE FOAM) ASSY.BUMP STOPPER CUP SPRING TOP RUBBER BOTTOM RUBBER(SHOCK ABSORBER TOP MTG.) ASSY.STRUT MOUNTING BRACKET_TOP TOP RUBBER

6.0

® 15 16 17 18 19

12 13 14

®

SUSPENSION

REAR SUSPENSION

20 21 22 23 24 25 26 27

®

8.0

8.0

- Specified Torque in Kgm

-Non Reusable Part

(SHOCK ABSORBER TOP MOUNTING) LOCK WASHER NYLOC NUT M10 HEX FL NUT AM10 RUBBER COVER (REAR SHOCK ABSORBER) HEX FL BOLT M10X70 NYLOC NUT M10 HEX BOLT M12 X 1.5 X 90 NYLOC NUT M12 X 1.5

®

SUSPENSION (LX & LXi)

NEXT

PREVIOUS

INDEX

®

GROUP INDEX

PART DESCRIPTION

ASSY.REAR HUB COMPLETE - ABS HUB CUM BRAKE DRUM (REAR)FOR ABS VERSION TAPER ROLLER BEARING-OUTER OUTER BEARING SPACER TUBE (BETWEEN BRGS OF REAR HUB) SHIM (1.00 THK) SHIM (0.50 THK) SHIM (0.40 THK)

1 2 3 4 5 6 6 6

®

SR. NO.

10-12

®

6 6 6 6 6 6 7 8 9 10

®

4.5

SHIM (0.30 THK) SHIM (0.25 THK) SHIM (0.20 THK) SHIM (0.15 THK) SHIM (0.100 THK) SHIM (0.05 THK) DOUBLE-LIP OIL SEAL TONER RING -REAR ON REAR BRAKE DRUM THRUST WASHER THIN CASTLE NUT M16X1.5

4.5

ASSEMBLY REAR HUB ABS

4.5

11 12 13 14 15 16 16 17 18

- Specified Torque in Kgm

-Non Reusable Part

SPLIT PIN 4X32 HUB COVER SPACER PLATE ASSY. SENSOR MTG.PLATE & SENSOR LH/RH HEX FL SCREW M6X12 HEX SCREW M10X28 HEX SCREW M10X25 SPRING WASHER B10 HEX NUT M10

®

SUSPENSION (LX & LXi)

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21

SUSPENSION

SUSPENSION (LX & LXi) REMOVAL OF REAR HUB 1.

Place wheel chokes at front wheels.

2.

Loosen rear wheel mounting bolts. Fig. 30

3.

Jack up the car.

4.

Support the trailing arm and remove the wheel.

5.

Take out hub cap.

5a. Remove connector wheel sensor. 6.

Remove split pin on the castle nut.

7.

Unscrew castle nut and take out thrust washer. Fig. 31

8.

Mount puller part No. 2702 5890 3501 over the holder part No. 2702 5890 3301 on the hub and take out the hub assembly from the spindle. Fig. 32

9.

SUSPENSION

Fig. 31

If required, Disconnect brake bundy tube from wheel cylinder Fig. 33, disconnect parking brake from anchor plate. Unscrew anchor plate mounting bolts and remove the anchor plate.

Fig. 32

Fig. 30

Fig. 33

22

INDEX

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SUSPENSION (LX & LXi) REAR HUB-DISMANTLING AND ASSEMBLY DISMANTLING 1.

Pry out rearoil seal.

2.

Take out inner race of inner taper roller bearing.

3.

Remove spacer tube along with the shims.

4.

Remove inner taper roller bearing outer race, using puller part No. 2702 5890 3502. Fig. 34

5.

Remove outer race of outer taper roller bearing using puller part No. 2702 5890 3503. Fig. 35

6.

Remove old grease completely from hub bearing etc.

SUSPENSION

REMOVAL OF INNER BEARING OUTER RACE

PULLER PART NO. 2702 5890 3502

Fig. 34

REMOVAL OF OUTER BEARING OUTER RACE

PULLER PART NO. 2702 5890 3503

Fig. 35

INDEX

GROUP INDEX

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PREVIOUS

23

SUSPENSION

SUSPENSION (LX & LXi) INSPECTION 1.

Check the taper roller bearings and the bearing seating in the hub and check the spindle.

2.

Check the contact surface for the radial seal on the spacer.

3.

Check the trust washer if necessary replace it.

4.

Generally bearing can be reused if the running surface and rollers show no visible damage or wear. For perfect judgement bearings should be cleaned in gasoline or tricholro-ethylene until all contamination’s are washed out of bearings. Bearing does not bind when rotated manually if it is free of any contamination. For judging silent running of bearings apply few drops of engine oil to clean bearing and rotate.

5.

Fig. 36

Bearings should not be cleaned with kerosene/ cotton waste.

ASSEMBLY Absolute cleanliness is required during bearing assembly in order to avoid entry of dirt, dust and foreign particle. 1.

Clean hub, bearings, spacer tube, shims, thrust washer, and spindle diameter with gasoline.

2.

Fit inner taper roller bearing outer race, using drift part No. 2702 5890 35 04.

3.

Pack roller cage of inner bearing race with recommended wheel bearing grease. Grease quantity 5gm.

4.

Fit inner race of inner taper roller bearing.

5.

Fit outer race of outer Taper roller bearing using drift Pt. No. 2651 5890 46 02. Fig.36

6.

Press new oil seal with drift part No. 2702 5890 35 05 fig.No.37a.Coat the contact surface of oil seal lip with recommended grease. The oil seal should be pressed in the hub such that the sealing lip and the spring faces towards the bearing Fig.37. Whenever bearings are removed/replaced use new oil seal and new grease.

Fig. 37a

Fig. 37 24

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SUSPENSION (LX & LXi)

1 2 15

3

14 13 4

16

5 12

7 6 8

11 17

9

10

18

1. Assembly Brake Drum 2. Toner Ring 3. Inner Taper Roller Bearing 4. Spacer Tube 5. Outer Taper Roller Bearing 6. Shims 7. Castle Nut 8. Hub Cap 9. Split Pin 10. Thrust Washer 11. Spacer for Oil Seal 12. Oil Seal 13. Sensor Mounting Plate 14. Wheel Speed Sensor 15. Anchor Plate 16. Semi Trailing arm 17. Spindle 18. Spacer plate

Fig.38.

ASSEMBLY OF REAR HUB ON SEMI-TRAILING ARM SPINDLE Fig.38. 1. If removed, fit anchor plate assembly, connect Parking brake cable, connect brake pipe. 2. Fit hub assembly on the spindle. Make sure that oil seal lip is not getting damaged during assembly. 3. Assemble the spacer tube on the spindle. 4. Fill the space between two taper roller bearings with 20 gm quantity of recommended grease. Note: Recommended wheel bearing grease and its quantity must be maintained. If grease in excess, excessive heat can be generated and may result in loss of lubricating power. Insufficient grease may prevent perfect lubrication of bearings.

INDEX

5. Insert a shim of suitable thickness (e.g.1.5 mm) over the spacer tube so that recommended axial play is achieved. For shim selection see page no. 27. 6. Pack roller cage of inner and outer bearing race with recommended wheel bearing grease. Grease quantity 5gm. 7. Fill the hub cap with 25gm of recommended wheel bearing grease before fitment. 8. Install inner race of outer bearing using drift part No. 2702 5890 26 02 Fig.No.39 & 40. 9. Install thrust washer.

GROUP INDEX

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25

SUSPENSION

SUSPENSION

SUSPENSION (LX & LXi) 10. Screw in castle nut and tighten to 10 to 12 kg-m torque Fig.No. 41 When tightening the castle nut, turn the rear hub constantly in either direction and tap with a soft hammer to ensure to correct seating of bearings. 11. Pull/Push the hub for checking bearing play.Turn the hub several times prior to any measurement of play. Fit the dial guage on the hub using magnetic stand. The dial should have a pretension of about 2mm. Measure the hub play on the dial guage stem on the spindle. Fig.41a. The recommended hub play is between 0.01 0.06mm.To achieve this hub play, shim may be added or removed. For increasing the hub play shims to be added and for reducing the hub play shims may be removed.Before checking bearing play ensure that the parking brake lever is in released condition.

Fig. 40

12. Insert the new spilt pin in the castle nut and lock the nut by bending the split pin. In case the spilt pin hole in the spindle does not align with the hole in the castle nut loosen / tighten castle nut just enough so that spilt pin can be inserted. Check the hub play once again it should be within 0.01 to 0.06 mm. 13. Fill the hub cap with recommended grease. Grease quantity 25 gm and fit the cap. While fitting the hub cap, hammer lightly at several locations on the collar of cap until collar comes closely into contact with hub. 14. Fit the wheel and tighten the wheel mounting bolts to recommended torque.

Fig. 41

Fig. 41a

Fig. 39 26

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SUSPENSION (LX & LXi) PROCEDURE FOR SELECTION OF SHIMS THICKNESS : For example, if the measured hub play with 1.5 mm shim as selected earlier (ref. point 5 as above) is 0.5 mm. Then correct size of shim for maintaining hub play of 0.03 mm will be as follows1.5 mm

shim (as selected earlier)

-0.5 mm

(play observed)

+0.03

(required hub play)

=1.03 mm (Correct shim thickness required instead of 1.5 mm shim thickness as selected earlier)

REMOVAL OF SHOCK ABSORBER ASSEMBLY 1.

Place wheel chokes at front wheels.

2.

Loosen rear wheel mounting bolts.

3.

Jack up the car, allowing the rear suspension to hang freely.

4.

Support the trailing arm.

5.

Unscrew wheel mounting bolts and remove the wheel.

6.

Unscrew and remove bottom mounting bolt of shock absorber Fig. 42.

7.

Unscrew upper mounting flange nuts of the shock absorber (which are accessible from luggage compartment) and remove shock absorber assembly Fig. 43.

INSTALLATION OF SHOCK ABSORBER ASSEMBLY 1.

Proceed in reverse order of removal.

2.

Tighten upper mounting flange nut to 4.5 kg-m torque.

3.

Tighten bottom mounting bolt to 6 kg-m torque.

Fig. 42

SUSPENSION

Fig. 43

DIS-ASSEMBLY AND ASSEMBLY OF SHOCK ABSORBER DIS-ASSEMBLY :1.

Compress the spring with spring compression tool part No. 2702 5890 3202 until the spring length is reduced such that load on upper and lower cups is released. Unscrew nut(1) and dismantle the parts Fig. 44.

INDEX

Fig. 44

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27

SUSPENSION (LX & LXi) ASSEMBLY : Fig. 46 & 46a. Check the condition of the components and replace if necessary. It is recommended that all the rubber components be replaced during the overhauling. 1.

Compress the spring with spring compression tool part No. 2702 5890 3202 to reduce length as done during dis-assembly. Fig. 45

2.

Insert the compressed spring on the Shock absorber (ensure that the spring end is located in the spring cup bottom of Shock absorber) Also ensure that smaller pitch end of spring is at bottom cup side.

3.

Pull shock absorber rod up as far as possible.

4.

Insert rear bump stopper.

5.

Fit dust cover on assembly bump stopper cup.

SUSPENSION

Fig. 45

1 5 4

3

6

2

9 7

1.

LOCK WASHER

2.

ASSEMBLY BUMP STOPPER CUP

3.

ASSEMBLY STRUT TOP BRACKET

4.

BOTTOM RUBBER (SHOCK ABSORBER MOUNTING)

5.

TOP RUBBER (SHOCK ABSORBER MOUNTING)

6.

RUBBER SEAT

7.

OUTER COIL SPRING

8.

BUMP STOPPER

9.

DUST COVER

8

Fig. 46 28

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SUSPENSION (LX & LXi) LOCK WASHER TOP RUBBER TOP BRACKET ASSEMBLY SPRING TOP RUBBER BOTTOM RUBBER BUMP STOPPER CUP ASSEMBLY

DUST COVER

NOTE : SPRING COIL END SHOULD REST FIRMLY ON HELICAL LUG OF THE SPRING SEAT & SPRING TOP RUBBER.

ROD COLLAR BUMP STOPPER

SUSPENSION

AXIS OF TOP MOUNTING PINS

OPEN COILS AT TOP SIDE SPRING

AXIS OF BOTTOM EYE TOP SIDE VIEW - RH SIDE AXIS OF TOP MOUNTING PINS

SHOCK ABSORBER ELEMENT SPRING SEAT

AXIS OF BOTTOM EYE TOP SIDE VIEW - LH SIDE

Fig. 46a

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29

SUSPENSION (LX & LXi) 6.

Install assembly bump stopper cup along with dust cover over the rear bump stopper.

7.

Fit spring rubber seat on the spring properly locating it with spring end.

8.

Install bottom rubber and shock absorber mounting bracket top.

9.

Fit assembly sub mounting bracket.

10. Fit top rubber. 11. Insert lock washer over the Shock absorber rod. 12. Tighten nyloc nut to 4-4.5 mkg torque. Fig. 47 13. Remove spring compressing tool carefully.

DIS-ASSEMBLY/ASSEMBLY OF TRAILING ARM (HUB REMOVED)

Fig. 47

DIS-ASSEMBLY 1.

Unscrew nyloc nut from inner and outer mounting pins Fig. 48.

2.

Remove mounting pins and take out the arm assembly from the brackets.

3.

Remove the rubber bushes from the trailing arm Fig. 49.

SUSPENSION

ASSEMBLY 1.

Fit rubber bushes in trailing arm by using dolly part No. 2702 5890 0108 (for inner bush) and 2702 5890 0109 (for outer bush).Apply soap water before fitment.

2.

Locate the trailing arm on the brackets and fit the pins.

3.

Tighten nyloc nut both inner and outer to 8 mkg torque.

Fig. 48 PRESS TRAILING ARM ASSEMBLY PIVOT BUSH SLEEVE INNER

Fig. 49 30

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SUSPENSION (LX & LXi) INSPECTION OF SHOCK ABSORBER / STRUT ON THE CAR

Checks to be carried out after removal of shockabsorber & strut.

Front Suspension

1.

Look for signs for breakage such as piston rod bent or heavy dents on the body. These are results of accident or abuse of suspension parts.

2.

Discoloration & light scratch marks on working area of piston rod is normal and doesnot need replacement, unless leakage is noticed & confirmed.

3.

Look for signs of suspected oil leakage such as oil patches or wet mud cakes on the damper body. The presence of oil patch or mud cake can also be result of oily sprayfrom road or accidental spillage of oil during servicing.

4.

Examine damper area near the seal. Presence of oil here is sign of oil leakage.

Noise due to loose brake hose 1.

Ensure that the brake hose is tightened fully, loose brake hose will give noise.

Noise due to fouling parts : 1.

Ensure that the Strut components are not fouling with any other parts near by.

2.

Ensure that the spring end is sitting securely on the spring seat at the correct place Fig. 50.

3.

Ensure the correct torque on the two bolts is correct : 8 kgf-m of the strut mounting at the bottom bracket. It may be noisy if there is any play in the bolts.

SUSPENSION

Rear suspension 1.

Ensure that the torque for shock absorber lower mounting bolt is correct : 6 mkg. if loose, there will be a distinct noise. Ensure that the strut components are not fouling with any other parts nearby any fouling part is bound to give a noise.

2.

Ensure that the shock absorber upper mounting bolt torque is correct: 4.5 mkg.

3.

Ensure that the strut spring end is sitting securely on the spring seat at the correct place.

4.

Ensure the alignment of the bottom eye of the shock absorber is proper before tightening, top bolts. If alignment is improper, and the top bolts are tightened first there may be a noise in the rear shock.

SPRING SEAT LOWER

SPRING SEAT UPPER

LUG

LUG

Fig. 50

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31

BRAKES LEi & LSi

LX & LXi

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BRAKES

INTRODUCTION :

Dual circuit, diagonal split hydraulic brakes through tandem master cylinder have been provided. The front brakes are ventilated disc brakes with floating type calipers while the rear brakes are drum brakes with self-shoe clearance (automatic) adjustment. No adjustments are required for front and rear brakes. The parking brake is a mechanical lever type, console mounted cable operated, acting on rear wheels. BRAKE

Pressure conscious regulating valves are provided on both circuits for the rear brakes to avoid locking of rear wheels and skidding of the car. For car fitted with ABS system, please refer the seperate section on ABS.

INDEX

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i

BRAKES CONTENTS Sr. No.

1. 2. 3.

3. 4.

5.

6. 7. 8.

9. 10. 11.

Description

Page No.

Technical Specification Tightening Torques Exploded Views : a) Servo and tmc assembly (9 inch, ø22.22) b) Caliper Assembly C - 54 c) Rear brake assembly (HASF ø200x30) d) Parking brake system e) Hydraulic lines - Non ABS Version - RHD How does your car’s brake work Front Brakes : a) Salient Features b) Caliper Operation c) Front Brake Service [Removal / Inspection / Installation of Pads, Calipers & Disc] Rear Brakes : a) Working of Hydraulic auto adjust service brake b) Rear Brake Service [Removal / Inspection / installation of Drum, brake shoes, Back Plate, & wheel cylinder] Bleeding of Hydraulic system Tandem Master Cylinder(for Non - ABS version) Vacuum Booster a) Working Principle b) Servicing c) Check list for ensuring satisfactory functioning of vacuum booster d) Vacuum Leak Test Pressure Conscious Regulating Valve (PCRV) Parking Brake [Removal, Installation & Adjustment] Troubleshooting of Brake system

INDEX

GROUP INDEX

1 2 3 4 5 6 7 8 9 9 10 11

21 23

BRAKE

30 33 36 37 38 40 41 42 43 46

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iii

BRAKES TECHNICAL SPECIFICATION BRAKES Type

FRONT

REAR

Single pot floating type caliper

180 dia x 30 mm Leading Trailing shoe type

Piston diameter - 51 mm

Wheel cylinder dia - 17.46 mm

2

Brake Lining Area

70 cm per brake

94.2 cm2 per brake

Lining Grade

RBL-AF-L6755 DP-23

TVS AF 2046

(Grey Colour) Type of Lining

Moulded non asbestos

Bonded Lining - non asbestos

Brake Details

Disc diameter - 231 mm

Drum inside dia - 180 mm

Disc thickness - 17 mm

Max. rebote dia-182mm

Discard Thickness - 15 mm

Out of round - 0.04 mm

Lateral runout - 0.05 mm Replacement service limits for pad /lining Tandem Master Cylinder

Vacuum Booster

15 mm Type Size Material Finish Stroke Stroke Circuit

2.6 mm - AS/AS (BIL*) - 22.22 mm dia (BIL*) - Aluminium - Anodized - 30 mm (Primary - 15 mm and Secondary -15 mm) (BIL*) - 28.5mm (KBX*) - Diagonal (Primary to Front Right / Rear and Left Secondary to Front Left / Rear Right)

Type

- LSC 65

Size

- 9 Inch

Boost Ratio

- 5:1

Pressure Conscious Regulating Valve (PCRV) For non ABS version

Valve Ratio : 3:7:1 (BIL*) & 4:1 (KBX*) Cut-in Pressure : 27 kg/cm2 (BIL*) & 25 kgcm2 (KBX*) Location : Rear Circuit

Brake Pedal

Free Play

- 8 mm

Height

- 200 mm

Stroke

-140 mm (Available)

Type

- IS8654 / DOT 3 / DOT 4

Capacity

- 0.270 Litres

Brake Fluid

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1

BRAKE

BRAKES TIGHTENING TORQUES : Sr. No.

Description

Torque in kg-m

1.

Booster mounting bolt to firewall

2.2 - 2.5

2.

Mounting nuts of master cylinder to vaccum booster

1.0 - 1.6

3.

All brake pipe lines joints (coupling nut)

1.4 - 1.6

4.

3 Way ('T') connector mounting to firewall

0.8 - 1.0

5.

Front caliper, retaining bolt to steering knuckle

7.0 - 8.0

6.

Front caliper carrier retaining bolt

2.2 - 3.2

7.

Front brake hose mounting (banjo) to caliper

2.3 - 2.5

8.

Front caliper bleed screw

0.7 - 1.0

9.

PCRV mounting to floor (for non ABS version)

0.6 - 0.8

10.

Rear stub axle castle nut

10 - 12

11.

Rear brake assembly to stub axle

4.2 - 5.0

12.

Rear wheel cylinder mounting to brake plate

1.0 - 1.3

13.

Rear brake hose / pipe mounting to wheel cylinder

1.4 - 1.8

14.

Rear wheel cylinder bleed screw

0.6 - 0.9

15.

Brake pipe line / parking brake cable clamps to shell

0.5 - 0.6

16.

Parking brake lever mounting to mounting plate

0.8 - 1.0

17.

Parking Brake Mounting plate to floor

0.8 - 1.0

18.

Parking brake cable clamp to long link bracket

0.8 - 1.0

19.

Dowels to front disc with hub / rear brake drum

0.6 - 0.8

20.

Wheel mounting bolts

7.9 - 8.1

21.

Vacuum line clamps

0.6 - 0.8

SPECIAL TOOL 1.

Spanner for brake bleeding

2779 5890 42 01

2

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BRAKES EXPLODED VIEW OF SERVO AND TMC ASSEMBLY (9 INCH, Ø22.22)

FILLER CAP ASSEMBLY (WITH FLWI)

FILLER CAP ASSEMBLY (WITH FLWI)

○

○

○

FLUID RESERVOIR SUB ASSEMBLY (WITHOUT FLWI) # * SEAL FLUID TANK

○

○

# * SEALING RING

# * SEAL - RECUPERATING # * SEAL GLAND PRIMARY # * SEAL GLAND SECONDARY 1.0 to 1.6

# * CIRCLIP

SPRING WASHER # PLUNGER SECONDARY

# STOP PIN # * WASHER (STOP PIN)

# PLUNGER ASSEMBLY PRIMARY # STOP WASHER BRAKE

# SPACER

GROMMET

2.0 to 2.5

FILTER

NON RETURN VALVE ASSEMBLY * - MAJOR REPAIR KIT

INDEX

DUST COVER

# - MINOR REPAIR KIT

GROUP INDEX

- SPECIFIED TORQUE IN Kgm

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3

BRAKES

CALIPER ASSEMBLY C - 51

ANTIRATTLE CLIP

PAD ASSEMBLY PAD SHIM # * DUST BOOT

0.7 to 1

# PISTON # * DUST CAP

@ # * SLIDING PIN BOOT @ SLIDING PIN @ # * GREASE SACHET

# * SEALING RING

@

2.2 to 3.2

- SPECIFIED TORQUE IN Kgm

# - MAJOR REPAIR KIT * - MINOR REPAIR KIT @ - SLIDING PIN KIT

4

INDEX

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BRAKES EXPLODED VIEW OF REAR BRAKE ASSEMBLY (HASF Ø180X30) 1.0 to 1.3

BACK PLATE ASSEMBLY - LH/RH WHEEL CYLINDER HOUSING

# DUST CAP

GROMMET

BLEEDING SCREW

# * DUST COVER

PIN

* PLUNGER # * GLAND SEAL

BRAKE

PIN - HAND BRAKE LEVER LEVER HAND BRAKE LH/RH CIRCLIP STRUT AND QUADRANT

SPRING SHOE RETURN

LINED SHOE ASSEMBLY

SPRING STRUT RETURN

SPRING SHOE RETURN CLIP - SHOE HOLD DOWN * - MAJOR REPAIR KIT

INDEX

# - MINOR REPAIR KIT

GROUP INDEX

- SPECIFIED TORQUE IN Kgm

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5

BRAKES PARKING BRAKE SYSTEM CENTRAL LOCATOR

EQUILISER HAND BRAKE SWITCH 0.8 to 1

ASSEMBLY PARKING BRAKE LEVER COMPLETE

EXTENSION SLEEVE

0.8 to 1

CLAMP

R CLAMP

0.6 to 0.8

ASSEMBLY PARKING BRAKE CABLE

CLAMP

CLIP NOTE : CABLE SLACKNESS ADJUSTMENTS BY HAND TIGHT

6

INDEX

GROUP INDEX

- SPECIFIED TORQUE IN Kgm

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BRAKES HYDRAULIC LINES - NON ABS VERSION - RHD ASSEMBLY TUBE-TMC PRI. PORT TO FRONT BRAKE RH

VACUUM BOOSTER AS/AS

ASSEMBLY TUBE BRAKE HOSE REAR RH TO WH CYL. RH REAR WH CYL RH

FRONT CALIPER RH

ASSEMBLY VACUUM PIPE MPFI RHD

HOSE CLAMP 20 ASSEMBLY TUBEASSEMBLY BRAKE REAR RH CONNECTOR HOSE REAR TO PCRV RH SIDE ASSEMBLY TUBEPCRV ASSEMBLY TMC PRI. PORT CONNECTOR LH

ASSEMBLY TUBETMC SEC. PORT TO 3 WAY CONNECTOR 0.8 to1

ASSEMBLY TUBET CONNECTOR TO FRONT BRAKE LH

ASSEMBLY TUBE3 WAY CONNECTOR REAR RH CONNECTOR

ASSEMBLY TUBEPCRV RH TO REAR BRAKE HOSE RH

FRONT CALIPER LH ASSEMBLY TUBECONNECTOR LH TO PCRV LH

3 WAY UNION (T CONNECTOR)

ASSEMBLY TUBEPCRV LH TO REAR BRAKE HOSE LH

BRAKE

REAR WH CYL LH 2.3 to 2.5

CONNECTOR (BRAKE CIRCUIT)

ASSEMBLY BRAKE HOSE FRONT

SEALING WASHER

PCRV ASSEMBLY CLIP (BRAKE HOSE)

0.8 to 1

SLEEVE

CLAMP

SLEEVE

0.6 to 0.8

CLAMP 0.6 to 0.8

0.6 to 0.8

COATED SINGLE CLAMP

CLAMP (PIPE 4.75X4.75)

NOTE : ALL COUPLING NUT TORQUE - 1.4 TO 1.6 Kgm

INDEX

GROUP INDEX

0.6 to 0.8

COATED DOUBLE CLAMP - SPECIFIED TORQUE IN Kgm

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7

BRAKES

REAR RIGHT SIDE

RIGHT SIDE 3

7

1

9

8 4 10

2

5 11 6 9

8 7

LEFT SIDE

REAR LEFT SIDE PRIMARY CIRCUIT SECONDARY CIRCUIT PARKING BRAKE SYSTEM

Fig. 1 - Schematic circuit diagram of brake system (Non ABS version).

1.

VACUUM BOOSTER

2.

TANDEM MASTER CYLINDER

3.

PRIMARY PORTS

4.

SECONDARY PORT

5.

‘3’ WAY CONNECTER

6.

STRAIGHT CONNECTER

7.

PRESSURE CONCIOUS REGULATING VALVE

8.

BRAKE CALIPER

9.

REAR WHEEL CYLINDER

HOW DOES YOUR CAR’S BRAKE WORK : Fig. 1 When the brake pedal is depressed, hydraulic pressure is developed in the Tandem Master Cylinder, which is used to actuate the brake (two in front and two in rear).

10. PARKING BRAKE LEVER ASSY. 11. PARKING BRAKE CABLE WITH GROMMET

The brake pipes are connected from the tandem master cylinder to the brakes. They make two independent circuits diagonally split. The primary circuit connects the Front Right and the Rear Left brake while the secondary connects Front Left and Rear Right brake through a 3-way connector. Pressure conscious regulating valve is provided at the rear brake to avoid rear brake locking and skidding of the vehicle. The parking brake system is of mechanical type. It applies brake force to only rear wheels by means of the cable and mechanical linkage system.

8

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BRAKES

8 9

Fig. 2 6 4 3 7 2 5 11

9 1

10 12

7 5 BRAKE

SR. NO. 1 2 3 4 5 6

DESCRIPTION CALIPER HOUSING SEALING RING PISTON DUST BOOT SLIDING PIN PAD ASSEMBLY

SR. NO. 7 8 9 10 11 12

DESCRIPTION SLIDING PIN BOOT CARRIER ANTI RATTLING CLIP BLEED SCREW DUST CAP SLIDING PIN BOLT

12

Fig. 3 - Exploded view of caliper assembly

FRONT BRAKES Ventilated disc brakes with Colette type single pot caliper of 54 mm piston diameter are provided for front brake. SALIENT FEATURES OF DISC BRAKES (Fig.2&3) : Colette type Caliper assy consists of a caliper carrier bolted to the knuckle and the body assy slides on two guide pins used in the carrier. The sliding pins are sealed against water and dust by sliding pin boots thereby avoiding possible unequal sliding loads caused by dirt, corrosion. Drag of the pads is taken directly by the Carrier, consequently the pins are loaded only by the weight of the caliper body.

INDEX

When the brake pedal is pressed, the hydraulic pressure from Tandem Master Cylinder pushes the piston in the caliper pot and with it the in-board pad on to the disc. The caliper body reacts and slides on the sliding pins to bring the out-board pad into contact with the disc. Thus the clamping forces on both sides of the disc become equal. When the hydraulic pressure is released, upon release of the brake pedal the sealing ring fitted in the groove of the caliper pot retracts the piston by a small amount which allows the moving parts to relax sufficiently for the disc pads to retract and remain in close proximity to disc, ready for the next brake application.

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9

BRAKES CALIPER OPERATION (Fig. 4) Single Piston Floating Caliper A single piston floating caliper type disc brake is employed in this model. A cylinder and a piston are used for this type (The cylinder is constructed as a monoblock with the caliper). Fluid pressure generated in the tandem master cylinder causes the pad (1) on the piston side to press against the disc. At the same time, the floating type caliper body is moved to the right by the cylinder pressure, as shown in Figure 3, which pulls pad (2) against the disc and hence applying brakes. The disc brake has no servo assistance as in drum braking, and it is necessary to increase the working pressure of the piston and pad. For this purpose, the caliper cylinder has a large bore. A little change in clearance between the disc and the pad causes large influence on the brake pedal stroke. It is always necessary to have the clearance adjusted to the minimum. The clearance adjustment is done by means of the piston (rubber) seal.

CYLINDER

PISTON SEAT (RUBBER SEAL)

Clearance Correction When fluid pressure is applied on the piston, the piston moves forward. The rubber seal, which exerts considerable pressure against the piston, is fixed into a groove in the caliper, hence the shape of the rubber seal is distorted at the I.D. as shown in Fig 3. When pressure is withdrawn from the brake pedal and fluid pressure is released from the piston, a restoring force is generated by the seal and it pushes the piston back to its original position. As the pads wear the clearance between the disc and the pads becomes larger, hence the piston has to move a larger distance. The seal then could change in shape further but, since the seal is fixed into the groove in the cylinder, the distortion is limited to the same amount as previously described. The piston moves further to cover the distance of clearance relative to the seal in the case. The piston returns by the same distance and the rubber seal recovers its shape as described above and thus the clearance between the disc and pads are maintained by adjustment automatically.

PISTON HYDRAULIC PRESSURE ‘OFF’

CYLINDER

PISTON SEAT (RUBBER SEAL)

The caliper brake needs no adjustment. PISTON HYDRAULIC PRESSURE ‘ON’

Fig. 4

10

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BRAKES REMOVAL OF PADS Apply the parking brake lever. Keep the gear shift lever in neutral position. Jack up front of the car ; support with stands and remove both front wheels. Visually inspect pads for wear and caliper for brake fluid leakage. If they are found to have worn, proceed as follows to replace them. Loosen and remove bottom sliding pin bolt with 12 mm spanner. Fig. 5 Swing up the caliper and hold with one hand. Remove both the pad assy one by one. Fig. 6

Fig. 5

NOTE : If you find any difficulty in swinging the caliper up, after removing the sliding pin retaining bolt, it may be necessary to push the caliper piston back along with the pad, using a screwdriver.

BRAKE

Fig. 6

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11

BRAKES INSPECTION OF PADS : Measure pad thickness (with lining) with a Vernier and if the thickness is found to be less than 6 mm any where in the pad, it is time to replace them Fig. 7

CALIPER PAD ASSEMBLY

Caution : Do not polish the pads with sand paper or emery paper. If the pads are polished with emery or sand paper, hard particles of sand paper will be deposited in pad and may damage the disc. Whenever pads require correction, replace them with new ones. Always use genuine recommended pad for replacement. Do not contaminate the pad surface with grease or oil.

Fig. 7

Thoroughly clean the disc. If it is scored exessively, replacement of new pads alone do not give optimum performance and service life. Hence follow instructions as given to recondition the disc. If there is no visible deterioration in piston dust boot and sliding pin boot, new pads can be fitted.

ANTIRATTLING CLIPS SLIDING PIN BOOT

Check for the condition of the anti rattling clips and if found without any damage the same clips can be fitted after cleaning.

SLIDING PIN

INSTALLATION OF PADS :

SLIDING PIN BOLT

Insert both the pads in between the carrier (Fig. 8) and disc in the stub axle such that the friction material is towards the disc and ensure proper seating of the anti rattling clips.

PAD FRICTION MATERIAL TOWARDS DISC

Fig. 8

12

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BRAKES After inserting, push both the pads against the disc with both hands and swing down the caliper and fit bottom sliding pin bolt. Tighten the sliding pin bolt to specified torque. Fig. 9 Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and make sure that the pads are sitting square with the disc without any tilt. Follow same procedure for the other wheel also. Fit wheel; jack down the vehicle. Tighten wheel mounting bolt to specified torque. Fig. 10 SLIDING PIN BOLT

Fig. 9

CAUTION : Apply brake couple of times with the engine started before taking the vehicle for a road test. Before applying an emergency brake, it is advisable to apply the brake gently several times at 50 kms per hour speed to allow the brakes pads to align. BRAKE

Heavy braking or prolonged braking should be avoided in the initial 100-150 kms of run until the new pads are bedded.

Fig. 10

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13

BRAKES DISMANTLING OF CALIPER : Apply the parking brake and keep the gear shift lever in neutral lever. Jack up the front of the vehicle, support on stands and remove wheels. Remove brake hose banjo bolt from the caliper. Fig. 11 Collect the brake fluid from the brake hose / caliper in a clean container. Block the bundy pipe using a dust cap to prevent loss of brake fluid and prevent contamination. As explained in fitment of new pads, remove pads by swinging the caliper. Unscrew the carrier mounting bolts and remove the caliper assembly.

Fig. 11

Clean the caliper assembly externally with a rug. Separate the carrier from the caliper housing. The housing can be taken out from the carrier by sliding it out while releasing the sliding pin boot from the carrier. Take out the remaining sliding pin left in the carrier by releasing the sliding pin boot from the carrier. Remove hose from Caliper body.

DUST BOOT PISTON

COMPRESSED AIR

Remove sliding pin from the housing by taking out sliding pin bolt after loosening. Keep a wooden piece in between the piston and the caliper housing and blow compressed air into the caliper gradually through the inlet port (where banjo bolt get connected). Fig. 12 Now you will observe the piston coming out of the caliper gradually. After cleaning the surfaces remove the dust boot from caliper housing by pulling the same with fingers. Fig. 13 Take out the piston from the housing and remove the boot from the piston.

WOODEN PIECE

Fig. 12

DUST BOOT

COMPRESSED

Fig. 13

14

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BRAKES Remove Sealing Ring from the groove in the caliper housing. Fig. 14 Remove the bleed screw from caliper housing. NOTE : 1.

Care is to be taken while removal so as to avoid puncturing of the dust boot.

2.

If punctured the dust boot should be replaced.

3.

Do not apply high compressed air, which will cause piston to jump out of the cylinder. It should be taken out gradually with moderately compressed air @ 2 bar. Do not place your fingers in front of piston when using compressed air.

4.

Care is to be taken not to damage inner bore of the cylinder.

SEALING RING

Fig. 14

INSPECTION OF CALIPER : Clean all the parts thoroughly with fresh brake fluid. Please do not use mineral oil like kerosene, petrol, diesel etc. After thoroughly cleaning, examine all the parts for damages and corrosion.

BRAKE

Piston : (Fig. 15) Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface.

BOOT

PISTON

Fig. 15

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15

BRAKES Piston Sealing Ring : (Fig. 16) Piston Sealing Ring is used to seal piston and cylinder and it is used to adjust the clearance between pad and disc. Replace the piston-sealing ring with a new one at every overhaul. Fit piston-sealing ring into groove in the cylinder taking care that it should not be twisted.

Fig. 16

CALIPER HOUSING : (Fig. 17) Bore should be free from score, pitting, and corrosion. The seal groove in the bore should be thoroughly cleaned and no nicks should be there at the edges. If the above conditions are quite satisfactory then replacement with appropriate kit will give satisfactory performance. If not the caliper assembly should be replaced. SLIDING PINS : It should be free from rust and bends and sliding pin boots should be soft and free from cracks or puncture. If in doubt, replace them. Fig. 17

INSTALLATION OF CALIPER : Smear the sealing ring with fresh brake fluid and fit it on to the groove in the caliper pot and work around with fingers until it is properly seated. Fig. 18

FITMENT OF SEALING RING

Smear fresh brake fluid to the piston surface. Fit dust boot in to the caliper groove.

Fig. 18

16

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BRAKES Assemble seal and boot in the respective grooves. Fig. 19 Apply compressed air at low pressure (@ 2 bar) through the supply port of caliper by nozzle or through valve. Fig. 20 Locate the piston on boot with the help of short hand bar. Air flow will get restricted and the dust boot will balloon on all sides. Make sure all sides of the boot has covered the piston. Insert the piston by pushing the hand bar against air pressure through caliper. So that piston can be pushed into the housing easily. Ensure that seal does not get damaged due to excessive push. If required slightly swivel the piston for the ease of entry.

DUST BOOT COMPRESSED AIR

Fig. 19

The moment you get a feel that piston has entered the seal immediately stop air flow then push the piston to the bottom of caliper. Ensure the outer end of the dust boot is properly seated in the piston groove and check for free movement of the piston. Smear sliding pins with special red rubber grease. Insert the loose sliding pins into the holes of the carrier and fit the sliding pin boots.

DUST BOOT BRAKE

PISTON

COMPRESSED AIR

Fit the carrier on the knuckle. Now fit the caliper housing to the carrier in the reverse order of removal. Fit the bottom guide pin dust cover's other end to carrier.

Fig. 20

Sliding Pin : Check pin for smooth movement as shown. If it is not free to move correct for free movement or replace the pin. Fig. 21 Apply red rubber grease to pin outer surface. Fit new pads as explained earlier under "Fitment of New Pads". BOOT SLIDING PIN

Fig. 21

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17

BRAKES Swing back the caliper to its place and fit sliding pins bolt and tighten to recommended torque (Fig. 22). Fit bleed screw. Connect the hose with caliper housing. Ensure new gaskets are used to ensure proper sealing. Before fully tightening make sure that the hose should be free from twists. Assemble front brake hose to caliper feed port as shown and tighten the banjo bolt to the specified torque. Connect bundy pipe nuts to the female end of the hose after removing the dust cap from the bundy tube fitted earlier and tighten to specified torque. DISC REMOVAL :

SLIDING PIN BOLT

Fig. 22

Jack up the front of the car and remove the wheel by removing the wheel mounting bolts. Remove the caliper assembly by loosening the carrier bolts (2 Nos.). Remove Brake disc counter sunk screw connecting the brake disc to the hub. Fig. 23 Pull the brake disc off by using two M8 bolts.

Fig. 23

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BRAKES DISC INSPECTION : Fig. 24 The disc should be free from score marks. If scored, this should be ground and refitted. But at no time more than 0.25 mm should be ground per side. If the total thickness of the disc after grinding is found to be less than disc discard thickness of 18.00 mm, then the disc should be changed. The disc thickness variation to be checked by measuring the thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made at the same distance from the edge of the rotor. After fitment, the face runout of the disc should be less than 0.10 mm. During the measurement confirm that the dial gauge probe be approx. 10 mm from the outer edge of the brake rotor, perpendicular to the disc and under slight preload. Check front wheel bearing for looseness before face runout measurement. The control of the braking surface finish is necessary to avoid pulls and erratic performance. It will also help in extending pad life.

BRAKE

Note : Measure the face runout of the disc and mark the low runout point around the wheel mounting bolt, which is nearest to the low runout point. This is important, as this marked point has to be matched with corresponding high point on the hub.

Fig. 24

This will ensure minimum runout of hub and disc assembly together, this will in turn minimize disc wobbling and uneven pad wear. The other side of the Caliper can be serviced in the same way. INSTALLATION OF DISC : Fig. 25 & 25a Install the disc to wheel hub such that the low runout point on disc matches with the high runout point on the hub and tighten the dowel as per the specified Torque. Install the caliper assembly to the steering knuckle and torque the caliper carrier bolts to specification. Fig. 25.

SLIDING PIN BOLT

Fig. 25

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19

BRAKES Fit the wheels and torque the wheel mounting bolts to the specified torque.

Fig. 25a

Bleed the brakes as explained under the "bleeding procedure" (Fig. 26,Fig.26a) If bleeding equipment or power bleeding is used to bleed the system, which does not necessitate application of pedal. But you must make sure several brake pedal applications are made to keep the piston free in the bore before taking the vehicle for road test.

a

b

a. Depress brake pedal several times and with pedal depressed, loosen bleed screw a little. b. With brake pedal depressed, retighten the bleed screw.

Fig. 26

Brake Hose and Pipes : Check brake hoses and pipe lines for leakage, crack, damages etc. and replace if necessary. Use light and mirror to inspect hose conditions.

bleeding nipple

Fig. 26a

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BRAKES REAR BRAKES : 27 26

24

25

16 15 7

21 22

23

65 4 2

20

14

9 8

18

19 12

11

13

1 10 BRAKE

17 3 SR. NO. 1 2 3 4 5 6 7 8

DESCRIPTION BACK PLATE LINED SHOE TRAILING LINED SHOE LEADING HAND BRAKE LEVER WAVE WASHER WASHER PLAIN SPLIT PIN HAND BRAKE LEVER PIN

SR. DESCRIPTION NO. 9 SHOE RETURN SPRING(CYLINDER END) 10 SHOE RETURN SPRING(ABUTMENT END) 11 STRUT RETURN SPRING RH 12 STRUT RETURN SPRING LH 13 STRUT ASSY. 14 WHEEL CYLINDER

SR. NO. 15 16 17 18 19 20 21 22

DESCRIPTION SPRING WASHER SET SCREW SHOE HOLD DOWN CLIP SHOE HOLD DOWN PIN GROMMET GROMMET DUST COVER PLUNGER

SR. NO. 23 24 25 26 27

DESCRIPTION GLAND SEAL WHEEL CYLINDER BODY SPRING BLEED SCREW DUST CAP

Fig. 27 : Exploded view of Rear Brake assembly

WORKING OF HYDRAULIC AUTO ADJUST SERVICE BRAKE (WITH FORWARD PULL HAND BRAKE) Fig. 27

To maintain the shoes square with the drum, both the rims rest on pads formed at suitable place on the back plate.

The hydraulic Auto adjust brake is simple in design, robust in construction with one trailing and leading shoe with bonded linings. The brakes self adjust during brake operation.

The shoe is held against the backplate by means of a shoe hold down clip. Mechanical lever mechanism is incorporated for normal hand brake operation, but the feature of the brake is that the automatic adjustment of the lined shoes takes place when the service brake is applied.

The shoe return spring are fitted from shoe to shoe to provide a positive shoe retraction thus avoiding any possibility of brake "hanging on".

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21

BRAKES To prevent damage to the brake drum due to over adjustment, a mechanism is incorporated on the automatic adjustment mechanism which is indicated by increase in foot pedal travel and hand brake lever movement, that maximum adjustment has been reached and the lined shoes need replacement. The leading and trailing shoes are connected at one end by an abutment plate riveted to the backplate. The other end of the shoes is connected by a twin piston wheel cylinder, hand brake lever and a strut assembly, which incorporates the automatic adjustment mechanism. The hand brake lever operates the trailing shoe whilst the leading shoe is operated by a quadrant lever. Quadrant and the strut are riveted and the quadrant is free to rotate. A hooked spring keeps the quadrant lever in contact with a knurled wheel, which is also riveted to the strut, but the wheel is fixed and does not rotate. When the foot pedal is operated, the brake shoes are pushed on to the drum by the wheel cylinder piston. As the shoe linings wear, the outward movement of the shoes exceeds a predetermined amount and this movement pulls the quadrant lever away from the knurled wheel. The quadrant moves on its pivot pin so that when the brakes are released and shoes move back, the quadrant has moved round on the knurled wheel to reduce the clearance between the brake shoes and drum to the desired minimum clearance. The adjustment is repeated, whenever necessary depending upon the lining wears.

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BRAKES REAR BRAKE SERVICE : DRUM REMOVAL : Jack up the car and remove the wheels by removing the wheel mounting bolt.

AUTO ADJUSTER WINDOW

Release the parking brake lever and remove parking brake lever cover. Loosen parking brake cable (slackness) adjustment nut.

LINING INSPECTION WINDOW

To increase the clearance between shoe-to-drum remove back plate grommet attached to the backside of the brake back plate. Insert screw driver till it grips the adjusting lever in Fig. 28. Pull it a little so that the shoe adjuster lever drops thus shoe to drum clearance can be increased.

Fig. 28

Remove wheel cap by slightly tapping at 3 - 4 places by using a mallet. Remove split pin from the spindle and loosen the wheel castle nut. Remove thrust washer and bearing outer race. Now remove the brake drum by mounting puller Part No 2702 5890 3501 over thr holder Part No 2702 5890 3301 Fig. 29

BRAKE

DRUM INSPECTION : Inspect the drum for cleanliness. Check for crack, scores etc. Check braking surface for its wear by measuring the inside diameter. Fig. 30 Brake Drum Inside Diameter

Standard

Service Limit

200 mm

202 mm

Fig. 29

Whenever brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves etc. Visual inspection of wheel cylinders for brake fluid leakage is to be performed. Drum to be discarded, if found cracked, scored exessively or grooved. Do not to weld a cracked drum. It is unsafe and must be replaced.

BRAKE DRUM

Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will be necessary to resurface drum-braking surface. If brake linings are slightly worn and drum is grooved, drum should be polished with fine emery cloth but should not be turned.

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Fig. 30

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23

BRAKES REMOVAL OF BRAKE SHOE : For drum removal follow the steps mentioned under drum removal. Push the lever handbrake away from the shoe rim and remove the cable from the operating hook. Using spring-plier remove the shoe return spring at the abutment end and spring at the wheel cylinder end. Fig. 31 Remove the shoe hold down clip from both the shoes. Then remove both the brake shoes from the back plate along with the strut and quadrant assembly, slip on elastic band over wheel cylinder to retain the piston within the cylinder. Fig. 32 Fig. 31

INSPECT BRAKE SHOE / LINING : To maintain the efficiency of the brake system, preventive maintenance is essential. Every 10000 km remove the brake drum and check the lining for wear. The lining must not be allowed to wear down below 1 mm from rim surface. Fig. 33 Increased foot pedal travel and hand brake lever movement is an indication that automatic adjustment mechanism has reached its stop. The lining shoes need replacement in pair on both sides of the axle. Always fit new shoe return spring when fitting new shoe. Do not polish lining with sandpaper or emery paper. If lining is polished with sandpaper or emery paper, hard particles of sandpaper will be deposited in the lining resulting in damage of drum surface.

Fig. 32

Whenever a lining is to be corrected replace it with the new one. Always use genuine grade of service replacement lined shoes. Do not contaminate the lining surface with oil or grease. Brake Lining

Standard

Service Limit

6 mm

2.6 mm

Thickness (Lining + Shoe Rim)

LINED SHOE ASSY.

Fig. 33

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BRAKES REMOVAL OF BRAKE BACK PLATE : Fig. 34 For the removal of brake drum and brake shoe lining refer Drum removal and Shoe removal respectively. Remove the brake back plate by removing the four mounting bolt from the stub axle. Clean the back plate and ensure the hand brake quadrant lever are free to rotate easily on the strut. Use graphite grease to lubricate the contact faces of the strut and hand brake lever, strut and the quadrant lever.Fig. 35 Also lubricate the tips of the shoes, the shoe platforms on the back plate and contact areas of the adjuster strut and back plate. Keep the grease away from the shoe linings and all hydraulic parts.

Fig. 34

Inspect the following components, if defective correct or replace. 1.

Ratchet of strut for wear or damage.

2.

Check for damage or weakening of spring.

3.

Check parking brake shoe lever for free movement against brake shoe webs.

BRAKE

Fig. 35

WHEEL CYLINDER SERVICING : Fig. 36 SECTIONAL VIEW OF WHEEL CYLINDER

The wheel cylinder should serviced using parts from appropriate repair kit, provided the plunger and the bore are in good condition without any damage.

Fig. 36

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25

BRAKES REMOVAL OF WHEEL CYLINDER : For removing brake drum, shoe etc. refer respective sections. When removing or servicing wheel cylinders, it is necessary to drain the brake fluid from the system and remove the brake shoes. Attach a transparent (vinyl) bleed tube to the bleed screw having first removing it's rubber dust cap. Fig. 37 Unscrew the bleed screw 1/2 to 3/4 turn Fig. 37 and pump out the brake fluid in a suitable container by operating the brake pedal. Remove the bleed tube. Disconnect the bundy pipe / Hose from wheel cylinder. Remove bleed screw.

Fig. 37

Fix rubber dust cap on to the bundy pipe to avoid brake fluid from spilling and contamination. Remove wheel cylinder mounting set screw and take out wheel cylinder from the backplate. Fig. 38 DISMANTLING OF WHEEL CYLINDER : Fig. 39 Clean the wheel cylinder externally. Remove the dust cover fitted on to the wheel cylinder assembly. Push out the piston with seals. Remove the seals from the plunger using a blunt edged connector. Discard all rubber parts. Clean all parts in fresh brake fluid or alcohol and place them on a clean sheet of paper. Never clean the wheel cylinder or internal parts with kerosene, petrol or diesel as it will lead to contamination and damaging the rubber parts.

Fig. 38

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BRAKES WHEEL CYLINDER

4 3

5

7 6 2 1 1. 2. 3. 4. 5. 6. 7.

Dust cover Plunger Gland Seal Dust Cap Bleed Screw Wheel Cyl. Body Spring BRAKE

Fig. 39

INSPECTION OF WHEEL CYLINDER : Examine the wheel cylinder bore and the piston. If they are not scored, corroded or ridged and are smooth to touch, then new seals can be fitted. If there is any doubt about the condition of the bore, a new cylinder must be installed. Inspect the wheel cylinder dust cover for cuts, cracks, hardening or other signs of deterioration. If in doubt, the dust cover needs replacement. If the system has been contaminated with mineral oil of any type, the system should be flushed out with fresh brake fluid or alcohol and all rubber parts including hoses should be replaced. For identification a contaminated seal can be compared with a new seal (but do not allow them to touch). If the old one is appreciably larger, seal contamination is indicated. Whenever wheel cylinders are serviced replace seals and dust covers from appropriate wheel cylinder kit.

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ASSEMBLING OF WHEEL CYLINDER : When properly inspected assemble as follows : Absolute cleanliness has to be maintained and clean brake fluid must be used. Never use brake fluid bled from the system as it may be certainly aerated. Lubricate the wheel cylinder bore liberally with fresh brake fluid. Dip new seals and piston in fresh brake fluid. Fit the gland seal on to the plunger groove in one of the piston and insert the piston with seal into the bore, such that the smaller stem of the piston is facing outside. Reverse the dust cover and fit the smaller dia of the dust cover onto the neck of the piston and fit dust cover on the wheel cylinder. Insert the spring assy in to the bore. Insert the other plunger with seal (Assemble as said before) and fit the dust cover as per step No. 3. Fit a rubber band around the piston to retain them within the bore.

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27

BRAKES INSTALLATION OF WHEEL CYLINDERS : Install the wheel cylinder assembly on to the backplate and with the set screw and the washers. Tighten the wheel cylinder mounting screws to a torque specified. Fit the bleed screw and tighten to the torque specified. Remove the rubber band from the wheel cylinder. Refit the brake shoes as described under "FITTING SHOES". Connect bundy pipe / hose to the inlet port. Refit the drum and wheel. INSTALLATION OF BRAKE BACK PLATE : Clean the back plate. Fit the wheel cylinder to the brake back plate as specified in the installation of wheel cylinder.

Fig. 40

Lightly smear high melting point graphite grease to the back plate back pads and abutment, contact faces of the strut, hand brake lever, quadrant lever etc Fig. 40 2

Keep the grease away from the brake shoe lining. Position the leading shoe on to the back plate, position the trailing shoe with the hand brake lever on the back plate. Position the strut and the quadrant assembly between the leading and trailing shoe web. Two slots are milled on the either end of the struts. One end of the strut is fitted with quadrant. Ensure that the strut return spring LH is fitted properly. The quadrant side of the strut should be located in the leading shoe slot. Fit the spring. Fig. 41

1 1. STRUT 2. RATCHET

Hook the spring at the abutment end (bottom) of the shoe and the spring towards the wheel cylinders end of the shoe. Connect the strut return spring to the trailing shoe and strut. Now fit the shoe hold down pin and the clip on both the shoes. Ensure the correct fitment of the clip by moving either side.

2

Connect the hand brake cable to the hand brake lever in the reverse order of removal.

1

Do not handle linings more then it is necessary and be sure that they are completely free from oil or grease. Centralise the brake shoe relative to the back plate before fitting the drum by lightly tapping in the required direction.

1. BRAKE SHOE 2. SHOE HOLD DOWN SPRING 3. PARKING BRAKE SHOE LEVER

Fig. 41

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BRAKES Fit the back plate to the stub axle and tighten the back plate bolts to the specified torque. Before installing brake drum maximize the drum to brake shoe clearance. (Follow the procedure as mentioned in the brake drum removal). Install the brake drum. Ensure the inside surface of the brake drum and brake shoes are free from dirt and oil. Put the brake shoe hold down spring back to its original position as shown. Install inner race of the outer bearing, washer, spindle, castle nut and split pin and assemble the wheel cap. Fit the wheel and tighten the wheel mounting bolts to the specified torque. Flushing Brake Hydraulic System It is always recommended that entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Periodical change of brake fluid is also recommended.

BRAKE

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29

BRAKES BLEEDING OF HYDRAULIC SYSTEM : The process of removing air from the hydraulic pipelines and cylinder is known as "Bleeding".

RIGHT BRAKE CALIPER 3

The brake hydraulic lines are based on diagonal split system. Whenever any brake line or hose was disconnected at the wheel, bleeding operation must be performed at both the ends of the line of the removed pipe or hose. (i.e. if the rear left side brake pipe or hose was disconnected both the rear left and front right side of the system to be bleeded.) When any joint part of the Master Cylinder, other joint part between the master cylinder and each brake of the wheel was removed or the level of brake fluid in the reservoir has been allowed to fall so low that the air has been drawn into the system. Then the hydraulic brake system must be bled at all 4 wheel brakes.

RIGHT WHEEL CYLINDER 2

FRONT

1 LEFT BRAKE CALIPER

REAR

4 LEFT WHEEL CYLINDER

Fig. 42

Caution Note : ALWAYS USE HEAVY DUTY BRAKE FLUID - IS8654/ DOT 3 / DOT 4 Entire bleeding operation should be carried out with the Engine ON (running) condition only. As the hydraulic lines of brake system is of DIAGONAL SPLIT, always perform bleeding operation starting from the Co-driver side front caliper 1st and then at the wheel cylinder diagonally opposite it. Repeat the same on the other brake line also (Fig. 42). Brake fluid may cause damage to paint. So make sure that brake fluid does not touch the painted surface. If it accidentally touches painted surface, wipe immediately and clean the surface.

Fig. 43

Bleeding Procedure Fig. 44 The sequence for bleeding the system is as shown. Carefully clean all dirt from around the reservoir filler cap.Fig. 43. Remove the filler cap, fill the reservoir with fresh brake fluid to the maximum marking indicated on the reservoir. Before commencing bleeding, at each bleed screw, remove the dust cap and clean thoroughly. Attach transparent (Vinyl) bleed tube to the bleeder screw top of the front left caliper and insert the other end in to a clean glass container containing recommended brake fluid to submerge the end of the tube as shown. Start the Engine since the entire bleeding operation has to be carried out with engine running condition only.

bleeding nipple

Fig. 44

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BRAKES Depress brake pedal slowly through out the full stroke of the pedal and then holding it depressed, loosen bleed screw about one-third to one-half turn. Which is sufficient enough to allow the brake fluid to flow freely. Note It is always better to close the bleed screw at the end of each downward pedal stroke to ensure full recuperation of brake fluid in the system.

a

There should be an interval of 3 to 4 seconds before making the next stroke. This action should be repeated until bubbles of air cease to appear at the end of the bleed tube. Fig. 45. Close the bleed screw immediately after the last downward stroke of the pedal. Whilst the pedal is thus held, securely tighten the bleed screw to recommended tightening torque and remove the tube. Replace the dust cap on the bleed screw.

b

a. Depress brake pedal several times and with pedal depressed, loosen bleed screw a little. b. With brake pedal depressed, retighten the bleed screw.

Fig. 45

bleeding nipple

Ensure that the fluid level in the master cylinder reservoir does not fall low enough to cause air to be drawn into the system, through out the bleeding operation. Repeat the same procedure on the rear right wheel cylinder, Fig. 46, followed by front right caliper assembly followed by the rear left wheel cylinder.

BRAKE

If the bleeding of any cylinder continues without success for a considerable time, it may be that air is being drawn in past the bleed screw threads. In such instances, the bleed screw should be closed at the end of each downward stroke of the pedal, allowing the pedal to return fully to its stop before reopening.

Fig. 46

Tighten the bleed screw finally after the last downward stroke of the pedal. Replace the dust cap on the bleed screw. Lock Nut

After completion of bleeding, apply the brake pedal hard and check for any leak at the joints and bleed screws.

Brake Light Switch 3+0.5 Set Brake Light Sw itc h As shown

Also check the brake pedal for "Sponginess" if found spongy repeat the complete procedure of bleeding. Set brake light switch dimension 3 + 0.5 mm and tighten the lock nut Fig. 46a

Brake Pedal

Fig. 46a

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31

BRAKES BRAKE FLUID LEVEL INSPECTION : After completion of brake bleeding check the brake fluid level in the reservoir. The fluid level should be between MIN and MAX level indicated on the brake master cylinder reservoir. If the warning light glows during Engine ON condition, replenish fluid to MAX line. Fig. 48 Never use a container which has been used for mineral oil or which is wet. Always keep all brake fluid containers capped to prevent contamination.

Fig. 48

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BRAKES TANDEM MASTER CYLINDER (FOR NON ABS VERSION)

FILLER CAP

FLUID RESERVOIR

SEAL O-RING

BACK SEAL

SPRING BRAKE

ASSEMBLY SECONDARY PLUNGER

ASSEMBLY PRIMARY PLUNGER

Fig. 49 Tandem Master Cylinder - Sectional view (AS/AS)

DESCRIPTION The simultaneous cut off (AS/AS) tandem master cylinder is designed for finer control of the fluid cut off point. The AS/AS master cylinder consists of two independent chambers in a single casting housing, primary and secondary plungers are fitted with seals having minimum friction. Each hydraulic system is so designed that any failure of a pressure seal in anyone of the chamber would not result in total failure of braking system, since the other chamber remains completely operational and ensures minimum safe braking performance. The specific design feature of this master cylinder is that pressure is developed in both the chambers simultaneously without any time lag.

INDEX

Under normal conditions when the brake pedal is depressed, the servo output rod pushes the primary plunger of the cylinder. At the same time, the force of the primary spring moves the secondary plunger forward. Simultaneously the recuperating pressure seals on both the plungers cover the cut off holes, developing pressure in both the chambers. The pressurized fluid from primary chamber is transmitted to front left and rear right brakes and from secondary chamber to the front right and rear left brakes. The fluid reservoir comprises of two separate chambers serving each system with a common topping up connection at the upper portion. The Filler cap comprises of a Fluid Level Warning Indicator (FLWI).

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33

BRAKES REMOVING THE MASTER CYLINDER : Fig. 50 When removing or servicing master cylinder, it is necessary to draw in the brake fluid from the system. Connect a bleed tube to the rear wheel cylinders bleed screw and drain the fluid into a container by pumping the pedal. Repeat the same by connecting the bleed tube to front caliper bleed screws and collect the fluid from the primary circuit and drain the system. Repeat the same procedure for the secondary circuit also. Disconnect all outlet pipes from the master cylinder. Loosen the master cylinder mounting nuts from the servo and remove the same.

Fig. 50

DISMANTLING OF THE TANDEM MASTER CYLINDER : Fig. 51 & 52 Clean the tandem master cylinder assembly externally with alcohol or fresh brake fluid before dismantling it. Remove the tank fixing spring pin. Hold the fluid reservoir and by rocking it on either side, lift the same out of the grommets in the master cylinder. Remove both the grommets from the master cylinder body, using a connector / screwdriver with a blunt edge. Remove the 'O' ring fitted in the groove on the spigot with a blunt edged pin. Slightly push the primary plunger with a round rod, hold it in depressed position and remove the stop pin and gasket.

Fig. 51

Without removing the stop pin, if any attempt is made to dismantle the master cylinder, the secondary plunger will get damaged and cannot be removed. Then clamp the cylinder (housing) in vice with soft jaws. With the help of circlip plier, remove the circlip. Remove the stop washer (spacer) and primary back seal from the shaft of the primary plunger. Remove the complete primary plunger assembly out of the bore. Removes the cylinder from the vice. Tap the cylinder, bore facing downwards, on a wooden block to allow the secondary plunger and the return spring to slide out of the bore. Discard all removed internal parts. Fig. 52

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BRAKES Clean the cylinder bore in fresh brake fluid or alcohol and blow with compressed air. Be sure that the Three holes visible through the primary and secondary inlet ports) in the cylinder body are clean, by blowing dry compressed air. Do not poke the holes with sharp instrument. CAUTION : Do not use kerosene (or) petrol (or) any other mineral oils to clean the cylinder and its internal parts. As it will lead to contamination and damage of rubber part wash all disassembled parts with brake fluid only. INSPECTION OF TANDEM MASTER CYLINDER : Examine the bore of the master cylinder. If it is not scored, ridged or corroded and is smooth to touch, the master cylinder assembly can be rebuilt using the appropriate parts from the genuine repair kit. If there is a slight doubt about the condition of the bore like having deep grooves or pit marks etc., fit a new master cylinder assembly. If contamination is observed on the removed seals (Normally they would have swollen and can be compared with new seals from the kit, which will show clearly that the size is enlarged). The entire rubber parts in the system including both front and rear hoses must be discarded and the entire system should be flushed with fresh brake fluid. ASSEMBLING THE TANDEM MASTER CYLINDER : Absolute cleanliness has to be maintained and clean fresh brake fluid must be used. Never use the brake fluid bled from the system as it is aerated. To facilitate easy assembly, smear the cylinder bore with fresh brake fluid liberally. Dip the plungers and all seals in fresh brake fluid. Fit the secondary back seal in the secondary plunger groove such that the seal lip faces the primary plunger assembly. Fit the seal shim and recuperating seal on the stem side of the secondary plunger in such a way that the lip of the seal faces towards the secondary spring. Fit the seal retainer in correct position as shown in figure and fit the secondary spring with the smaller dia coil coming on to the plunger stem.

round-ended rod. Press it down fully and whilst holding, screw in the stop pin with a new gasket and tighten to the specified torque. Slowly let the secondary plunger back till it touches the stop screw. Now insert the new primary plunger assembly as shown in Figure (3) into the bore. First fit the stop washer on to the primary plunger shaft. Fit the washer primary back seal followed by spacer and back seal on to the primary plunger shaft. Now fit the circlip by using circlip plier. NOTE While fitting the primary back seal, make sure that the lip of the seal is facing forward. Actuate the primary plunger assembly for couple of times and check for the quick return of the plungers. Fit a new 'O' ring into the groove on the spigot of the body. Fit new grommet into both the inlet ports by liberally lubricating the same with fresh brake fluid. Fit the fluid reservoir by positioning the same into the grommets and by slightly rocking them on to either side, press it home. Fit the locking pin as shown in Figure. NOTE

BRAKE

It is essential that the reservoir filler cap must be removed. Clean the filter. Refit the filler cap. Clean the filter. Replace the sealing ring the filter cap during overhaul. Refit the filler cap. Now the master cylinder is ready for fitment on to the Servo. Fit the master cylinder to servo using nuts along with spring washer and tighten to the specified torque. Connect the outlet pipes to the master cylinder. Tighten the coupling nut to the specified torque. Fill the reservoir with recommended brake fluid and bled the system. Check for brake fluid leakage. NOTE Do not alter the stand out of the output rod of the servo unit. Make sure that Vaccum Booster output rod is correctly assembled into the primary plunger bore.

Clamp the cylinder body with its mouth pointing upwards in a vice fitted with soft jaws. Insert secondary plunger assembly into the bore with the secondary spring leading into the bore.

Make sure that the primary outlet is connected to the front left and rear right and secondary outlet to the rear left and front right brakes.

Then slowly push the plunger down the bore with a

Do not polish bore of the tandem master cylinder. Never use cloth to clean or dry the master cylinder.

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35

BRAKES VACCUM BOOSTER

SR. NO. 1 2 3 4 5 6

DESCRIPTION

SR. NO.

BODY GASKET STOP PIN SPRING SPRING RETAINER RECUPERATING SEAL

7 8 9 10 11 12

DESCRIPTION

SR. NO.

SHIM

13

14 SECONDARY PLUNGER 15 GLAND SEAL PRIMARY PLUNGER ASSY. 16 WASHER 17 PRIMARY BACK SEAL 18

DESCRIPTION SR. NO. SPACER CIRCLIP BOOSTER ASSY. FILTER BOOT NUT

DESCRIPTION

SR. NO.

DESCRIPTION

19

CLEVIS

25

RESERVOIR

20 21 22 23 24

26 GROMMET (NRV) NON RETURN VALVE 27 28 SPRING WASHER NUT GROMMET

FILLER CAP PIN ‘O’ RING

Fig. 53 Exploded view of TMC assembly & Vaccum Booster Assembly (LSC65 + ø22.22AS/AS)

There is a mechanical vaccum booster unit fitted on the car. The above unit is designed to provide controlled power assistance to the effort applied by the driver's foot to the brake pedal. Vacuum supplied to the booster unit is obtained from the vacuum created in the engine inlet manifold in case of petrol engine and Vacuum generated by vacuum pump in case of diesel engine. The vacuum is applied to both the sides of a diaphragm and by admitting atmospheric pressure to one side of the diaphragm the power is obtained.

operates the master cylinder. Should a vacuum failure occur, the two push rods act as a single rod and the brakes will work in the conventional manner, but more pedal effort will be required and the fatigue of the driver will increase.

The unit is connected to the brake pedal and the master cylinder. The vaccum booster input push rod is connected to brake pedal while the output push rod

36

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BRAKES WORKING PRINCIPLE BRAKE OFF Fig. 54 The diaphragm is fully retracted and is held against the rear shell by the diaphragm return spring. The input rod assembly is also fully retracted by the brake pedal return spring, as far as the stop key, or valve retaining plate will allow. With the input rod in this position, the vacuum port is open and there is vacuum on both the sides of the diaphragm. BRAKE APPLIED Fig. 55 When the brake pedal is depressed, the input rod assy moves forward inside the diaphragm plate until the control valve closes the vacuum port; at this juncture vacuum is still present on both the sides of the diaphragm. As the input rod continues to move forward, the control plunger moves away from the control valve, opening the atmospheric port, which is formed between these two parts. Air enters the rear shell behind the diaphragm and the effect of atmospheric pressure assisted by the valve rod helps in pushing the diaphragm plate forward and thus the output rod actuates the Master Cylinder Plunger.

Fig. 54

BRAKE HELD ON Fig. 56

BRAKE

When the brake pedal is held on, the diaphragm will momentarily continue to move forward and so compress the outer edges of the reaction disc. This movement causes the centre of the disc to extrude, pressing back the input rod and thus closing the atmospheric port. Thus the output force is balanced against that of the input force. Further movement of the brake pedal either opens the vacuum port or the atmospheric port depending on whether the brake pedal is released or depressed.

Fig. 55

Fig. 56

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37

BRAKES BRAKE RELEASED Fig. 57 Immediately after the brake pedal is released, the vacuum port is opened and the atmospheric pressure in the rear chamber is extracted into the front chamber and from there to the inlet manifold via the non-return valve. The atmospheric port remains closed whilst the input rod assy returns to its original position, as shown. The diaphragm is then again 'suspended' in vacuum until the brake pedal is depressed. BOOSTER REMOVAL Disconnect the vacuum hose from the booster. Remove the booster input rod clevis pin from the brake pedal and remove the booster mounting nut (2 Nos.) from control mounting bracket. Unscrew the booster mounting nuts from the firewall end (2 Nos.) and remove the booster from the vehicle. Fig. 58

Fig. 57

SERVICING The parts available to service the unit are - a filter a non-return valve kit and a service kit. Servicing of the internal parts is not recommended and if a major fault is apparent, a new complete guaranteed unit should be fitted. The air filter should be changed every 40000 kms. or two years. If dusty conditions prevail, the filters should be changed more frequently. The output rod is retained internally and cannot be extracted. If the rod or the domed screw on the rod end is damaged the Supervac Unit must be replaced complete.

Fig. 58

No attempt should be made to disturb the domed screw. This is correctly set at the factory and should never be disturbed.

900

REPLACING THE FILTER Fig. 59 Pull back the dust cover and filter retainer. Hook out the filters and cut to remove from the input rod. Cut the new filter, press into the neck of the valve body as shown and refit the filter retainer and dust cover. If the dust cover is damaged fit a new one from Repair Kit.

Fig. 59

38

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BRAKES REPLACING THE NON RETURN VALVE Before removing the non-return valve note the angle of the same in relation to the front shell so that the new valve can be fitted in the same position. The non-return valve fitted is a push-in type valve. To remove this valve insert a flat bladed screwdriver between the rubber grommet and valve collar, lever the valve from the grommet. Then remove the grommet from the front shell and make sure that even by mistake you do not drop the same into the vacuum chamber. Fit the new grommet. Lubricate the ribs of the new non-return valve with castor oil and push fully into the grommet.

Fig. 60

INSTALLATION OF THE BOOSTER Assemble the booster to the control-mounting bracket through firewall panel. Ensure that booster push rod stand out dimension is 115 + 0.5 mm. Fig. 61 Install the input rod pin (smear pin with molykote grease) clevis to the brake pedal with the split pin.

BRAKE

Ensure that clevis pin is free to rotate. Tighten the booster mounting nuts from both sides to the specified torque. Fig. 60 Assemble master cylinder on to booster. Ensure correct orientation of ports & NRV. Tighten the nuts to the specified torque. (Refer table Page 2) Connect the vacuum hose to the booster and fill the master cylinder reservoir with recommended brake fluid.

115 +0.5

Booster Push Rod Length From Mtg. Face to Hole Center

Brake Pedal

Fig. 61

Bleed the system - refer brake bleeding procedure.

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39

BRAKES CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF VACUUM BOOSTER Engine Off : Depress and release brake pedal several times to remove vacuum from the system.

Depress pedal and hold with light pressure (7-12 kg) and start engine.

If vaccum booster is operative, pedal will fall slightly and then hold. Less pressure will be needed to hold pedal down, than with the engine in 'off'' condition.

If vaccum booster is not operative disconnect the vacuum hose from the vaccum booster nonreturn valve. Then with engine running, check the vacuum supply with a vacuum gauge. There should be atleast 20” of vacuum.

If vaccum booster is operative, do the vacuum leak test as given.

If vacuum supply is below 20 “ replace or repair the vacuum hose and vacuum fittings. If the vacuum supply is 20" or more the vaccum booster is defective and should be replaced with new vaccum booster Assemby.

With new hose fitting repeat the basic test.

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BRAKES VACUUM LEAK TEST

Run the engine to medium speed. Release the accelerator and turn the engine off. This builds up vacuum.

Wait 90 seconds and apply the brakes. Two or more applications should be vaccum booster assisted.

If the applications are vaccum booster assisted, there is no vacuum leak.

If the applications are not vaccum booster assisted disconnect the vacuum hose from the non-return valve. Then attach a short length of hose to the valve.

Blow air through the hose. The valve is defective if air passes through.

BRAKE

If the non-return valve is defective install a new non-return valve and repeat the vacuum leak test.

INDEX

If the non return valve is OK, the vaccum booster is leaking. Replace the vaccum booster with a new kit.

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41

BRAKES PRESSURE CONSCIOUS REGULATING VALVE (PCRV) (for non ABS version only) Fig. 62

•

The purpose of this valve is to regulate hydraulic pressure to rear brakes.

•

It is necessary to regulate hydraulic pressure to rear brakes to avoid rear wheel locking and skidding of the vehicle.

•

This valve is used in between the brake master cylinder and the rear brakes.

•

This unit is not serviceable and has to be replaced as an assembly only.

INLET

PCRV

Fig. 62

42

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OUTLET

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BRAKES PARKING BRAKE PARKING BRAKE LEVER

PARKING BRAKE ADJUSTMENT EQUALISER

PARKING BRAKE CABLE

PARKING BRAKE CABLE

BRAKE

BRAKE DRUM BRAKE DRUM

SEMITRAILING ARM LH SEMITRAILING ARM RH

Fig. 63

PARKING BRAKE The parking brake arrangement is cable operated console mounted mechanical type brake acting on rear wheels. The hand brake lever situated in the cab operates it. When the hand brake lever is pulled up, the parking brake lever arrangement in the rear brake assembly inside the rear brake drum brake is also pulled through the cable system. This action expands the rear brake shoes against the drum, thus applying the rear brakes. Fig. 63 PARKING BRAKE HANDLE CONSTRUCTION Fig. 64

INDEX

This is a safety device so designed that the parking brake does not get released accidentally. To release parking brake, lift the handle slightly and keeping release button pressed, push down the lever fully. When release button is pushed as above, pawl rod also gets pushed, disengaging pawl from ratchet, thus releasing the parking brake. REMOVAL OF PARKING BRAKE LEVER Place wheels chocks at the rear wheels.

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43

BRAKES Remove the parking brake cover plate located in the cabin. Remove the parking brake adjustment nut and the spacer and remove the equalizer and the central locator from the parking brake lever. Fig. 64 Remove the console and disconnect the electrical connection to parking brake lever. Unscrew the parking brake lever mounting bolts and take out the lever. REMOVAL OF PARKING BRAKE CABLE Remove the brake drum - refer Removal brake drum. Remove the parking brake clip from the rear brake assembly. Disconnect the parking brake cable from the shoe lever - refer Brake shoe removal.

Fig. 64

Remove the cable from the rear brake assembly. Loosen the parking brake slackness adjustment nut and disconnect the parking brake cable from the equalizer. Remove the parking brake cable snap fit from the cablemounting bracket located inside the cabin. Remove the cable grommet from the shell. Fig. 65 Now disconnect all the parking brake cable clamps from the body mountings. INSTALLATION OF CABLE Install the cable in the reverse order of removal. Note

Fig. 65

Fit the cable to the brake shoe lever. Fit the parking brake cable clip to the brake back plate securely. Fig. 66

Fig. 66

44

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BRAKES INSTALLATION OF PARKING BRAKE LEVER Fig. 67 Proceed in the reverse order of removal. Tighten the mounting bolts of the parking brake lever to the torque specified. PARKING BRAKE ADJUSTMENT NUT

Adjust the parking brake cable slackness as per the procedure given. Reconnect the electrical connections to the parking brake switch assembly and confirm that the parking brake lamp becomes "ON" when parking brake lever is at first notch. PARKING BRAKE CABLE ADJUSTMENT Before parking brake cable slackness adjustment confirm the following conditions.

Fig. 67

Bleeding should be completed. (i.e. there should not be air trapped in the brake system). PARKING BRAKE APPLIED

Confirm pedal travel by depressing the brake pedal for few times. Check the lining condition of the rear brake it should not have been worn out beyond limit. After confirming all the above points start adjusting the parking brake lever stroke by either loosening or tightening the self locking slackness adjustment nut.

RELEASE BUTTON

PARKING BRAKE LIGHT SWITCH

Parking Brake Lever Stroke When a force of 20 kg is applied to pull up the lever.

Travel should be within 3rd - 6th notch.

After adjustment check for dragging of rear brake drum.

Fig 68.

INSPECTION OF PARKING BRAKE : Pull the parking brake lever at its centre by 20 kg force, with this force the travel should not exceed 5th notch position. Fig. 68 Check both the wheels are locked in this condition and release the lever (i.e. take it to the notch) and check for free rolling of the wheels. For counting the notches easily, listen to the click sound from the ratchet while pulling the parking brake lever without pressing the button. A click sound pertaining to each notch movement.

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45

BRAKE

BRAKES TROUBLE SHOOTING OF BRAKE SYSTEM HEADING

CAUSE

SPONGY BRAKE PEDAL1. Air in hydraulic system

BRAKE ROUGH OR CHATTER ON APPLICATION

EXCESSIVE BRAKE PEDAL EFFORT (HARD PEDAL)

REMEDY 1. Bleed the system and top up.

2. Soft or weak hose

2. Check and Replace

3. Poor quality brake fluid

3. Flush the system and refill with recommended grade of brake fluid.

4. Excessive worn / Weak drums in Rear

4. Replace

1. Excessive lateral run out in disc or 1. Repair if possible or replace the parallelism disc. not within specification. 2. Rear drum out of round

2. Check runout, repair or replace drum as necessary.

3. Broken anti-rattle clip

3. Replace

4. Incorrect parking brake adjustment

4. Check and adjust as per specifications.

5. Seized caliper pistons

5. Overhaul Calipers

6. Damaged or loose wheel bearing

6. Replace wheel bearing

7. Distorted steering knuckle or rear wheel spindle

7. Replace knuckle or rear wheel spindle

1.Lining soiled with brake fluid, oil or grease. 2. Brake pad worn below recommended thickness.

1. Replace

3. Malfunctioning of Servo.

3. Identify the trouble in Servo and rectify

4. Partial system failure (in tandem master cylinder).

4. Check both front and rear circuits and rectify.

2. Replace

5. Piston in calipers stuck or sluggish 5. Remove caliper and rebuild 6. Fading brake due to non recommended grade of brake pads.

6. Replace with approve grade of brake pads.

7. Kinked, dented or clogged bundy pipes, hoses or 'T' connections.

7. Identify and Replace

8. Binding pedal linkage

8. Lubricate and free up the system.

46

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BRAKES HEADING BRAKE NOISE

EXCESSIVE PEDAL TRAVEL

CAUSE

REMEDY

1. Glazed shoe linings or foreign matters stuck on linings

1. Repair or replace shoe linings.

2. Worn or distorted shoe linings

2. Replace shoe linings or pads

3. Loose front wheel bearings

3. Replace wheel bearing

4. Distorted backing plate or loose mounting bolts.

4. Replace or retighten

1. Incorrect pedal free play

1. Adjust as per specification.

2. Partial brake system failure either in dual circuit or in Master Cylinder

2. Identify and repair by replacing necessary parts.

3. Air in system (pedal soft / spongy) 3. Bleed and top up with recommended brake fluid.

GRABBING OR PULLING OF CAR

4. Soft or bulging hose

4. Replace

5. Excessive clearance between lining and drum in rear brakes due to malfunctioning of auto adjusters.

5. Check auto adjuster mechanism

6. Lining pad knock back caused by loose or worn wheel bearing or other related parts.

6. Adjust or replace faulty parts as necessary.

7. Insufficient fluid in master cylinder reservoir

7. Fill reservoir with approved brake fluid check for leak and air in brake system. Check warning light, bleed system if required.

8. Ben brake shoes or shoes worn out.

8. Replace brake shoes.

1. Incorrect type pressure (or) inflated unequally.

1. Inflate both front tyres to the recommended pressure.

2. Wrong wheel alignment.

2. Check and adjust as per recommended procedure

3. Loose suspension parts

3. Check all suspension mountings and tighten

4. Incorrect parking brake adjustment on rear brake.

4. Check and adjust to correct specification.

BRAKE

Note : If the above problems are not there then proceed further with the checking of brakes for grabbing.

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47

BRAKES HEADING

CAUSE

REMEDY

5. Drum to shoe clearance out of adjustment (malfunctioning auto adjusting mechanism).

5. Check for auto adjusting mechanism.

6. Loose caliper mounting

6. Tighten to specified torque.

7. Restricted brake pipes or hose

7. Check for soft hoses and damaged line, replace parts as necessary.

8. One side caliper piston stuck.

8. Remove and rebuild caliper, lubricate the caliper slide bush properly.

9. One side brake pad / shoe lining soiled with brake fluid, oil or grease

9. Replace

10.Caliper not aligned with Disc

10.Align properly.

11. Disc or drum is out of round.

11. Align properly.

12.Weakened or broken return springs in the brake.

12.Replace

13.Sluggish parking - brake cable or linkage

13.Repair or replace

14.Master cylinder piston not returning correctly.

14.Repair master cylinder.

BRAKE WARNING LIGHT 1.Parking brake lever in applied LIGHTS AFTER ENGINE condition. START

1. Release parking brake and check that brake warning light turns off.

2. Brake fluid level very low.

2. Add brake fluid

3. Leakage of brake fluid.

3. Investigate and correct leaky point. Add brake fluid.

4. Brake warning light circuit faulty

4. Repair circuit.

BRAKE WARNING LIGHT 1. Leakage of brake fluid. TURNS ON WHEN BRAKE IS APPLIED 2. Brake fluid level very low.

BRAKE WARNING LIGHT 1. Brake warning light circuit faulty FAILS TO TURN ON EVEN WHEN PARKING BRAKE IS APPLIED.

1. Investigate and correct leaky point. Add brake fluid. 2. Add brake fluid.

1. Repair circuit or Replace bulb.

48

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BRAKES

INTRODUCTION :

Dual circuit, diagonal split hydraulic brakes through tandem master cylinder have been provided. The front brakes are ventilated disc brakes with floating type calipers while the rear brakes are drum brakes with self-shoe clearance (automatic) adjustment. No adjustments are required for front and rear brakes. The parking brake is a mechanical lever type, console mounted cable operated, acting on rear wheels. BRAKE

Pressure conscious regulating valves are provided on both circuits for the rear brakes to avoid locking of rear wheels and skidding of the car. For car fitted with ABS system, please refer the seperate section on ABS.

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i

BRAKES CONTENTS Sr. No.

1. 2. 3.

3. 4.

5.

6. 7. 8.

9. 10. 11.

Description

Page No.

Technical Specification Tightening Torques Exploded Views : a) Servo and tmc assembly (9 inch, ø22.22) b) Caliper Assembly C - 54 c) Rear brake assembly (HASF ø200x30) d) Parking brake system e) Hydraulic lines - Non ABS Version - RHD How does your car’s brake work Front Brakes : a) Salient Features b) Caliper Operation c) Front Brake Service [Removal / Inspection / Installation of Pads, Calipers & Disc] Rear Brakes : a) Working of Hydraulic auto adjust service brake b) Rear Brake Service [Removal / Inspection / installation of Drum, brake shoes, Back Plate, & wheel cylinder] Bleeding of Hydraulic system Tandem Master Cylinder(for Non - ABS version) Vacuum Booster a) Working Principle b) Servicing c) Check list for ensuring satisfactory functioning of vacuum booster d) Vacuum Leak Test Pressure Conscious Regulating Valve (PCRV) Parking Brake [Removal, Installation & Adjustment] Troubleshooting of Brake system

INDEX

GROUP INDEX

1 2 3 4 5 6 7 8 9 9 10 11

21 23

BRAKE

30 33 36 37 38 40 41 42 43 46

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iii

BRAKES TECHNICAL SPECIFICATION BRAKES Type

FRONT

REAR

Single pot floating type caliper

200 dia x 30 mm Leading Trailing shoe type

Piston diameter - 54 mm

Wheel cylinder dia - 17.46 mm

2

Brake Lining Area

80 cm per brake

115 cm2 per brake

Lining Grade

RBL-AF-L6755 DP-23

TVS AF 2046

(Grey Colour) Type of Lining

Moulded non asbestos

Bonded Lining - non asbestos

Brake Details

Disc diameter - 231 mm

Drum inside dia - 200 mm

Disc thickness - 20 mm

Max. rebore dia - 202 mm

Discard Thickness - 18 mm

Out of round - 0.04 mm

Lateral runout - 0.05 mm Replacement service limits for pad /lining

6 mm

Tandem Master Cylinder

Type Size Material Finish Stroke Circuit

- AS/AS (for non ABS) & CV/CV (for ABS) - 22.22 mm dia - Aluminium - Anodized - 30 mm (Primary - 15 mm and Secondary - 15 mm) - Diagonal (Primary to Front Right / Rear and Left Secondary to Front Left / Rear Right)

Type

- LSC 65

Size

- 9 Inch

Boost Ratio

- 5:1

Vacuum Booster

2.6 mm

Pressure Conscious Regulating Valve (PCRV) For non ABS version

Valve Ratio : 3:7:1 Cut-in Pressure : 20 kg/cm2 Location : Rear Circuit

Brake Pedal

Free Play

- 8 mm

Height

- 200 mm

Stroke

-140 mm (Available)

Type

- IS8654 / DOT 3 / DOT 4

Capacity

- 0.270 Litres

Brake Fluid

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BRAKE

1

BRAKES TIGHTENING TORQUES : Sr. No.

Description

Torque in kg-m

1.

Booster mounting bolt to firewall

2.2 - 2.5

2.

Mounting nuts of master cylinder to vaccum booster

1.0 - 1.6

3.

All brake pipe lines joints (coupling nut)

1.4 - 1.6

4.

3 Way ('T') connector mounting to firewall

0.8 - 1.0

5.

Front caliper, retaining bolt to steering knuckle

7.0 - 8.0

6.

Front caliper carrier retaining bolt

2.2 - 3.2

7.

Front brake hose mounting (banjo) to caliper

2.3 - 2.5

8.

Front caliper bleed screw

0.7 - 1.0

9.

PCRV mounting to floor (for non ABS version)

0.6 - 0.8

10.

Rear stub axle castle nut

10 - 12

11.

Rear brake assembly to stub axle

4.2 - 5.0

12.

Rear wheel cylinder mounting to brake plate

1.0 - 1.3

13.

Rear brake hose / pipe mounting to wheel cylinder

1.4 - 1.8

14.

Rear wheel cylinder bleed screw

0.6 - 0.9

15.

Brake pipe line / parking brake cable clamps to shell

0.5 - 0.6

16.

Parking brake lever mounting to mounting plate

0.8 - 1.0

17.

Parking Brake Mounting plate to floor

0.8 - 1.0

18.

Parking brake cable clamp to long link bracket

0.8 - 1.0

19.

Dowels to front disc with hub / rear brake drum

0.6 - 0.8

20.

Wheel mounting bolts

7.9 - 8.1

21.

Vacuum line clamps

0.6 - 0.8

SPECIAL TOOL 1.

Spanner for brake bleeding

2779 5890 42 01

2

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BRAKES EXPLODED VIEW OF SERVO AND TMC ASSEMBLY (9 INCH, Ø22.22)

FILLER CAP ASSEMBLY (WITH FLWI)

FILLER CAP ASSEMBLY (WITH FLWI)

○

○

○

FLUID RESERVOIR SUB ASSEMBLY (WITHOUT FLWI) # * SEAL FLUID TANK

○

○

# * SEALING RING

# * SEAL - RECUPERATING # * SEAL GLAND PRIMARY # * SEAL GLAND SECONDARY 1.0 to 1.6

# * CIRCLIP

SPRING WASHER # PLUNGER SECONDARY

# STOP PIN # * WASHER (STOP PIN)

# PLUNGER ASSEMBLY PRIMARY # STOP WASHER BRAKE

# SPACER

GROMMET

2.0 to 2.5

FILTER

NON RETURN VALVE ASSEMBLY * - MAJOR REPAIR KIT

INDEX

DUST COVER

# - MINOR REPAIR KIT

GROUP INDEX

- SPECIFIED TORQUE IN Kgm

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3

BRAKES

CALIPER ASSEMBLY C - 54

ANTIRATTLE CLIP

PAD ASSEMBLY PAD SHIM # * DUST BOOT

0.7 to 1

# PISTON # * DUST CAP

@ # * SLIDING PIN BOOT @ SLIDING PIN @ # * GREASE SACHET

# * SEALING RING

@

2.2 to 3.2

- SPECIFIED TORQUE IN Kgm

# - MAJOR REPAIR KIT * - MINOR REPAIR KIT @ - SLIDING PIN KIT

4

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BRAKES EXPLODED VIEW OF REAR BRAKE ASSEMBLY (HASF Ø200X30) 1.0 to 1.3

BACK PLATE ASSEMBLY - LH/RH WHEEL CYLINDER HOUSING

# DUST CAP

GROMMET

BLEEDING SCREW

# * DUST COVER

PIN

* PLUNGER # * GLAND SEAL

BRAKE

PIN - HAND BRAKE LEVER LEVER HAND BRAKE LH/RH CIRCLIP STRUT AND QUADRANT

SPRING SHOE RETURN

LINED SHOE ASSEMBLY

SPRING STRUT RETURN

SPRING SHOE RETURN CLIP - SHOE HOLD DOWN * - MAJOR REPAIR KIT

INDEX

# - MINOR REPAIR KIT

GROUP INDEX

- SPECIFIED TORQUE IN Kgm

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5

BRAKES PARKING BRAKE SYSTEM CENTRAL LOCATOR

EQUILISER HAND BRAKE SWITCH 0.8 to 1

ASSEMBLY PARKING BRAKE LEVER COMPLETE

EXTENSION SLEEVE

0.8 to 1

CLAMP

R CLAMP

0.6 to 0.8

ASSEMBLY PARKING BRAKE CABLE

CLAMP

CLIP NOTE : CABLE SLACKNESS ADJUSTMENTS BY HAND TIGHT

6

INDEX

GROUP INDEX

- SPECIFIED TORQUE IN Kgm

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BRAKES HYDRAULIC LINES - NON ABS VERSION - RHD ASSEMBLY TUBE-TMC PRI. PORT TO FRONT BRAKE RH

VACUUM BOOSTER AS/AS

ASSEMBLY TUBE BRAKE HOSE REAR RH TO WH CYL. RH REAR WH CYL RH

FRONT CALIPER RH

ASSEMBLY VACUUM PIPE MPFI RHD

HOSE CLAMP 20 ASSEMBLY TUBEASSEMBLY BRAKE REAR RH CONNECTOR HOSE REAR TO PCRV RH SIDE ASSEMBLY TUBEPCRV ASSEMBLY TMC PRI. PORT CONNECTOR LH

ASSEMBLY TUBETMC SEC. PORT TO 3 WAY CONNECTOR 0.8 to1

ASSEMBLY TUBET CONNECTOR TO FRONT BRAKE LH

ASSEMBLY TUBE3 WAY CONNECTOR REAR RH CONNECTOR

ASSEMBLY TUBEPCRV RH TO REAR BRAKE HOSE RH

FRONT CALIPER LH ASSEMBLY TUBECONNECTOR LH TO PCRV LH

3 WAY UNION (T CONNECTOR)

ASSEMBLY TUBEPCRV LH TO REAR BRAKE HOSE LH

BRAKE

REAR WH CYL LH 2.3 to 2.5

CONNECTOR (BRAKE CIRCUIT)

ASSEMBLY BRAKE HOSE FRONT

SEALING WASHER

PCRV ASSEMBLY CLIP (BRAKE HOSE)

0.8 to 1

SLEEVE

CLAMP

SLEEVE

0.6 to 0.8

CLAMP 0.6 to 0.8

0.6 to 0.8

COATED SINGLE CLAMP

CLAMP (PIPE 4.75X4.75)

NOTE : ALL COUPLING NUT TORQUE - 1.4 TO 1.6 Kgm

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0.6 to 0.8

COATED DOUBLE CLAMP - SPECIFIED TORQUE IN Kgm

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7

BRAKES

REAR RIGHT SIDE

RIGHT SIDE 3

7

1

9

8 4 10

2

5 11 6 9

8 7

LEFT SIDE

REAR LEFT SIDE PRIMARY CIRCUIT SECONDARY CIRCUIT PARKING BRAKE SYSTEM

Fig. 1 - Schematic circuit diagram of brake system (Non ABS version).

1.

VACUUM BOOSTER

2.

TANDEM MASTER CYLINDER

3.

PRIMARY PORTS

4.

SECONDARY PORT

5.

‘3’ WAY CONNECTER

6.

STRAIGHT CONNECTER

7.

PRESSURE CONCIOUS REGULATING VALVE

8.

BRAKE CALIPER

9.

REAR WHEEL CYLINDER

HOW DOES YOUR CAR’S BRAKE WORK : Fig. 1 When the brake pedal is depressed, hydraulic pressure is developed in the Tandem Master Cylinder, which is used to actuate the brake (two in front and two in rear).

10. PARKING BRAKE LEVER ASSY. 11. PARKING BRAKE CABLE WITH GROMMET

The brake pipes are connected from the tandem master cylinder to the brakes. They make two independent circuits diagonally split. The primary circuit connects the Front Right and the Rear Left brake while the secondary connects Front Left and Rear Right brake through a 3-way connector. Pressure conscious regulating valve is provided at the rear brake to avoid rear brake locking and skidding of the vehicle. The parking brake system is of mechanical type. It applies brake force to only rear wheels by means of the cable and mechanical linkage system.

8

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BRAKES

8 9

Fig. 2 6 4 3 7 2 5 11

9 1

10 12

7 5 BRAKE

SR. NO. 1 2 3 4 5 6

DESCRIPTION CALIPER HOUSING SEALING RING PISTON DUST BOOT SLIDING PIN PAD ASSEMBLY

SR. NO. 7 8 9 10 11 12

DESCRIPTION SLIDING PIN BOOT CARRIER ANTI RATTLING CLIP BLEED SCREW DUST CAP SLIDING PIN BOLT

12

Fig. 3 - Exploded view of caliper assembly

FRONT BRAKES Ventilated disc brakes with Colette type single pot caliper of 54 mm piston diameter are provided for front brake. SALIENT FEATURES OF DISC BRAKES (Fig.2&3) : Colette type Caliper assy consists of a caliper carrier bolted to the knuckle and the body assy slides on two guide pins used in the carrier. The sliding pins are sealed against water and dust by sliding pin boots thereby avoiding possible unequal sliding loads caused by dirt, corrosion. Drag of the pads is taken directly by the Carrier, consequently the pins are loaded only by the weight of the caliper body.

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When the brake pedal is pressed, the hydraulic pressure from Tandem Master Cylinder pushes the piston in the caliper pot and with it the in-board pad on to the disc. The caliper body reacts and slides on the sliding pins to bring the out-board pad into contact with the disc. Thus the clamping forces on both sides of the disc become equal. When the hydraulic pressure is released, upon release of the brake pedal the sealing ring fitted in the groove of the caliper pot retracts the piston by a small amount which allows the moving parts to relax sufficiently for the disc pads to retract and remain in close proximity to disc, ready for the next brake application.

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9

BRAKES CALIPER OPERATION (Fig. 4) Single Piston Floating Caliper A single piston floating caliper type disc brake is employed in this model. A cylinder and a piston are used for this type (The cylinder is constructed as a monoblock with the caliper). Fluid pressure generated in the tandem master cylinder causes the pad (1) on the piston side to press against the disc. At the same time, the floating type caliper body is moved to the right by the cylinder pressure, as shown in Figure 3, which pulls pad (2) against the disc and hence applying brakes. The disc brake has no servo assistance as in drum braking, and it is necessary to increase the working pressure of the piston and pad. For this purpose, the caliper cylinder has a large bore. A little change in clearance between the disc and the pad causes large influence on the brake pedal stroke. It is always necessary to have the clearance adjusted to the minimum. The clearance adjustment is done by means of the piston (rubber) seal.

CYLINDER

PISTON SEAT (RUBBER SEAL)

Clearance Correction When fluid pressure is applied on the piston, the piston moves forward. The rubber seal, which exerts considerable pressure against the piston, is fixed into a groove in the caliper, hence the shape of the rubber seal is distorted at the I.D. as shown in Fig 3. When pressure is withdrawn from the brake pedal and fluid pressure is released from the piston, a restoring force is generated by the seal and it pushes the piston back to its original position. As the pads wear the clearance between the disc and the pads becomes larger, hence the piston has to move a larger distance. The seal then could change in shape further but, since the seal is fixed into the groove in the cylinder, the distortion is limited to the same amount as previously described. The piston moves further to cover the distance of clearance relative to the seal in the case. The piston returns by the same distance and the rubber seal recovers its shape as described above and thus the clearance between the disc and pads are maintained by adjustment automatically.

PISTON HYDRAULIC PRESSURE ‘OFF’

CYLINDER

PISTON SEAT (RUBBER SEAL)

The caliper brake needs no adjustment. PISTON HYDRAULIC PRESSURE ‘ON’

Fig. 4

10

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BRAKES REMOVAL OF PADS Apply the parking brake lever. Keep the gear shift lever in neutral position. Jack up front of the car ; support with stands and remove both front wheels. Visually inspect pads for wear and caliper for brake fluid leakage. If they are found to have worn, proceed as follows to replace them. Loosen and remove bottom sliding pin bolt with 12 mm spanner. Fig. 5 Swing up the caliper and hold with one hand. Remove both the pad assy one by one. Fig. 6

Fig. 5

NOTE : If you find any difficulty in swinging the caliper up, after removing the sliding pin retaining bolt, it may be necessary to push the caliper piston back along with the pad, using a screwdriver.

BRAKE

Fig. 6

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11

BRAKES INSPECTION OF PADS : Measure pad thickness (with lining) with a Vernier and if the thickness is found to be less than 6 mm any where in the pad, it is time to replace them Fig. 7

CALIPER PAD ASSEMBLY

Caution : Do not polish the pads with sand paper or emery paper. If the pads are polished with emery or sand paper, hard particles of sand paper will be deposited in pad and may damage the disc. Whenever pads require correction, replace them with new ones. Always use genuine recommended pad for replacement. Do not contaminate the pad surface with grease or oil.

Fig. 7

Thoroughly clean the disc. If it is scored exessively, replacement of new pads alone do not give optimum performance and service life. Hence follow instructions as given to recondition the disc. If there is no visible deterioration in piston dust boot and sliding pin boot, new pads can be fitted.

ANTIRATTLING CLIPS SLIDING PIN BOOT

Check for the condition of the anti rattling clips and if found without any damage the same clips can be fitted after cleaning.

SLIDING PIN

INSTALLATION OF PADS :

SLIDING PIN BOLT

Insert both the pads in between the carrier (Fig. 8) and disc in the stub axle such that the friction material is towards the disc and ensure proper seating of the anti rattling clips.

PAD FRICTION MATERIAL TOWARDS DISC

Fig. 8

12

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BRAKES After inserting, push both the pads against the disc with both hands and swing down the caliper and fit bottom sliding pin bolt. Tighten the sliding pin bolt to specified torque. Fig. 9 Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and make sure that the pads are sitting square with the disc without any tilt. Follow same procedure for the other wheel also. Fit wheel; jack down the vehicle. Tighten wheel mounting bolt to specified torque. Fig. 10

SLIDING PIN BOLT

Fig. 9

CAUTION : Apply brake couple of times with the engine started before taking the vehicle for a road test. Before applying an emergency brake, it is advisable to apply the brake gently several times at 50 kms per hour speed to allow the brakes pads to align. BRAKE

Heavy braking or prolonged braking should be avoided in the initial 100-150 kms of run until the new pads are bedded.

Fig. 10

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13

BRAKES DISMANTLING OF CALIPER : Apply the parking brake and keep the gear shift lever in neutral lever. Jack up the front of the vehicle, support on stands and remove wheels. Remove brake hose banjo bolt from the caliper. Fig. 11 Collect the brake fluid from the brake hose / caliper in a clean container. Block the bundy pipe using a dust cap to prevent loss of brake fluid and prevent contamination. As explained in fitment of new pads, remove pads by swinging the caliper. Unscrew the carrier mounting bolts and remove the caliper assembly.

Fig. 11

Clean the caliper assembly externally with a rug. Separate the carrier from the caliper housing. The housing can be taken out from the carrier by sliding it out while releasing the sliding pin boot from the carrier. Take out the remaining sliding pin left in the carrier by releasing the sliding pin boot from the carrier. Remove hose from Caliper body.

DUST BOOT PISTON

COMPRESSED AIR

Remove sliding pin from the housing by taking out sliding pin bolt after loosening. Keep a wooden piece in between the piston and the caliper housing and blow compressed air into the caliper gradually through the inlet port (where banjo bolt get connected). Fig. 12 Now you will observe the piston coming out of the caliper gradually. After cleaning the surfaces remove the dust boot from caliper housing by pulling the same with fingers. Fig. 13 Take out the piston from the housing and remove the boot from the piston.

WOODEN PIECE

Fig. 12

DUST BOOT

COMPRESSED

Fig. 13

14

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BRAKES Remove Sealing Ring from the groove in the caliper housing. Fig. 14 Remove the bleed screw from caliper housing. NOTE : 1.

Care is to be taken while removal so as to avoid puncturing of the dust boot.

2.

If punctured the dust boot should be replaced.

3.

Do not apply high compressed air, which will cause piston to jump out of the cylinder. It should be taken out gradually with moderately compressed air @ 2 bar. Do not place your fingers in front of piston when using compressed air.

4.

Care is to be taken not to damage inner bore of the cylinder.

SEALING RING

Fig. 14

INSPECTION OF CALIPER : Clean all the parts thoroughly with fresh brake fluid. Please do not use mineral oil like kerosene, petrol, diesel etc. After thoroughly cleaning, examine all the parts for damages and corrosion.

BRAKE

Piston : (Fig. 15) Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface.

BOOT

PISTON

Fig. 15

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15

BRAKES Piston Sealing Ring : (Fig. 16) Piston Sealing Ring is used to seal piston and cylinder and it is used to adjust the clearance between pad and disc. Replace the piston-sealing ring with a new one at every overhaul. Fit piston-sealing ring into groove in the cylinder taking care that it should not be twisted.

Fig. 16

CALIPER HOUSING : (Fig. 17) Bore should be free from score, pitting, and corrosion. The seal groove in the bore should be thoroughly cleaned and no nicks should be there at the edges. If the above conditions are quite satisfactory then replacement with appropriate kit will give satisfactory performance. If not the caliper assembly should be replaced. SLIDING PINS : It should be free from rust and bends and sliding pin boots should be soft and free from cracks or puncture. If in doubt, replace them. Fig. 17

INSTALLATION OF CALIPER : Smear the sealing ring with fresh brake fluid and fit it on to the groove in the caliper pot and work around with fingers until it is properly seated. Fig. 18

FITMENT OF SEALING RING

Smear fresh brake fluid to the piston surface. Fit dust boot in to the caliper groove.

Fig. 18

16

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BRAKES Assemble seal and boot in the respective grooves. Fig. 19 Apply compressed air at low pressure (@ 2 bar) through the supply port of caliper by nozzle or through valve. Fig. 20 Locate the piston on boot with the help of short hand bar. Air flow will get restricted and the dust boot will balloon on all sides. Make sure all sides of the boot has covered the piston. Insert the piston by pushing the hand bar against air pressure through caliper. So that piston can be pushed into the housing easily. Ensure that seal does not get damaged due to excessive push. If required slightly swivel the piston for the ease of entry.

DUST BOOT COMPRESSED AIR

Fig. 19

The moment you get a feel that piston has entered the seal immediately stop air flow then push the piston to the bottom of caliper. Ensure the outer end of the dust boot is properly seated in the piston groove and check for free movement of the piston. Smear sliding pins with special red rubber grease. Insert the loose sliding pins into the holes of the carrier and fit the sliding pin boots.

DUST BOOT BRAKE

PISTON

COMPRESSED AIR

Fit the carrier on the knuckle. Now fit the caliper housing to the carrier in the reverse order of removal. Fit the bottom guide pin dust cover's other end to carrier.

Fig. 20

Sliding Pin : Check pin for smooth movement as shown. If it is not free to move correct for free movement or replace the pin. Fig. 21 Apply red rubber grease to pin outer surface. Fit new pads as explained earlier under "Fitment of New Pads". BOOT SLIDING PIN

Fig. 21

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17

BRAKES Swing back the caliper to its place and fit sliding pins bolt and tighten to recommended torque (Fig. 22). Fit bleed screw. Connect the hose with caliper housing. Ensure new gaskets are used to ensure proper sealing. Before fully tightening make sure that the hose should be free from twists. Assemble front brake hose to caliper feed port as shown and tighten the banjo bolt to the specified torque. Connect bundy pipe nuts to the female end of the hose after removing the dust cap from the bundy tube fitted earlier and tighten to specified torque. DISC REMOVAL :

SLIDING PIN BOLT

Fig. 22

Jack up the front of the car and remove the wheel by removing the wheel mounting bolts. Remove the caliper assembly by loosening the carrier bolts (2 Nos.). Remove Brake disc dowels (2 Nos.) connecting the brake disc to the hub. Fig. 23 Pull the brake disc off by using two M8 bolts.

Fig. 23

18

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BRAKES DISC INSPECTION : Fig. 24 The disc should be free from score marks. If scored, this should be ground and refitted. But at no time more than 0.25 mm should be ground per side. If the total thickness of the disc after grinding is found to be less than disc discard thickness of 18.00 mm, then the disc should be changed. The disc thickness variation to be checked by measuring the thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made at the same distance from the edge of the rotor. After fitment, the face runout of the disc should be less than 0.10 mm. During the measurement confirm that the dial gauge probe be approx. 10 mm from the outer edge of the brake rotor, perpendicular to the disc and under slight preload. Check front wheel bearing for looseness before face runout measurement. The control of the braking surface finish is necessary to avoid pulls and erratic performance. It will also help in extending pad life.

BRAKE

Note : Measure the face runout of the disc and mark the low runout point around the wheel mounting bolt, which is nearest to the low runout point. This is important, as this marked point has to be matched with corresponding high point on the hub.

Fig. 24

This will ensure minimum runout of hub and disc assembly together, this will in turn minimize disc wobbling and uneven pad wear. The other side of the Caliper can be serviced in the same way. INSTALLATION OF DISC : Fig. 25 & 25a Install the disc to wheel hub such that the low runout point on disc matches with the high runout point on the hub and tighten the dowel as per the specified Torque. Install the caliper assembly to the steering knuckle and torque the caliper carrier bolts to specification. Fig. 25. Fig. 25

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19

BRAKES Fit the wheels and torque the wheel mounting bolts to the specified torque.

Fig. 25a

Bleed the brakes as explained under the "bleeding procedure" (Fig. 26,Fig.26a) If bleeding equipment or power bleeding is used to bleed the system, which does not necessitate application of pedal. But you must make sure several brake pedal applications are made to keep the piston free in the bore before taking the vehicle for road test.

a

b

a. Depress brake pedal several times and with pedal depressed, loosen bleed screw a little. b. With brake pedal depressed, retighten the bleed screw.

Fig. 26

Brake Hose and Pipes : Check brake hoses and pipe lines for leakage, crack, damages etc. and replace if necessary. Use light and mirror to inspect hose conditions.

Fig. 26a

20

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BRAKES REAR BRAKES : 1

13

18 12

15

10

16

20 19 14

17

5

4 6

3 9 2 7

8

11

BRAKE

SR. DESCRIPTION NO. 1. 2. 3. 4. 5. 6.

BACK PLATE ASSY LINED SHOE ASSY STRUT AND QUADRANT LEVER HAND BRAKE PIN - HAND BRAKE LEVER CIRCLIP

SR. DESCRIPTION NO. 7. 8. 9. 10. 11. 12.

SR. NO.

SPRING SHOE RETURN SPRING SHOE RETURN SPRING STRUT AND RETURN PIN CLIP GROMMET

DESCRIPTION

13. SCREW 14. 15. 16. 17. 18.

WHEEL CYLINDER BODY PLUNGER GLAND SEAL SPRING DUST COVER

SR. DESCRIPTION NO. 19. BLEED SCREW 20. DUST CAP

Fig. 27 : Exploded view of Rear Brake assembly

WORKING OF HYDRAULIC AUTO ADJUST SERVICE BRAKE (WITH FORWARD PULL HAND BRAKE) Fig. 27

To maintain the shoes square with the drum, both the rims rest on pads formed at suitable place on the back plate.

The hydraulic Auto adjust brake is simple in design, robust in construction with one trailing and leading shoe with bonded linings. The brakes self adjust during brake operation.

The shoe is held against the backplate by means of a shoe hold down clip. Mechanical lever mechanism is incorporated for normal hand brake operation, but the feature of the brake is that the automatic adjustment of the lined shoes takes place when the service brake is applied.

The shoe return spring are fitted from shoe to shoe to provide a positive shoe retraction thus avoiding any possibility of brake "hanging on".

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21

BRAKES To prevent damage to the brake drum due to over adjustment, a mechanism is incorporated on the automatic adjustment mechanism which is indicated by increase in foot pedal travel and hand brake lever movement, that maximum adjustment has been reached and the lined shoes need replacement. The leading and trailing shoes are connected at one end by an abutment plate riveted to the backplate. The other end of the shoes is connected by a twin piston wheel cylinder, hand brake lever and a strut assembly, which incorporates the automatic adjustment mechanism. The hand brake lever operates the trailing shoe whilst the leading shoe is operated by a quadrant lever. Quadrant and the strut are riveted and the quadrant is free to rotate. A hooked spring keeps the quadrant lever in contact with a knurled wheel, which is also riveted to the strut, but the wheel is fixed and does not rotate. When the foot pedal is operated, the brake shoes are pushed on to the drum by the wheel cylinder piston. As the shoe linings wear, the outward movement of the shoes exceeds a predetermined amount and this movement pulls the quadrant lever away from the knurled wheel. The quadrant moves on its pivot pin so that when the brakes are released and shoes move back, the quadrant has moved round on the knurled wheel to reduce the clearance between the brake shoes and drum to the desired minimum clearance. The adjustment is repeated, whenever necessary depending upon the lining wears.

22

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BRAKES REAR BRAKE SERVICE : DRUM REMOVAL : Jack up the car and remove the wheels by removing the wheel mounting bolt.

AUTO ADJUSTER WINDOW

Release the parking brake lever and remove parking brake lever cover. Loosen parking brake cable (slackness) adjustment nut.

LINING INSPECTION WINDOW

To increase the clearance between shoe-to-drum remove back plate grommet attached to the backside of the brake back plate. Insert screw driver till it grips the adjusting lever in Fig. 28. Pull it a little so that the shoe adjuster lever drops thus shoe to drum clearance can be increased.

Fig. 28

Remove wheel cap by slightly tapping at 3 - 4 places by using a mallet. Remove split pin from the spindle and loosen the wheel castle nut. Remove thrust washer and bearing outer race. Now remove the brake drum by mounting puller Part No 2702 5890 3501 over thr holder Part No 2702 5890 3301 Fig. 29

BRAKE

DRUM INSPECTION : Inspect the drum for cleanliness. Check for crack, scores etc. Check braking surface for its wear by measuring the inside diameter. Fig. 30 Brake Drum Inside Diameter

Standard

Service Limit

200 mm

202 mm

Fig. 29

Whenever brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves etc. Visual inspection of wheel cylinders for brake fluid leakage is to be performed. Drum to be discarded, if found cracked, scored exessively or grooved. Do not to weld a cracked drum. It is unsafe and must be replaced.

BRAKE DRUM

Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and it will be necessary to resurface drum-braking surface. If brake linings are slightly worn and drum is grooved, drum should be polished with fine emery cloth but should not be turned.

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Fig. 30

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23

BRAKES REMOVAL OF BRAKE SHOE : For drum removal follow the steps mentioned under drum removal. Push the lever handbrake away from the shoe rim and remove the cable from the operating hook. Using spring-plier remove the shoe return spring at the abutment end and spring at the wheel cylinder end. Fig. 31 Remove the shoe hold down clip from both the shoes. Then remove both the brake shoes from the back plate along with the strut and quadrant assembly, slip on elastic band over wheel cylinder to retain the piston within the cylinder. Fig. 32 Fig. 31

INSPECT BRAKE SHOE / LINING : To maintain the efficiency of the brake system, preventive maintenance is essential. Every 10000 km remove the brake drum and check the lining for wear. The lining must not be allowed to wear down below 1 mm from rim surface. Fig. 33 Increased foot pedal travel and hand brake lever movement is an indication that automatic adjustment mechanism has reached its stop. The lining shoes need replacement in pair on both sides of the axle. Always fit new shoe return spring when fitting new shoe. Do not polish lining with sandpaper or emery paper. If lining is polished with sandpaper or emery paper, hard particles of sandpaper will be deposited in the lining resulting in damage of drum surface.

Fig. 32

Whenever a lining is to be corrected replace it with the new one. Always use genuine grade of service replacement lined shoes. Do not contaminate the lining surface with oil or grease. Brake Lining

Standard

Service Limit

6 mm

2.6 mm

Thickness (Lining + Shoe Rim)

LINED SHOE ASSY.

Fig. 33

24

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BRAKES REMOVAL OF BRAKE BACK PLATE : Fig. 34 For the removal of brake drum and brake shoe lining refer Drum removal and Shoe removal respectively. Remove the brake back plate by removing the four mounting bolt from the stub axle. Clean the back plate and ensure the hand brake quadrant lever are free to rotate easily on the strut. Use graphite grease to lubricate the contact faces of the strut and hand brake lever, strut and the quadrant lever.Fig. 35 Also lubricate the tips of the shoes, the shoe platforms on the back plate and contact areas of the adjuster strut and back plate. Keep the grease away from the shoe linings and all hydraulic parts.

Fig. 34

Inspect the following components, if defective correct or replace. 1.

Ratchet of strut for wear or damage.

2.

Check for damage or weakening of spring.

3.

Check parking brake shoe lever for free movement against brake shoe webs.

BRAKE

Fig. 35

WHEEL CYLINDER SERVICING : Fig. 36 SECTIONAL VIEW OF WHEEL CYLINDER

The wheel cylinder should serviced using parts from appropriate repair kit, provided the plunger and the bore are in good condition without any damage.

Fig. 36

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25

BRAKES REMOVAL OF WHEEL CYLINDER : For removing brake drum, shoe etc. refer respective sections. When removing or servicing wheel cylinders, it is necessary to drain the brake fluid from the system and remove the brake shoes. Attach a transparent (vinyl) bleed tube to the bleed screw having first removing it's rubber dust cap. Fig. 37 Unscrew the bleed screw 1/2 to 3/4 turn Fig. 37 and pump out the brake fluid in a suitable container by operating the brake pedal. Remove the bleed tube. Disconnect the bundy pipe / Hose from wheel cylinder. Remove bleed screw.

Fig. 37

Fix rubber dust cap on to the bundy pipe to avoid brake fluid from spilling and contamination. Remove wheel cylinder mounting set screw and take out wheel cylinder from the backplate. Fig. 38 DISMANTLING OF WHEEL CYLINDER : Fig. 39 Clean the wheel cylinder externally. Remove the dust cover fitted on to the wheel cylinder assembly. Push out the piston with seals. Remove the seals from the plunger using a blunt edged connector. Discard all rubber parts. Clean all parts in fresh brake fluid or alcohol and place them on a clean sheet of paper. Never clean the wheel cylinder or internal parts with kerosene, petrol or diesel as it will lead to contamination and damaging the rubber parts.

Fig. 38

26

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BRAKES WHEEL CYLINDER

4 3

5

7 6 2 1 1. 2. 3. 4. 5. 6. 7.

Dust cover Plunger Gland Seal Dust Cap Bleed Screw Wheel Cyl. Body Spring BRAKE

Fig. 39

INSPECTION OF WHEEL CYLINDER : Examine the wheel cylinder bore and the piston. If they are not scored, corroded or ridged and are smooth to touch, then new seals can be fitted. If there is any doubt about the condition of the bore, a new cylinder must be installed. Inspect the wheel cylinder dust cover for cuts, cracks, hardening or other signs of deterioration. If in doubt, the dust cover needs replacement. If the system has been contaminated with mineral oil of any type, the system should be flushed out with fresh brake fluid or alcohol and all rubber parts including hoses should be replaced. For identification a contaminated seal can be compared with a new seal (but do not allow them to touch). If the old one is appreciably larger, seal contamination is indicated. Whenever wheel cylinders are serviced replace seals and dust covers from appropriate wheel cylinder kit.

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ASSEMBLING OF WHEEL CYLINDER : When properly inspected assemble as follows : Absolute cleanliness has to be maintained and clean brake fluid must be used. Never use brake fluid bled from the system as it may be certainly aerated. Lubricate the wheel cylinder bore liberally with fresh brake fluid. Dip new seals and piston in fresh brake fluid. Fit the gland seal on to the plunger groove in one of the piston and insert the piston with seal into the bore, such that the smaller stem of the piston is facing outside. Reverse the dust cover and fit the smaller dia of the dust cover onto the neck of the piston and fit dust cover on the wheel cylinder. Insert the spring assy in to the bore. Insert the other plunger with seal (Assemble as said before) and fit the dust cover as per step No. 3. Fit a rubber band around the piston to retain them within the bore.

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27

BRAKES INSTALLATION OF WHEEL CYLINDERS : Install the wheel cylinder assembly on to the backplate and with the set screw and the washers. Tighten the wheel cylinder mounting screws to a torque specified. Fit the bleed screw and tighten to the torque specified. Remove the rubber band from the wheel cylinder. Refit the brake shoes as described under "FITTING SHOES". Connect bundy pipe / hose to the inlet port. Refit the drum and wheel. INSTALLATION OF BRAKE BACK PLATE : Clean the back plate. Fit the wheel cylinder to the brake back plate as specified in the installation of wheel cylinder.

Fig. 40

Lightly smear high melting point graphite grease to the back plate back pads and abutment, contact faces of the strut, hand brake lever, quadrant lever etc Fig. 40 2

Keep the grease away from the brake shoe lining. Position the leading shoe on to the back plate, position the trailing shoe with the hand brake lever on the back plate. Position the strut and the quadrant assembly between the leading and trailing shoe web. Two slots are milled on the either end of the struts. One end of the strut is fitted with quadrant. Ensure that the strut return spring LH is fitted properly. The quadrant side of the strut should be located in the leading shoe slot. Fit the spring. Fig. 41

1 1. STRUT 2. RATCHET

Hook the spring at the abutment end (bottom) of the shoe and the spring towards the wheel cylinders end of the shoe. Connect the strut return spring to the trailing shoe and strut. Now fit the shoe hold down pin and the clip on both the shoes. Ensure the correct fitment of the clip by moving either side.

2

Connect the hand brake cable to the hand brake lever in the reverse order of removal.

1

Do not handle linings more then it is necessary and be sure that they are completely free from oil or grease. Centralise the brake shoe relative to the back plate before fitting the drum by lightly tapping in the required direction.

1. BRAKE SHOE 2. SHOE HOLD DOWN SPRING 3. PARKING BRAKE SHOE LEVER

Fig. 41

28

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BRAKES Fit the back plate to the stub axle and tighten the back plate bolts to the specified torque. Before installing brake drum maximize the drum to brake shoe clearance. (Follow the procedure as mentioned in the brake drum removal). Install the brake drum. Ensure the inside surface of the brake drum and brake shoes are free from dirt and oil. Put the brake shoe hold down spring back to its original position as shown. Install inner race of the outer bearing, washer, spindle, castle nut and split pin and assemble the wheel cap. Fit the wheel and tighten the wheel mounting bolts to the specified torque. Flushing Brake Hydraulic System It is always recommended that entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Periodical change of brake fluid is also recommended.

BRAKE

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29

BRAKES BLEEDING OF HYDRAULIC SYSTEM : The process of removing air from the hydraulic pipelines and cylinder is known as "Bleeding".

RIGHT BRAKE CALIPER 3

The brake hydraulic lines are based on diagonal split system. Whenever any brake line or hose was disconnected at the wheel, bleeding operation must be performed at both the ends of the line of the removed pipe or hose. (i.e. if the rear left side brake pipe or hose was disconnected both the rear left and front right side of the system to be bleeded.) When any joint part of the Master Cylinder, other joint part between the master cylinder and each brake of the wheel was removed or the level of brake fluid in the reservoir has been allowed to fall so low that the air has been drawn into the system. Then the hydraulic brake system must be bled at all 4 wheel brakes.

RIGHT WHEEL CYLINDER 2

FRONT

1 LEFT BRAKE CALIPER

REAR

4 LEFT WHEEL CYLINDER

Fig. 42

Caution Note : ALWAYS USE HEAVY DUTY BRAKE FLUID - IS8654/ DOT 3 / DOT 4 Entire bleeding operation should be carried out with the Engine ON (running) condition only. As the hydraulic lines of brake system is of DIAGONAL SPLIT, always perform bleeding operation starting from the Co-driver side front caliper 1st and then at the wheel cylinder diagonally opposite it. Repeat the same on the other brake line also (Fig. 42). Brake fluid may cause damage to paint. So make sure that brake fluid does not touch the painted surface. If it accidentally touches painted surface, wipe immediately and clean the surface.

Fig. 43

Bleeding Procedure Fig. 44 The sequence for bleeding the system is as shown. Carefully clean all dirt from around the reservoir filler cap.Fig. 43. Remove the filler cap, fill the reservoir with fresh brake fluid to the maximum marking indicated on the reservoir. Before commencing bleeding, at each bleed screw, remove the dust cap and clean thoroughly. Attach transparent (Vinyl) bleed tube to the bleeder screw top of the front left caliper and insert the other end in to a clean glass container containing recommended brake fluid to submerge the end of the tube as shown. Start the Engine since the entire bleeding operation has to be carried out with engine running condition only.

Fig. 44

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BRAKES Depress brake pedal slowly through out the full stroke of the pedal and then holding it depressed, loosen bleed screw about one-third to one-half turn. Which is sufficient enough to allow the brake fluid to flow freely. Note It is always better to close the bleed screw at the end of each downward pedal stroke to ensure full recuperation of brake fluid in the system.

a

There should be an interval of 3 to 4 seconds before making the next stroke. This action should be repeated until bubbles of air cease to appear at the end of the bleed tube. Fig. 45. Close the bleed screw immediately after the last downward stroke of the pedal. Whilst the pedal is thus held, securely tighten the bleed screw to recommended tightening torque and remove the tube. Replace the dust cap on the bleed screw.

b

a. Depress brake pedal several times and with pedal depressed, loosen bleed screw a little. b. With brake pedal depressed, retighten the bleed screw.

Fig. 45

Ensure that the fluid level in the master cylinder reservoir does not fall low enough to cause air to be drawn into the system, through out the bleeding operation. Repeat the same procedure on the rear right wheel cylinder, Fig. 46, followed by front right caliper assembly followed by the rear left wheel cylinder.

BRAKE

If the bleeding of any cylinder continues without success for a considerable time, it may be that air is being drawn in past the bleed screw threads. In such instances, the bleed screw should be closed at the end of each downward stroke of the pedal, allowing the pedal to return fully to its stop before reopening.

Fig. 46

Tighten the bleed screw finally after the last downward stroke of the pedal. Replace the dust cap on the bleed screw. Lock Nut

After completion of bleeding, apply the brake pedal hard and check for any leak at the joints and bleed screws.

Brake Light Switch 3+0.5 Set Brake Light Sw itc h As shown

Also check the brake pedal for "Sponginess" if found spongy repeat the complete procedure of bleeding. Set brake light switch dimension 3 + 0.5 mm and tighten the lock nut Fig. 46a

Brake Pedal

Fig. 46a

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31

BRAKES BRAKE FLUID LEVEL INSPECTION : After completion of brake bleeding check the brake fluid level in the reservoir. The fluid level should be between MIN and MAX level indicated on the brake master cylinder reservoir. If the warning light glows during Engine ON condition, replenish fluid to MAX line. Fig. 48 Never use a container which has been used for mineral oil or which is wet. Always keep all brake fluid containers capped to prevent contamination.

Fig. 48

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BRAKES TANDEM MASTER CYLINDER (FOR NON ABS VERSION)

FILLER CAP

FLUID RESERVOIR

SEAL O-RING

BACK SEAL

SPRING BRAKE

ASSEMBLY PRIMARY PLUNGER

ASSEMBLY SECONDARY PLUNGER

Fig. 49 Tandem Master Cylinder - Sectional view (AS/AS)

DESCRIPTION The simultaneous cut off (AS/AS) tandem master cylinder is designed for finer control of the fluid cut off point. The AS/AS master cylinder consists of two independent chambers in a single casting housing, primary and secondary plungers are fitted with seals having minimum friction. Each hydraulic system is so designed that any failure of a pressure seal in anyone of the chamber would not result in total failure of braking system, since the other chamber remains completely operational and ensures minimum safe braking performance. The specific design feature of this master cylinder is that pressure is developed in both the chambers simultaneously without any time lag.

INDEX

Under normal conditions when the brake pedal is depressed, the servo output rod pushes the primary plunger of the cylinder. At the same time, the force of the primary spring moves the secondary plunger forward. Simultaneously the recuperating pressure seals on both the plungers cover the cut off holes, developing pressure in both the chambers. The pressurized fluid from primary chamber is transmitted to front left and rear right brakes and from secondary chamber to the front right and rear left brakes. The fluid reservoir comprises of two separate chambers serving each system with a common topping up connection at the upper portion. The Filler cap comprises of a Fluid Level Warning Indicator (FLWI).

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33

BRAKES REMOVING THE MASTER CYLINDER : Fig. 50 When removing or servicing master cylinder, it is necessary to draw in the brake fluid from the system. Connect a bleed tube to the rear wheel cylinders bleed screw and drain the fluid into a container by pumping the pedal. Repeat the same by connecting the bleed tube to front caliper bleed screws and collect the fluid from the primary circuit and drain the system. Repeat the same procedure for the secondary circuit also. Disconnect all outlet pipes from the master cylinder. Loosen the master cylinder mounting nuts from the servo and remove the same.

Fig. 50

DISMANTLING OF THE TANDEM MASTER CYLINDER : Fig. 51 & 52 Clean the tandem master cylinder assembly externally with alcohol or fresh brake fluid before dismantling it. Remove the tank fixing spring pin. Hold the fluid reservoir and by rocking it on either side, lift the same out of the grommets in the master cylinder. Remove both the grommets from the master cylinder body, using a connector / screwdriver with a blunt edge. Remove the 'O' ring fitted in the groove on the spigot with a blunt edged pin. Slightly push the primary plunger with a round rod, hold it in depressed position and remove the stop pin and gasket.

Fig. 51

Without removing the stop pin, if any attempt is made to dismantle the master cylinder, the secondary plunger will get damaged and cannot be removed. Then clamp the cylinder (housing) in vice with soft jaws. With the help of circlip plier, remove the circlip. Remove the stop washer (spacer) and primary back seal from the shaft of the primary plunger. Remove the complete primary plunger assembly out of the bore. Removes the cylinder from the vice. Tap the cylinder, bore facing downwards, on a wooden block to allow the secondary plunger and the return spring to slide out of the bore. Discard all removed internal parts. Fig. 52

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BRAKES Clean the cylinder bore in fresh brake fluid or alcohol and blow with compressed air. Be sure that the Three holes visible through the primary and secondary inlet ports) in the cylinder body are clean, by blowing dry compressed air. Do not poke the holes with sharp instrument. CAUTION : Do not use kerosene (or) petrol (or) any other mineral oils to clean the cylinder and its internal parts. As it will lead to contamination and damage of rubber part wash all disassembled parts with brake fluid only. INSPECTION OF TANDEM MASTER CYLINDER : Examine the bore of the master cylinder. If it is not scored, ridged or corroded and is smooth to touch, the master cylinder assembly can be rebuilt using the appropriate parts from the genuine repair kit. If there is a slight doubt about the condition of the bore like having deep grooves or pit marks etc., fit a new master cylinder assembly. If contamination is observed on the removed seals (Normally they would have swollen and can be compared with new seals from the kit, which will show clearly that the size is enlarged). The entire rubber parts in the system including both front and rear hoses must be discarded and the entire system should be flushed with fresh brake fluid. ASSEMBLING THE TANDEM MASTER CYLINDER : Absolute cleanliness has to be maintained and clean fresh brake fluid must be used. Never use the brake fluid bled from the system as it is aerated. To facilitate easy assembly, smear the cylinder bore with fresh brake fluid liberally. Dip the plungers and all seals in fresh brake fluid. Fit the secondary back seal in the secondary plunger groove such that the seal lip faces the primary plunger assembly. Fit the seal shim and recuperating seal on the stem side of the secondary plunger in such a way that the lip of the seal faces towards the secondary spring. Fit the seal retainer in correct position as shown in figure and fit the secondary spring with the smaller dia coil coming on to the plunger stem.

round-ended rod. Press it down fully and whilst holding, screw in the stop pin with a new gasket and tighten to the specified torque. Slowly let the secondary plunger back till it touches the stop screw. Now insert the new primary plunger assembly as shown in Figure (3) into the bore. First fit the stop washer on to the primary plunger shaft. Fit the washer primary back seal followed by spacer and back seal on to the primary plunger shaft. Now fit the circlip by using circlip plier. NOTE While fitting the primary back seal, make sure that the lip of the seal is facing forward. Actuate the primary plunger assembly for couple of times and check for the quick return of the plungers. Fit a new 'O' ring into the groove on the spigot of the body. Fit new grommet into both the inlet ports by liberally lubricating the same with fresh brake fluid. Fit the fluid reservoir by positioning the same into the grommets and by slightly rocking them on to either side, press it home. Fit the locking pin as shown in Figure. NOTE

BRAKE

It is essential that the reservoir filler cap must be removed. Clean the filter. Refit the filler cap. Clean the filter. Replace the sealing ring the filter cap during overhaul. Refit the filler cap. Now the master cylinder is ready for fitment on to the Servo. Fit the master cylinder to servo using nuts along with spring washer and tighten to the specified torque. Connect the outlet pipes to the master cylinder. Tighten the coupling nut to the specified torque. Fill the reservoir with recommended brake fluid and bled the system. Check for brake fluid leakage. NOTE Do not alter the stand out of the output rod of the servo unit. Make sure that Vaccum Booster output rod is correctly assembled into the primary plunger bore.

Clamp the cylinder body with its mouth pointing upwards in a vice fitted with soft jaws. Insert secondary plunger assembly into the bore with the secondary spring leading into the bore.

Make sure that the primary outlet is connected to the front left and rear right and secondary outlet to the rear left and front right brakes.

Then slowly push the plunger down the bore with a

Do not polish bore of the tandem master cylinder. Never use cloth to clean or dry the master cylinder.

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35

BRAKES VACCUM BOOSTER

SR. NO. 1 2 3 4 5 6

DESCRIPTION

SR. NO.

BODY GASKET STOP PIN SPRING SPRING RETAINER RECUPERATING SEAL

7 8 9 10 11 12

DESCRIPTION

SR. NO.

SHIM

13

14 SECONDARY PLUNGER 15 GLAND SEAL PRIMARY PLUNGER ASSY. 16 WASHER 17 PRIMARY BACK SEAL 18

DESCRIPTION SR. NO. SPACER CIRCLIP BOOSTER ASSY. FILTER BOOT NUT

DESCRIPTION

SR. NO.

DESCRIPTION

19

CLEVIS

25

RESERVOIR

20 21 22 23 24

26 GROMMET (NRV) NON RETURN VALVE 27 28 SPRING WASHER NUT GROMMET

FILLER CAP PIN ‘O’ RING

Fig. 53 Exploded view of TMC assembly & Vaccum Booster Assembly (LSC65 + ø22.22AS/AS)

There is a mechanical vaccum booster unit fitted on the car. The above unit is designed to provide controlled power assistance to the effort applied by the driver's foot to the brake pedal. Vacuum supplied to the booster unit is obtained from the vacuum created in the engine inlet manifold in case of petrol engine and Vacuum generated by vacuum pump in case of diesel engine. The vacuum is applied to both the sides of a diaphragm and by admitting atmospheric pressure to one side of the diaphragm the power is obtained.

operates the master cylinder. Should a vacuum failure occur, the two push rods act as a single rod and the brakes will work in the conventional manner, but more pedal effort will be required and the fatigue of the driver will increase.

The unit is connected to the brake pedal and the master cylinder. The vaccum booster input push rod is connected to brake pedal while the output push rod 36

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BRAKES WORKING PRINCIPLE BRAKE OFF Fig. 54 The diaphragm is fully retracted and is held against the rear shell by the diaphragm return spring. The input rod assembly is also fully retracted by the brake pedal return spring, as far as the stop key, or valve retaining plate will allow. With the input rod in this position, the vacuum port is open and there is vacuum on both the sides of the diaphragm. BRAKE APPLIED Fig. 55 When the brake pedal is depressed, the input rod assy moves forward inside the diaphragm plate until the control valve closes the vacuum port; at this juncture vacuum is still present on both the sides of the diaphragm. As the input rod continues to move forward, the control plunger moves away from the control valve, opening the atmospheric port, which is formed between these two parts. Air enters the rear shell behind the diaphragm and the effect of atmospheric pressure assisted by the valve rod helps in pushing the diaphragm plate forward and thus the output rod actuates the Master Cylinder Plunger.

Fig. 54

BRAKE HELD ON Fig. 56

BRAKE

When the brake pedal is held on, the diaphragm will momentarily continue to move forward and so compress the outer edges of the reaction disc. This movement causes the centre of the disc to extrude, pressing back the input rod and thus closing the atmospheric port. Thus the output force is balanced against that of the input force. Further movement of the brake pedal either opens the vacuum port or the atmospheric port depending on whether the brake pedal is released or depressed.

Fig. 55

Fig. 56

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37

BRAKES BRAKE RELEASED Fig. 57 Immediately after the brake pedal is released, the vacuum port is opened and the atmospheric pressure in the rear chamber is extracted into the front chamber and from there to the inlet manifold via the non-return valve. The atmospheric port remains closed whilst the input rod assy returns to its original position, as shown. The diaphragm is then again 'suspended' in vacuum until the brake pedal is depressed. BOOSTER REMOVAL Disconnect the vacuum hose from the booster. Remove the booster input rod clevis pin from the brake pedal and remove the booster mounting nut (2 Nos.) from control mounting bracket. Unscrew the booster mounting nuts from the firewall end (2 Nos.) and remove the booster from the vehicle. Fig. 58

Fig. 57

SERVICING The parts available to service the unit are - a filter a non-return valve kit and a service kit. Servicing of the internal parts is not recommended and if a major fault is apparent, a new complete guaranteed unit should be fitted. The air filter should be changed every 40000 kms. or two years. If dusty conditions prevail, the filters should be changed more frequently. The output rod is retained internally and cannot be extracted. If the rod or the domed screw on the rod end is damaged the Supervac Unit must be replaced complete.

Fig. 58

No attempt should be made to disturb the domed screw. This is correctly set at the factory and should never be disturbed.

900

REPLACING THE FILTER Fig. 59 Pull back the dust cover and filter retainer. Hook out the filters and cut to remove from the input rod. Cut the new filter, press into the neck of the valve body as shown and refit the filter retainer and dust cover. If the dust cover is damaged fit a new one from Repair Kit.

Fig. 59

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BRAKES REPLACING THE NON RETURN VALVE Before removing the non-return valve note the angle of the same in relation to the front shell so that the new valve can be fitted in the same position. The non-return valve fitted is a push-in type valve. To remove this valve insert a flat bladed screwdriver between the rubber grommet and valve collar, lever the valve from the grommet. Then remove the grommet from the front shell and make sure that even by mistake you do not drop the same into the vacuum chamber. Fit the new grommet. Lubricate the ribs of the new non-return valve with castor oil and push fully into the grommet.

Fig. 60

INSTALLATION OF THE BOOSTER Assemble the booster to the control-mounting bracket through firewall panel. Ensure that booster push rod stand out dimension is 115 + 0.5 mm. Fig. 61 Install the input rod pin (smear pin with molykote grease) clevis to the brake pedal with the split pin.

BRAKE

Ensure that clevis pin is free to rotate. Tighten the booster mounting nuts from both sides to the specified torque. Fig. 60 Assemble master cylinder on to booster. Ensure correct orientation of ports & NRV. Tighten the nuts to the specified torque. (Refer table Page 2) Connect the vacuum hose to the booster and fill the master cylinder reservoir with recommended brake fluid.

115 +0.5

Booster Push Rod Length From Mtg. Face to Hole Center

Brake Pedal

Fig. 61

Bleed the system - refer brake bleeding procedure.

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39

BRAKES CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF VACUUM BOOSTER Engine Off : Depress and release brake pedal several times to remove vacuum from the system.

Depress pedal and hold with light pressure (7-12 kg) and start engine.

If vaccum booster is operative, pedal will fall slightly and then hold. Less pressure will be needed to hold pedal down, than with the engine in 'off'' condition.

If vaccum booster is not operative disconnect the vacuum hose from the vaccum booster nonreturn valve. Then with engine running, check the vacuum supply with a vacuum gauge. There should be atleast 20” of vacuum.

If vaccum booster is operative, do the vacuum leak test as given.

If vacuum supply is below 20 “ replace or repair the vacuum hose and vacuum fittings. If the vacuum supply is 20" or more the vaccum booster is defective and should be replaced with new vaccum booster Assemby.

With new hose fitting repeat the basic test.

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BRAKES VACUUM LEAK TEST

Run the engine to medium speed. Release the accelerator and turn the engine off. This builds up vacuum.

Wait 90 seconds and apply the brakes. Two or more applications should be vaccum booster assisted.

If the applications are vaccum booster assisted, there is no vacuum leak.

If the applications are not vaccum booster assisted disconnect the vacuum hose from the non-return valve. Then attach a short length of hose to the valve.

Blow air through the hose. The valve is defective if air passes through.

BRAKE

If the non-return valve is defective install a new non-return valve and repeat the vacuum leak test.

INDEX

If the non return valve is OK, the vaccum booster is leaking. Replace the vaccum booster with a new kit.

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41

BRAKES PRESSURE CONSCIOUS REGULATING VALVE (PCRV) (for non ABS version only) Fig. 62

•

The purpose of this valve is to regulate hydraulic pressure to rear brakes.

•

It is necessary to regulate hydraulic pressure to rear brakes to avoid rear wheel locking and skidding of the vehicle.

•

This valve is used in between the brake master cylinder and the rear brakes.

•

This unit is not serviceable and has to be replaced as an assembly only.

INLET

PCRV

Fig. 62

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OUTLET

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BRAKES PARKING BRAKE

PARKING BRAKE LEVER

PARKING BRAKE ADJUSTMENT EQUALISER

PARKING BRAKE CABLE

PARKING BRAKE CABLE

BRAKE

BRAKE DRUM BRAKE DRUM

SEMITRAILING ARM LH SEMITRAILING ARM RH

Fig. 63

PARKING BRAKE The parking brake arrangement is cable operated console mounted mechanical type brake acting on rear wheels. The hand brake lever situated in the cab operates it. When the hand brake lever is pulled up, the parking brake lever arrangement in the rear brake assembly inside the rear brake drum brake is also pulled through the cable system. This action expands the rear brake shoes against the drum, thus applying the rear brakes. Fig. 63 PARKING BRAKE HANDLE CONSTRUCTION Fig. 64

INDEX

This is a safety device so designed that the parking brake does not get released accidentally. To release parking brake, lift the handle slightly and keeping release button pressed, push down the lever fully. When release button is pushed as above, pawl rod also gets pushed, disengaging pawl from ratchet, thus releasing the parking brake. REMOVAL OF PARKING BRAKE LEVER Place wheels chocks at the rear wheels.

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43

BRAKES Remove the parking brake cover plate located in the cabin. Remove the parking brake adjustment nut and the spacer and remove the equalizer and the central locator from the parking brake lever. Fig. 64 Remove the console and disconnect the electrical connection to parking brake lever. Unscrew the parking brake lever mounting bolts and take out the lever. REMOVAL OF PARKING BRAKE CABLE Remove the brake drum - refer Removal brake drum. Remove the parking brake clip from the rear brake assembly. Disconnect the parking brake cable from the shoe lever - refer Brake shoe removal.

Fig. 64

Remove the cable from the rear brake assembly. Loosen the parking brake slackness adjustment nut and disconnect the parking brake cable from the equalizer. Remove the parking brake cable snap fit from the cablemounting bracket located inside the cabin. Remove the cable grommet from the shell. Fig. 65 Now disconnect all the parking brake cable clamps from the body mountings. INSTALLATION OF CABLE Install the cable in the reverse order of removal. Note

Fig. 65

Fit the cable to the brake shoe lever. Fit the parking brake cable clip to the brake back plate securely. Fig. 66

Fig. 66

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BRAKES INSTALLATION OF PARKING BRAKE LEVER Fig. 67 Proceed in the reverse order of removal. Tighten the mounting bolts of the parking brake lever to the torque specified. PARKING BRAKE ADJUSTMENT NUT

Adjust the parking brake cable slackness as per the procedure given. Reconnect the electrical connections to the parking brake switch assembly and confirm that the parking brake lamp becomes "ON" when parking brake lever is at first notch. PARKING BRAKE CABLE ADJUSTMENT Before parking brake cable slackness adjustment confirm the following conditions.

Fig. 67

Bleeding should be completed. (i.e. there should not be air trapped in the brake system). PARKING BRAKE APPLIED

Confirm pedal travel by depressing the brake pedal for few times. Check the lining condition of the rear brake it should not have been worn out beyond limit. After confirming all the above points start adjusting the parking brake lever stroke by either loosening or tightening the self locking slackness adjustment nut.

RELEASE BUTTON

PARKING BRAKE LIGHT SWITCH

Parking Brake Lever Stroke When a force of 20 kg is applied to pull up the lever.

Travel should be within 3rd - 6th notch.

After adjustment check for dragging of rear brake drum.

Fig 68.

INSPECTION OF PARKING BRAKE : Pull the parking brake lever at its centre by 20 kg force, with this force the travel should not exceed 5th notch position. Fig. 68 Check both the wheels are locked in this condition and release the lever (i.e. take it to the notch) and check for free rolling of the wheels. For counting the notches easily, listen to the click sound from the ratchet while pulling the parking brake lever without pressing the button. A click sound pertaining to each notch movement.

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45

BRAKE

BRAKES TROUBLE SHOOTING OF BRAKE SYSTEM HEADING

CAUSE

SPONGY BRAKE PEDAL1. Air in hydraulic system

BRAKE ROUGH OR CHATTER ON APPLICATION

EXCESSIVE BRAKE PEDAL EFFORT (HARD PEDAL)

REMEDY 1. Bleed the system and top up.

2. Soft or weak hose

2. Check and Replace

3. Poor quality brake fluid

3. Flush the system and refill with recommended grade of brake fluid.

4. Excessive worn / Weak drums in Rear

4. Replace

1. Excessive lateral run out in disc or 1. Repair if possible or replace the parallelism disc. not within specification. 2. Rear drum out of round

2. Check runout, repair or replace drum as necessary.

3. Broken anti-rattle clip

3. Replace

4. Incorrect parking brake adjustment

4. Check and adjust as per specifications.

5. Seized caliper pistons

5. Overhaul Calipers

6. Damaged or loose wheel bearing

6. Replace wheel bearing

7. Distorted steering knuckle or rear wheel spindle

7. Replace knuckle or rear wheel spindle

1.Lining soiled with brake fluid, oil or grease. 2. Brake pad worn below recommended thickness.

1. Replace

3. Malfunctioning of Servo.

3. Identify the trouble in Servo and rectify

4. Partial system failure (in tandem master cylinder).

4. Check both front and rear circuits and rectify.

2. Replace

5. Piston in calipers stuck or sluggish 5. Remove caliper and rebuild 6. Fading brake due to non recommended grade of brake pads.

6. Replace with approve grade of brake pads.

7. Kinked, dented or clogged bundy pipes, hoses or 'T' connections.

7. Identify and Replace

8. Binding pedal linkage

8. Lubricate and free up the system.

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BRAKES HEADING BRAKE NOISE

EXCESSIVE PEDAL TRAVEL

CAUSE

REMEDY

1. Glazed shoe linings or foreign matters stuck on linings

1. Repair or replace shoe linings.

2. Worn or distorted shoe linings

2. Replace shoe linings or pads

3. Loose front wheel bearings

3. Replace wheel bearing

4. Distorted backing plate or loose mounting bolts.

4. Replace or retighten

1. Incorrect pedal free play

1. Adjust as per specification.

2. Partial brake system failure either in dual circuit or in Master Cylinder

2. Identify and repair by replacing necessary parts.

3. Air in system (pedal soft / spongy) 3. Bleed and top up with recommended brake fluid.

GRABBING OR PULLING OF CAR

4. Soft or bulging hose

4. Replace

5. Excessive clearance between lining and drum in rear brakes due to malfunctioning of auto adjusters.

5. Check auto adjuster mechanism

6. Lining pad knock back caused by loose or worn wheel bearing or other related parts.

6. Adjust or replace faulty parts as necessary.

7. Insufficient fluid in master cylinder reservoir

7. Fill reservoir with approved brake fluid check for leak and air in brake system. Check warning light, bleed system if required.

8. Ben brake shoes or shoes worn out.

8. Replace brake shoes.

1. Incorrect type pressure (or) inflated unequally.

1. Inflate both front tyres to the recommended pressure.

2. Wrong wheel alignment.

2. Check and adjust as per recommended procedure

3. Loose suspension parts

3. Check all suspension mountings and tighten

4. Incorrect parking brake adjustment on rear brake.

4. Check and adjust to correct specification.

BRAKE

Note : If the above problems are not there then proceed further with the checking of brakes for grabbing.

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47

BRAKES HEADING

CAUSE

REMEDY

5. Drum to shoe clearance out of adjustment (malfunctioning auto adjusting mechanism).

5. Check for auto adjusting mechanism.

6. Loose caliper mounting

6. Tighten to specified torque.

7. Restricted brake pipes or hose

7. Check for soft hoses and damaged line, replace parts as necessary.

8. One side caliper piston stuck.

8. Remove and rebuild caliper, lubricate the caliper slide bush properly.

9. One side brake pad / shoe lining soiled with brake fluid, oil or grease

9. Replace

10.Caliper not aligned with Disc

10.Align properly.

11. Disc or drum is out of round.

11. Align properly.

12.Weakened or broken return springs in the brake.

12.Replace

13.Sluggish parking - brake cable or linkage

13.Repair or replace

14.Master cylinder piston not returning correctly.

14.Repair master cylinder.

BRAKE WARNING LIGHT 1.Parking brake lever in applied LIGHTS AFTER ENGINE condition. START

1. Release parking brake and check that brake warning light turns off.

2. Brake fluid level very low.

2. Add brake fluid

3. Leakage of brake fluid.

3. Investigate and correct leaky point. Add brake fluid.

4. Brake warning light circuit faulty

4. Repair circuit.

BRAKE WARNING LIGHT 1. Leakage of brake fluid. TURNS ON WHEN BRAKE IS APPLIED 2. Brake fluid level very low.

BRAKE WARNING LIGHT 1. Brake warning light circuit faulty FAILS TO TURN ON EVEN WHEN PARKING BRAKE IS APPLIED.

1. Investigate and correct leaky point. Add brake fluid. 2. Add brake fluid.

1. Repair circuit or Replace bulb.

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ABS

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ABS

INTRODUCTION :

Dual circuit, diagonal split hydraulic brakes through tandem master cylinder have been Provided. The front brakes are ventilated disc brakes with floating type calipers while the rear brakes are drum brakes with self-shoe clearance (automatic) adjustment. No adjustments are required for front & rear brakes. The parking brake is a mechanical lever type, console mounted cable operated, acting on rear wheels. ABS

Anti lock braking system ABS 5.3 with electronic brake distribution EBD is provided as optional. It ensures great stability and steerability while braking and also avoids wheel locking and skidding of wheels during panic braking. Electronic brake distribution EBD substitutes Pressure conscious reducing valves (PCRV) of traditional braking system and ensures precise brake pressure distribution on rear wheels.

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i

ABS CONTENTS Sr. No. 1. 2. 3. 4. 5.

6.

7.

8. 9. 10. 11. 12.

Description

Page No.

Technical Specification Wheel Slip How ABS works Braking without ABS Braking with ABS: a) Description of operation - Pressure Maintaining phase - Pressure Reduction phase - Pressure Increase phase ABS Components a) Tandem Master Cylinder b) Wheel speed sensor d) Electronic Control Unit - EBD control necessity - Principle - Action - Effect - Safety Workshop Testing a) Wheel speed sensor test b) Dynamic test Electronic Control Unit [Removal, Installation] Front wheel speed sensor [Removal, Installation] Rear wheel speed sensor [Removal, Installation] Inspection of front Toner Ring Inspection of rear Toner Ring

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1 2 3 6 6 7 8 9 10 11 12 14 15 16 16 16 18 18 18

ABS

18 20 22 23 23

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iii

ABS TECHNICAL SPECIFICATION

General

Hydraulic control unit (HCU)

Electronic Control unit (ECU)

System Description

Specification

System

ABS 5.3

Type

4-Sensor and 4-channel

Mode

ABS + EBD4

Type

Diagonal (X) Split

Hydraulic Control Method

3 modes - Pressure maintain /Reduction / Increase

Type of Pump

Two Piston Pump

Type of Motor

DC

Operating Voltage

12 v

Operating Temperature

-40º c to 120º c ABS

ABS Sensors

Type

Passive Variable Reluctance

Resistance Air Gap

INDEX

1600 ohm ± 320 ohm Front

0.3 to 1.2 mm

Rear

0.1 to 1.5 mm

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1

ABS ANTI LOCK BRAKE SYSTEM : Anti lock Brake system (ABS) is a closed loop system, which modulates the brake pressure in response to the brake slip rate of the wheel so as to prevent the controlled wheel or wheels from becoming fully locked above a preset minimum speed. During emergency braking situations at high speeds, panic braking will be applied under conditions like un-anticipated obstacle and mistakes committed by other drivers and pedestrians or braking under more critical driving conditions such as driving on wet and slippery road surfaces like ice etc, the wheels tends to lock which in turn will skid. This will lead to loss of steerability and stability of the vehicle as it looses traction. A : Stable Range B : Unstable range

Wheel slip : Fig. 1 The vehicle can stop in relation to how well the tire contact surface grips the road.At 0% slip, the tyre rotates freely and at 100% slip, the tire and wheel are locked and the weight of the vehicle pushes the locked tires along the road surface. In this situation, vehicle stability and steerability will be lost. ABS

During gradual braking, the %slip will be in between 10 to 20% and at this condition vehicle stopping distance and steering control will be at their best. This optimum slip (10 to 20 %) is required for achieving maximum braking Performance & for stopping the wheel. The theory behind ABS is simple. Whenever a driver brakes, the wheels of the vehicle have to transfer this braking force to the ground surface for achieving braking. As long as driver brakes gradually, the braking force is transferred through the tyres to the ground surface & optimum braking is achieved.But when driver applies panic braking, the tyres will stop rotating instantaneously (locking condition). The vehicle drags all the 4 wheels in the same direction (at the point of braking) & also driver cannot steer the vehicle so as to avoid any accident.

1: 2: 3. 4.

Dry Asphalt Wet Concrete Snow Polished Ice

Fig 1.

vehicle stability and steerability. i.e. This system prevents the wheel locking during emergency braking situations and thereby helps the driver to maintain stability of the vehicle & also in bringing the vehicle to a complete stop with a minimum possible stopping distance in the safest possible way. The purpose of ABS 5.3, 4-sensor 4-wheel, Diagonal split system is to provide 1. Enhanced steering control by enabling the vehicle to move in a driver’s intended direction, even during panic braking. 2. Enhanced braking stability by making the most of available traction on all surfaces. 3. It’s operational throughout the vehicles entire speed range, effective down to the speed of 2.75 km/ h.

To avoid the wheels from getting locked & skidding while panic braking, Antilock brakes system is provided.The main benefits of ABS are in the area of 2

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ABS

Fig 2. ABS

It is capable of rapid adaptation to changes in surface traction. ( Dry road with patches of ice) and capable of slowing down the yaw effect on the vehicle when vehicle is driven on a µ split track, so that even an average driver can initiate compensatory counter steer. ECU continually monitors the operating status of ABS. Incase of ABS failure driver will be alerted and conventional braking will still be operational without ABS.

HOW ABS WORKS : Fig. 2 and Fig. 3

the Front Left and the Rear Right brake while the secondary connects Front Right and Rear Left brake through connectors. Anti lock braking system ABS 5.3 is a 4-channel diagonal (X) split system consists of an ECU attached to hydraulic unit and 4 wheels speed sensors (one at each wheel).The ECU controls the hydraulic unit. Each of the four wheels has one individual pair of inlet and outlet solenoid valves to control each wheel speed individually.

When the brake pedal is depressed, hydraulic pressure is developed in the Tandem Master Cylinder, which is used to actuate the brake (two in front and two in rear). The brake pipes are connected to the brakes through the ABS Hydraulic unit.They make two independent circuits diagonally split.The primary circuit connects

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3

ABS HYDRAULIC UNIT

MC2 D2

MC1

O1

RP2

RP1

M

LR REAR LEFT

LFEV

RFAV

LFAV

RF

LF

FRONT RIGHT

FRONT LEFT

RREV

NRV4

RFEV

NRV2

LRAV

ABS

A1

NRV3

NRV1

A2 LREV

D1

O2

RRAV

RR REAR RIGHT

Fig 3. MC1 & MC2

: Primary & Secondary brake circuits

RREV & RRAV : Inlet & outlet solenoid valves of Rear Right wheel LFEV & LFAV : Inlet & outlet solenoid valves of Front Left wheel RFEV & RFAV : Inlet & outlet solenoid valves of Front Right wheel LREV & LRAV : Inlet & outlet solenoid valves of Rear Left wheel A1 & A2 RP1 & RP2

M D1 & D2 O1 & O2 NRV1, NRV2, NRV3 & NRV4

: Motor for driving recirculating pumps : Damping chambers. : Orifices : Non return Valves of Rear left, Front right, Front left & Rear right wheels respectively.

: Accumulators of the circuits MC1 & MC2 respectively. : Recirculating pump of the circuits MC1 & MC2 respectively.

4

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ABS Whenever ABS system recognizes incipient wheel lock at one or more wheels, it ensures the stability of wheel/ vehicle by modulating the brake pressure in 3 phases which are, (1) Pressure increase, (2) Pressure hold & (3) Pressure decrease. The wheel speed sensor sends alternating voltage signals to the Electronic Control Unit (ECU). The ECU calculates the vehicle reference speed every 10 msec. From this data the ECU calculates the % slip when the wheels are braked. When the % slip is above the permissible limit (varies with tire to road traction), the ECU sends signal to the solenoid valves in the HU to carry out pressure maintaining and reduction phase. When % slip recovers within limits, pressure is increased to achieve optimum stopping distance. When one or more wheels are about to lock due to rapid deceleration, the ABS comes into action. It modulates (increases, holds or decreases) the brake pressure to avoid wheel lock. The ABS 5.3 controls all the 4 channels (both front and rear) independently. The brake pressure required to bring ABS into operation may vary depending upon road surface and tire adhesion. A dry pavement surface requires a higher brake force than a slippery surface to engage ABS.

ABS

The ABS comes into play when panic braking is applied on the car during emergency. The driver feels the effort of the ABS through the pulsating (up and down movement) of the brake pedal and audible noise in the brake system. This is absolutely Normal. This should not be interpreted as a fault in the brakes. On the contrary it’s the indication that the ABS is working. This is an intentional warning to the driver that a wheel or wheels are tending to lock up due to the limit of tire to road adhesion. In this situation it is important to keep the brake pedal depressed fully so that the ABS can regulate the brake application. On No account pump the brake pedal.

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5

ABS

HYDRAULIC UNIT

MC2 D2

MC1

O1

O2

RP2

RP1

M

LR REAR LEFT

LFEV

RFAV

LFAV

RF

LF

FRONT RIGHT

FRONT LEFT

RREV

NRV4

RFEV

NRV2

LRAV

ABS

A1

NRV3

NRV1

A2 LREV

D1

RRAV

RR REAR RIGHT

Fig 4.

Braking without ABS :

Braking with ABS :

Incase of brake operation without ABS, when driver presses the brake pedal, brake pressure developed in the TMC reaches each wheel through HU. During this phase, both inlet & outlet solenoid valves are not switched ON (or excited) by ECU. Hence the inlet valve is open and outlet valve remains closed.

DESCRIPTION OF OPERATION OF THE ANTI-LOCK BRAKING SYSTEM

When the driver releases the brake pedal, the brake fluid flows back from the respective wheel, through the respective NRV (Non Return Valve) & reaches TMC. In this way, the whole brake system functions just like in a vehicle with normal hydraulic brake system (without ABS system).

6

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On the basis of the signals received from the rpm sensors located on the front and rear wheels, the electronic control unit instructs the hydraulic unit, so as to vary the pressure of the brake fluid delivered to the brake calipers, passing through the three stages described on next page:

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ABS Pressure Maintaining (Hold) Phase : Fig. 5 During any panic braking situation, whenever the wheel tends to lock (because of the higher brake pressure than optimum). ECU instructs Hydraulic Unit to block the brake pressure coming from Master cylinder, so that no further pressure gets into wheel cylinder. By default, the inlet solenoid valve remains open & the out let solenoid valve remains closed. These are the positions of the valves under unexcited condition. During the pressure maintaining phase, ABS ECU actuates only the inlet solenoid valve (EV) & there by closes it. The outlet solenoid valve remains closed in its default position. Since both the solenoid valves are shut the liquid channel is interrupted. The pressure channel is closed, so that further increase of pressure in the brake circuit is obstructed. Non return valve mounted in parallel to the inlet valve helps in speedy reduction of pressure when brake pedal is released.

Solenoid valve INLET OUTLET

INDEX

Electricity status ON OFF

DAMPING CHAMBER

RECIRCULATION PUMP

ACCUMULATOR

INLET VALVE (CLOSED)

OUTLET VALVE (CLOSED)

Fig 5. Valve open-close

Open-close channel

CLOSE

Master cylinderWheel cylinder

CLOSE

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ABS

Wheel cylinderreservoir

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7

ABS Pressure Reduction Phase : Fig. 6 Even after the pressure hold phase, if already the existing pressure in the wheel cylinder is too much, by which the wheel is further tending to lock, then the ECU activates outlet solenoid valve and lets some amount of brake fluid to reach the acumulator, which serves the purpose of temporary storage. ECU activates both Inlet & Outlet solenoid valves. The closed Inlet solenoid valve shuts the liquid channel from master cylinder. The outlet valve opens and connects the wheel circuit to the secondary circuit. Brake fluid gets discharged into the accumulator. The recirculation pump (which is driven by a motor which is not shown in the figure) pumps the brake fluid back to the master cylinder through the damping chamber. The damping chamber avoids the pulsations of the returning brake fluid from getting transferred to the driver’s foot. The pressure reduction is continued till the wheel speed recovers to the vehicle reference speed.

Solenoid valve

ABS

DAMPING CHAMBER

RECIRCULATION PUMP

ACCUMULATOR

OUTLET VALVE (OPEN)

Fig 6.

Electricity status

Valve open-close

INLET

ON

CLOSE

OUTLET

ON

OPEN

8

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INLET VALVE (CLOSED)

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Open close channel Master cylinder-Wheel cylinder Wheel cylinder-reservoir

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ABS DAMPING CHAMBER

Pressure increase Phase : Fig. 7 As the wheel speed increases and goes beyond the reference speed, the ECU closes the outlet valve and opens the inlet valve to increase the pressure in small steps. This pressure increase is achieved by ECU through interrupting electricity to both inlet & outlet solenoid valves. In this position, inlet valve is open & outlet valve remains closed. With this, the brake fluid from the master cylinder enters the wheel cylinder & increases the brake pressure for that wheel.

RECIRCULATION PUMP

ACCUMULATOR OUTLET VALVE (CLOSED)

INLET VALVE (OPEN)

Fig 7. Solenoid valve

Electricity status

Valve open-close

Open-close channel

INLET

OFF

OPEN

Master cylinder-Wheel cylinder

OUTLET

OFF

CLOSE

Wheel cylinder-reservoir

ABS

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9

ABS ABS Components : CV/CV TMC CROSS SECTIONAL VIEW (ABS)

Fig 8. ABS

Typical ABS consists of : Tandem Master Cylinder for ABS version: Fig. 8 and Fig. 9 A CV/CV type Tandem Master Cylinder is made of light aluminium alloy. This is provided with a central valve installed in the piston.

Removal : Dismantling, overhauling and servicing of Tandem Master Cylinder is not recommended. Therefore in case of any failure or malfunction the entire Tandem Master Cylinder assy is to be replaced.

Fig 9. 10

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ABS Wheel Speed Sensor : Fig.10 and Fig.11

signal whose frequency is proportional to wheel rotational velocity. The ECU derives the wheel speeds from the signal sent by the wheel speed sensor. Inductive wheel speed

Electromagnetic pulse pick up with toothed wheels mounted directly to the rotating components of the drive train or wheel hubs. These devices provide a digital

FRONT

ELECTRICAL WIRE

OVERMOULD

PERMANENT MAGNET

COIL POLE PIECE

TARGET WHEEL

REAR

Fig 10. ABS

Vmax

V min

TECHNICAL DATA : Principle : Variable Reluctance Coil Resistance : 1600 ohm + 320 ohm Inductivity : 800 mH to 1800 mH Operating temp : -40oC to 115oC

t

TEETH P1 P2 P1 P2 P1 P2 P1 P2

POLE PIECES

MAGNETIC DISPERSION

Vmin

COIL

TIME t V max VOLTAGE V

TARGET WHEEL

PERMANENT MAGNET

VELOCITY

USEFUL MAGNETIC FLUX

Fig 11.

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11

ABS sensor (DF6) has a stator pole with coil windings and installed directly above the Tone Wheel. The Tone Wheel is generally fitted on to the wheel hub. The stator pole is linked to a permanent magnet, thus inducing a magnetic field into the tone wheel. The alternating teeth and gap that accompanies the wheel rotation induces corresponding fluctuation in the magnetic field through the stator pole. This variation in magnetic field induces an alternating current at the end of the winding. The frequency of the current is proportional to the speed of the wheel. The voltage is zero when the vehicle is stationary. The minimum detectable rotation rate is decided by factors like tooth geometry, gap, voltage rise rate and the ECU sensitivity to incoming signals. The sensor has to be installed on a stable mount to prevent oscillation pattern from the brakes resulting in distorting sensor signals. The wheel speed sensor also has a coating of grease to prevent it from dirt and water spray

Electronic Control Unit (ECU) : Fig. 12

ABS

Solid state electronic device containing computer functions, sensor signal processing circuits, output device drives for the various ABS valves & components and Failure Detection Logic. The ECU is integrated in a single package with the Hydraulic Unit (HU). It has 2 Micro controllers, which utilize the same program for independent data processing and monitoring functions. One of the Micro controllers has an EEPROM to retain memory data in case battery supply is interrupted. The EEPROM is a non-volatile data storage device employed to store error codes, which can be read out for diagnosis. When an error is encountered ABS switches itself off and triggers the ABS warning lamp. An independent module controls the solenoid valve relay and return pump motor. This module supplies a stabilized voltage, monitors microcontroller operations and triggers the ABS lamp in response to malfunction.

12

INDEX

Fig 12.

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ABS Brake Pressure / Hydraulic Modulator : Fig.12 and Fig.13 HYDRAULIC UNIT

MC2 D2

MC1

O1

O2

RP2

RP1

M A1

LRAV

LFEV

RFAV

RREV

NRV4

NRV2

RFEV

NRV3

NRV1

A2 LREV

D1

LFAV

RRAV

ABS

LR REAR LEFT

RF

LF

FRONT RIGHT

FRONT LEFT

RR REAR RIGHT

Fig 13. MC1 & MC2

: Primary & Secondary brake circuits

RREV & RRAV : Inlet & outlet solenoid valves of Rear Right wheel LFEV & LFAV : Inlet & outlet solenoid valves of Front Left wheel RFEV & RFAV : Inlet & outlet solenoid valves of Front Right wheel LREV & LRAV : Inlet & outlet solenoid valves of Rear Left wheel A1 & A2 RP1 & RP2

M D1 & D2 O1 & O2 NRV1, NRV2, NRV3 & NRV4

: Motor for driving recirculating pumps : Damping chambers. : Orifices : Non return Valves of Rear left, Front right, Front left & Rear right wheels respectively.

: Accumulators of the circuits MC1 & MC2 respectively. : Recirculating pump of the circuits MC1 & MC2 respectively.

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13

ABS Brake Pressure / Hydraulic Modulator : This is an Electro-hydraulic device for reducing, holding & restoring pressure to one or more wheel cylinders, independent of the brake pedal effort applied by the driver. It consists of a Return Pumps, Solenoid Valves, Damping Chamber, Accumulator, Non-Return Valve and Motor. It forms the link between the TMC and the foundation brakes. It implements the commands issued by the ECU by using solenoid valves to control the pressure at the foundation brakes. There are four pairs (4-channel system) of Inlet and Outlet valves and are located in the upper section of the modulator. Solenoid valves are responsible for modulating the pressure in the brake cylinder during active ABS control. The Return Pump element is installed in the center of the modulator and is driven by an electric Motor. The pump transfers the brake fluid emerging from the wheel brakes through the accumulator on its way back to the TMC through damping chamber. The pump actuation can be felt on the foot pedal as pulsations. In order to prevent damage to the TMC primary seals from the compensating port, the design of TMC is changed to central valve type (CV/CV) ABS

Accumulator and Damping Chambers are Located in the lower section of the hydraulic modulator. The accumulator absorbs the surge in brake fluid that accompanies the pressure reduction phase. The Damping Chamber suppresses pressure oscillations within the hydraulic system, preventing them from being propagated back to the brake pedal and reduces noise levels in the system.

ELECTRONIC BRAKE DISTRIBUTION (EBD) :

FORCE

EBD substitutes Pressure conscious reducing valves (PCRV). Its function is not determined by the brake pressure or the weight transfer but by the amount of wheel slip. EBD function is an additional program to the conventional ABS program. It reduces the pressure at the rear depending upon the wheel slip and pressure reduction is carried out after certain pressure-maintaining phase. It maintains the brake pressure to both the rear wheels same. If any of the rear wheels is still over braked, ABS becomes

14

INDEX

operational. EBD warning lamp is turned on in case of error in the EBD system. EBD failure does not necessarily mean ABS failure. EBD (Electronic Brake-force Distribution) Control Necessity 1. During braking, whenever the rear axle wheels lock before the front axle wheels, the vehicle will loose its control & it may start to spin. This is because, braking is always associated with a certain weight transfer from rear axle onto the front axle wheels. Due to this drift of the vehicle weight, there will be lesser normal force acting on the rear axle when compared to the front axle. Due to lesser normal force, rear axle wheels can support lesser brake pressure. In a passenger car, as a counter measure to this problem, the brake circuit for the rear axle will be fitted with PCRV (Pressure conscious regulating valve). This PCRV allows only the predetermined max. pressure to the rear axle wheels & hence avoids the locking of rear axle wheels before the front axle wheels. 2. But PCRV is a mechanical vehicle component and it cannot result in ideal brake force distribution for the rear axle wheels. 3.

PCRV because of its design limitation, cannot allow higher brake pressure onto the rear axle wheels, when the vehicle is driven in full load condition on a high friction surface like Asphalt. This results in lesser brake force onto the rear axle wheels than the ideal brake force & hence less efficient braking. This is viewed as a problem.

4. The brake force required for optimum braking maybe different for each wheel. This is depending on the road surface, the condition of the friction material of brake lining/ pad & also the condition of the tyres (old/ new). With PCRV, when the same brake force reaches both the rear axle wheels, ideal braking cannot be achieved by the rear axle wheels.

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ABS

In this vehicle with ABS system, the ECU incorporates a special function by name EBD (Electronic Brake force Distribution). With this EBD, the conventional mechanical PCRV has been eliminated from the rear brake circuit.

EBD results in ideal pressure distribution for the rear axle wheels. With EBD, the rear axle wheels either lock along with front axle wheels during partial braking OR the rear axle wheels may lock after the front axle wheels. EBD never allows the rear axle wheels to lock before the front axle wheels.

Principle : Fig.14 and Fig.15 1. The principle is precise control of the rear axle brake pressure such that it follows the ideal brake pressure distribution curve closely. This is achieved by the inclusion of a special control logic to the ABS ECU (instead of PCRV).

Ideal Distribution lines

Outlet Pressurev

6.

Laden

Unladen Cut-in point

Inlet Pressure Fig 14. With PCRV Laden Unladen Outlet Pressure

5. When the PCRV fails in any car, the driver has no chance of knowing about this failure. Under this condition, when braked, the vehicle may deviate/spin (depending on the brake force applied by the driver) from the intended driving direction.

Cut-in point

ABS

2.

Rear brake pressure is controlled so that rear slip ratio will always be less than or same as that of front. The brake slip of each wheel during braking is calculated by means of the wheel speed signal of the respective wheel.

3.

Therefore rear wheel locking does not precede that of front wheel.

4.

Consequently brake force at the rear axle can be made to follow the ideal pressure distribution curve more closely (Figure 15). This enhances the contribution of the rear axle wheels for braking & thereby improves braking efficiency.

5.

With this precise brake force control of each rear wheel as per its individual requirement, at the particular point of time, can be achieved.

INDEX

Inlet Pressure Fig 15. With EBD

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15

ABS Action :

Effect :

1. Just before rear wheel tends to lock preceding to front wheel, the EBD function of ABS ECU actuates the inlet solenoid valve & closes it, so that the brake oil pressure from TMC is blocked at HU only instead of reaching that particular wheel cylinder & hence the locking is prevented. Some times, EBD also actuates outlet solenoid valve & opens it for very short intervals of time, so that locking of the rear wheels is avoided.

1. Braking distance is decreased as rear brake force is enhanced in comparison with existing PCRV

2.

Soon after the rear wheels recover from locking phase, the inlet & outlet solenoid valves are switched OFF, so that the brake pressure applied at MC be transmitted to the rear wheel cylinder / caliper.

3.

2.

Stability is secured at time of partial braking, since the right and left rear wheel liquid pressures are controlled independently from each other.

3. Stable braking effect can be achieved because front brake pad abrasion and temperature rise etc. are decreased as braking effect of rear brake is increased at braking time. 4.

PCRV can be eliminated.

Motor pump does not act at this time.

Category At time of failure

Vehicle equipped with EBD system When it is transferred to ordinary brake, please drive slowly because of the chances of generation of spin, since there is no PCRV. Restrain from behavior of taking a sudden brake; go to Service center at once to take measures.

ABS

Safety I. Even if ABS fails EBD continues to control even in the following situations : 1) One wheel speed sensor failure. 2) Motor pump failure. 3) Failure by low voltage of battery (Minimum voltage for EBD functioning 6.5 V)

lamp which is nothing but the parking brake lamp will glow indicating the driver about the failure. Now the driver should drive carefully till the authorized workshop to set right the problem.

II. There is no alarm instrument for PCRV by which driver may always be informed if there is any failure with PCRV. Hence, during such situations the driver has no chance to know about the failure. Braking under this condition is dangerous as the vehicle is deviate from the intended direction/ it may spin depending on the intensity of braking. In case of ABS vehicle, if there is any failure with EBD,immediately the EBD warning

16

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ABS III. EBD fail-safe Cause of system failure None

System

Warning lamp

ABS operate

EBD

ABS

EBD

operate

OFF

OFF

1 Sensor failure

does not operate

operate

ON

OFF

Pump failure

does not operate

operate

ON

OFF

Low voltage of battery

does not operate operate(at > 6.5V )

ON

OFF

does not operate

ON

ON

Failure of 2 or more sensors, Valve failure ECU failure Other failures

does not operate

ABS

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17

ABS WORKSHOP TESTING : Any malfunction in the ABS is signaled by the warning lamp in the instrument cluster,which can be later on diagnosed at the workshop using a diagnostic tool. Malfunction code retrieval serves as the basis for detecting and evaluating defects and inconsistent performance. Data are analyzed using special diagnostic tool. Following are some of the common errors that occur a. Electrical circuit problem such as intermittent contact. b. Component and sensor failure c. Sensor signal that deviates from specified levels d. Unusual response and malfunction in the actuators Some of the common test which needs to be done before drive test. This involves a check for the following:

• • •

ABS

• • • • •

Correct functioning of all input and output signals of the ECU Correct functioning of wheel speed sensors Correct functioning of all valves and hydraulic components Communication set up ECU identification Clear and read fault code memory Wheel speed sensor test Dynamic ABS test

WHEEL SPEED SENSOR TEST This is conducted to check the correlation of the sensors ,signal quality by running individual wheels one after the other. The tester picks up the wheel speed data of the ECU and verifies the signal. This data gives insight about the correctness of tone wheel, air gap, right connection, eccentricities etc.

DYNAMIC TEST

This is designed to check the correct correlation of the solenoid valves and the wheel speed sensor. The pedal is held in constant position and the software turns the valves into pressure release and pressure increase cycles. This deceleration rates are measured by the ECU and transmitted to the tester for comparison with given limits

18

INDEX

Removal of Electronic Control Unit (ECU) : Fig16-18 1.Turn OFF the ignition. 2.Disconnect ECU wiring harness connector from Electronic Control Unit (ECU) assembly. 3.Never apply a 12V-power source to any terminal of the ECU connector when it’s disconnected. 4.Identify the brake pipes going into and out of the Hydraulic Unit (HU) with tags so that reinstallation of the brake lines will be easy. 5. Proper care should be taken before removing the brake pipes from HU; the HU must be thoroughly cleaned to prevent dirt Particles from falling into the ports of HU or entering the brake pipes. 6. Remove the brake pipes from the HU and plug the ports with suitable grommet. 5.Remove the Nuts attaching ECU / HU to the mounting bracket and then take out the ECU/HU from ECU / HU mounting bracket. 6. Clean the top of the HU with a clean, dry cloth. 7. Visually inspect the ECU ports, grommets etc. If grommet is found damaged replace it with new one.

Installation of Electronic Control Unit (ECU): Fig. 16-18 1.Put the grommets and the mounting studs at appropriate places as shown 2. Align the bottom ECU grommet to the dowel in mounting bracket and insert ECU so that both the mounting studs get aligned onto the bracket slot. 3. Tighten the nut to the ECU / HU stud with mounting bracket to specified Torque (2.65N +/- 0.3 N). 4. Reconnect six brake lines. Be certain that the four outlet and two inlet lines have been connected to the correct ports. Tighten the nuts to specification. 5. When installing the brake pipelines on the HU valve block, they must be located correctly in the valve block to ensure proper ABS operation. 6. Connect the ECU harness connector. 7. Bleed the brake system. 8. Road test vehicle to ensure proper operation of the base and ABS systems.

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ABS

Fig 16.

Fig 17. 0.3

GROMMET

STUD FOR ABS ECU/HU MOUNTING

ABS

THREADED HOLE FOR POWER STEERING RESERVOIR MOUNTING

CENTRAL DOWEL FOR LOCATING ECU

-- SPECIFIED TORQUE IN Kgm

Fig 18. Assembly ECU/HU (Brake Fluid Filled Unit)

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19

ABS

LOOP FROM STRUT BRACKE TO BRACKET ON BIW

Fig 19.

BELOW THE BRAKE HOSE INTO BIW HOLE

Fig 20.

Removal Front wheel speed sensor : Fig. 19-22 Take proper precaution while disconnecting the wheel speed sensor from vehicle wiring harness, by not damaging pins on connector. 1. Remove harness connector.

ABS

2. Remove sensor bolt and remove the wheel speed sensor and the sensor mounting plate from the steering knuckle. 3. Remove the sensor cable anchorage on the front strut & on suspension tower.

SMALLER BRACKET

FROM STEERING KNUCKLE

Fig 21.

4. Take out the sensor cable connector from the engine cabin through the hole on the wheel arch. 5. Measure speed sensor resistance. Resistance: 1600 ohm ± 320 ohm BELOW THE SENSOR CABLE (COMING FROM STRUT) INTO THE HOLE IN WHEEL ARCH

Fig 22. 20

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ABS

SENSOR SENSOR MOUNTING PLATE

DRIVE SHAFT WITH TONER RING

Fig. 23

Installation of Front wheel speed sensor : Fig. 23 ABS

1. Clean speed sensor and its mounting surface. 2. Check the sensor mounting plate for rusting, and damage. Replace it with new one if found damaged.

6. Make sure that the sensor cable connector is fully seated and locked into vehicle wiring harness connector.

3. Anchor both the sensor grommets to the strut and single grommet to shell. Route the sensor cable as shown in Fig. 20-22.

7. Insert the sensor into the sensor mounting plate and fit it to the front steering knuckle by butting it against the face on the knuckle and tighten the bolt to the specified torque.

4. Insert the sensor cable connector through the hole in the suspension tower, ensure that the cable is routed with a loop as shown in the Fig. 20.

8. Check the air gap between the face of the wheel speed sensor and the top surface of the toner wheel.

5. Install the wiring harness connector with wheel speed sensor cable.

Air gap: 0.3 to 1.2 mm 9. Road test vehicle to ensure proper operation of the basic and ABS brake system.

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21

ABS Rear wheel speed sensor Removal : Fig. 24-26

SENSOR

Take proper precaution while disconnecting the wheel speed sensor from vehicle wiring harness, by not damaging pins on connector. 1. Remove the harness connector. 2. Remove the grommet from wheel arch rear and take out the sensor connector end from the passenger cabin. 3. Jack up the wheels and remove the brake drum.

ASSEMBLY REAR BRAKE

Fig 24.

4. Unscrew the four anchor plate mounting bolts and remove the sensor with the sensor mounting plate. ASSEMBLY REAR BRAKE

5. Remove the sensor bolt and remove the speed sensor from the sensor mounting plate.

BRAKE DRUM WITH TONER RING

SENSOR

6. Measure speed sensor resistance. Resistance:1600 ohm ± 320 ohm ABS

SENSOR MOUNTING SEMI TRAILING ARM MOUNTING PLATE PLATE

Fig 25.

Fig 26. 22

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ABS Installation of Rear wheel speed sensor 1. Clean speed sensor and it’s mounting surface. 2. Check the sensor mounting plate for rusting and damage; Replace it with new one if found damaged. 3. Mount the sensor onto the sensor mounting plate and tighten the bolt to the specified torque. 4. Mount the rear brake assembly onto the semitrailing arm with the sensor mounting plate and tighten the bolt to the specified torque. Fig 27.

5. Fit the brake drum. 6. Anchor the sensor cable on to the semi-trailing arm. 7. Insert the sensor cable connector end through the hole in the rear wheel arch and mount the grommet on the wheel arch bracket. Fig. 26 8. Install the wiring harness connector with wheel speed sensor cable.

ABS

9. Make sure that the sensor cable connector is fully seated and locked into vehicle wiring harness connector. 10.Road test vehicle to ensure proper operation of the basic and ABS brake system. Inspection of Front Toner ring. 1. Jack the vehicle and properly support front of the vehicle. 2. Steer the wheel to extreme steering locks position so that the Tone ring on the drive shaft is easily seen. 3. Closely inspect the tone ring by slowly rotating the wheel and remove the dust and mud/iron particles in between teeth.

INDEX

Fig 28. 4. Check for any damaged teeth. (Front tone ring has got 42 teeth) Fig. 27 5. Replace tone ring if any teeth are missing or damaged. Inspection of Rear Toner ring 1. Jack the vehicle removes the wheels. 2. Remove the brake drum. 3. Closely inspect the tone ring and remove the dust and mud/iron particles in between teeth. 4. Check for any damaged teeth. (Rear tone ring has got 42 teeth) Fig. 28 5. Replace tone ring if teeth are missing or damaged

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23

ABS SERVO AND TMC ASSEMBLY (LSC 65 AND DIAMETER 22.22)

MC ASSEMBLY (DIAMETER 22.22 CV/CV)

ABS

SERVO ASSEMBLY (LSC 65)

24

INDEX

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ABS ASSEMBLY ECU/HU (BRAKE FLUID FILLED UNIT)

0.3

STUD FOR ABS ECU/HU MOUNTING

GROMMET FOR ABS ECU/HU MOUNTING

THREADED HOLE FOR POWER STEERING RESERVOIR MOUNTING

ABS

CENTRAL DOWEL FOR LOCATING ECU

- SPECIFIED TORQUE IN Kgm

INDEX

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25

GROUP INDEX

ASSEMBLY TUBE CONNECTOR LH TO FRONT BRAKE HOSE LH

HU

ELECTRONIC/HYDRAULIC CONTROL UNIT

ECU

ASSEMBLY TUBE ECU/HU RR TO REAR CONNECTOR RH

NOTE : ALL COUPLING NUT TORQUE - 1.4 TO 1.6 Kgm

ASSEMBLY BRAKE HOSE FRONT

2.3 to 2.5

FRONT CALIPER LH

ASSEMBLY TUBE - ECU/HU LF TO FRT LH CONNECTOR

ASSEMBLY TUBE CONNECTOR RH TO FRONT BR. HOSE RH

FRONT CALIPER LH

SECONDARY

REAR WHEEL CYL. LH

ASSEMBLY TUBE - BRAKE HOSE REAR LH TO WH CYL REAR LH

ASSEMBLY TUBE - BRAKE HOSE REA RH TO WH CYL REAR RH

HOSE CLAMP 20

REAR WHEEL CYL. RH

VACUUM BOOSTER CV/ CV TYPE

ASSEMBLY TUBE FROM TMC TO ECU/HU PORT MC1

- SPECIFIED TORQUE IN Kgm

ASSEMBLY TUBE - REAR ASSEMBLY BRAKE LH CONNECTOR (2) TO HOSE REAR BRAKE HOSE REAR LH

ASSEMBLY TUBE - REAR LH CONNECTOR (1) TO REAR LH CONNECTOR (2)

ASSEMBLY TUBE - REAR LH CONNECTOR (1) TO REAR LH CONNECTOR (2)

ASSEMBLY VACUUM PIPE - MPFI - RHD

PRIMARY

ASSEMBLY TUBE FROM TMC TO ECU/HU PORT MC2

CONNECTOR (BRAKE CIRCUIT)

ASSEMBLY TUBE ECU/HU LR TO REAR CONNECTOR LH

ABS

LF

SEALING WASHER

MC2

RF

ASSEMBLY TUBE ECU/HU RF TO FRONT RH CONNECTOR

LR

INDEX RR

26 MC1

ABS

HYDRAULIC LINES - ABS VERSION - RHD

ABS

NEXT

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MECHANICAL STEERING LEi & LSi

LX & LXi

GROUP INDEX

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MECHANICAL STEERING

INTRODUCTION :

The steering system installed on Indica LEi, LSi MPFI is of rack and pinion type. When the steering wheel is turned, the motion is transmitted to pinion through steering shaft and joints. As the pinion teeth are in mesh with rack, the motion gets transferred to rack and changed to linear motion. Thus the steering turning force is transmitted to steering knuckles through tie rods which turn the wheels. This section gives details of mechanical steering system which might be available in some vehicle versions.

MECHANICAL STEERING

INDEX

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i

MECHANICAL STEERING CONTENTS Sr. No.

Description

Page No.

1.

Specifications

1

2.

Tightening Torques

1

3.

List of Special Tools

1

4.

Exploded view : a) Steering System

2

5.

General Description

3

6.

Steering Wheel & Column

5

a) Removal & Installation of steering wheel

5

b) Removal & Installation of combination switch

5

c) Removal & Installation of steering column

6

d) Removal & Installation of steering lock cum Ignition switch

7

6.

Removal & Installation of Rack & Pinion assembly

8

7.

Procedure for Wheel Alignment

9

8.

Wheel Alignment Values

10

9.

Disassembly of Rack & Pinion

11

a) Inspection

12

b) Assembly of Rack & Pinion

13

Trouble shooting

17

10.

MECHANICAL STEERING

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iii

MECHANICAL STEERING SPECIFICATIONS 1. No. of turns (lock to lock)

:

4.27

2. Free pinion rotation torque

:

8-15 kg-cm .

Sterak Grease @ Rack, Pinion, Bearing & Rack Bush

:

20 grams

Silicon Grease @ Bellow lip Inner Ball Joint

:

Smear

Lubrication : Pinion to be lubricated with sterak grease. Lubrication

TIGHTENING TORQUES Sr. No.

Description

Torque (mkg)

1)

Steering Gear box mounting screw on firewall

5

2)

Steering column mounting bolts

3)

Steering wheel nut

4)

Steering lock cum ignition switch mounting screws

5)

Ball joints of tie rod in the steeing knuckle

5

6)

Eccentric pin Nyloc nut on strut

8

7)

Bottom mounting bolt of strut

8

2.5 4 1.5

LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1)

Tie Rod End Puller.

2702 5890 46 02

2)

Steering Wheel Puller (Four spoke)

2779 5890 46 01

3)

Steering Wheel Puller (Two spoke)

2702 5890 46 01

3)

19 mm socket for OBJ nyloc nut loosening / tightening

2779 5890 46 08 N

4)

17 mm socket for IBJ nyloc nut loosening / tightening

2779 5890 46 09 N

5)

14 mm (double ended spanner) for front toe-in & toe-out adjustment

2779 5890 46 10 N

6)

29 mm (double ended spanner) for IBJ loosening / tightening

2779 5890 46 11 N

7)

21 mm (double ended spanner) for rack holding.

2779 5890 46 12 N

8)

Guide bush and mandrel

2779 5890 46 13 N

9)

Yoke cover loosening tool

2779 5890 46 14 N

10)

Pinion cover loosening tool

2779 5890 46 15 N

11)

Adaptor to rotate the pinion to check free pinion troque

2779 5890 46 16 N

12)

IBJ staking tool

2779 5890 46 17 N

INDEX

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MECHANICAL STEERING

1

MECHANICAL STEERING EXPLODED VIEW OF STEERING SYSTEM

4.0

2.5

ASSY STEERING COLUMN

ASSY RUBBER BELLOW LOCKING RING

1.0

2.5 DUST SHIELD/RUBBER BELLOW

5.0

5.0

-- SPECIFIED TORQUE IN Kgm

2

INDEX

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MECHANICAL STEERING GENERAL DESCRIPTION Fig. 1 STEERING WHEEL

A rack and pinion steering gear is used on Indica MPFI . Its design is simple, light and responsive. It uses minimum linkage parts. The rack and pinion steering gear takes the place of centre link in a ball and nut type steering gear. The gear housing containing a helical teeth rack is fastened to the front of the body (firewall) in engine compartment. The rack ends, under rubber bellows, are joined to the tie rods with ball joints at ends. A helical pinion on the steering shaft directly meshes with the rack. A yoke bearing (thrust pad) puts a preload on the rack directly across from the pinion.

STEERING COLUMN

MECHANICAL STEERING

COMBI SWITCH ASSEMBLY RACK & PINION STEERING GEAR ASSEMBLY

Fig.1 Mechanical Steering Assembly

INDEX

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3

MECHANICAL STEERING

STEERING WHEEL END

BALL BEARING

CAPSULE UPPER MOUNTING BRACKET

COLUMN BUSH LOWER MOUNTING BRACKET UPPER UNIVERSAL JOINT

INTERMEDIATE SHAFT ASSEMBLY

STEERING GEAR END UNIVERSAL JOINT

RUBBER BELLOW ASSEMBLY

Steering Column Assembly 4

INDEX

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MECHANICAL STEERING STEERING WHEEL AND COLUMN The steering column can be easily removed and installed. For installation, it is important that only the genuine spare parts i.e. screws, bolts and nuts are used and they are tightened to the specified torque. While removing the column assembly from the car, care must be taken in handling. Use Puller part no. 2779 5890 46 01 for steering wheel. REMOVAL AND INSTALLATION OF STEERING WHEEL : Caution: Please refer to Body Section safety precautions of Airbag and it removal.

Fig. 2

REMOVAL : 1

Park the car with front wheel in straight ahead position.

2

Apply parking brake and place wheel chocks at rear wheels.

3

Disconnect battery cables

4

Remove two screws of air bag

5

Disconnect the wiring connections.Fig. 2.Take out DAB

6

Unscrew the steering wheel nut.

7

Make alignment marks on steering wheel and shaft for guiding during refitment.

8

Remove steering wheel using puller Fig. 3.

MECHANICAL STEERING

Fig. 3 INSTALLATION : Proceed in reverse order of removal. Align the marks made on the steering wheel and shaft and then fit the steering wheel. Tighten the steering wheel nut to 4 mkg torque. REMOVAL AND INSTALLATION OF COMBINATION SWITCH : REMOVAL : 1

Disconnect battery cables

2

Before removing combi switch, remove steering wheel.

3

Unscrew three screws and remove the nacelle. Fig. 4

4

Remove lever assemblies along with connectors,

INDEX

Fig. 4

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5

MECHANICAL STEERING 5

Remove connectors from lever assys Fig. 5

6

Unscrew combi. switch block screw Fig. 6

7

Remove combi. switch block from steering column.

NOTE : Combi switch can also be removed alongwith RH/LH side levers after disconnecting the connectors. INSTALLATION : Proceed in reverse order of removal. Ensure that side levers are fitted in their respective place and correct connectors are connected. Fig. 5 CAUTION :

Fig. 5

When tightening upper tray cover, ensure that combination switch wires are not caught between covers. For installing steering wheel refer STEERING WHEEL INSTALLATION REMOVAL AND INSTALLATION OF STEERING COLUMN : REMOVAL : 1

Disconnect battery cables.

2

Remove steering wheel (Ref. STEERING WHEEL REMOVAL).

3

Remove combiswitch (Ref. COMBINATION SWITCH REMOVAL) Remove instrument cluster & dash board.

4

Disconnect wires & connectors from ignition switch.

5

Mark the location of electrical connector and remove them from the panel.

6

Remove the Ignition switch (For procedure refer ahead)

7

Remove steering column mounting nuts ( Top and Bottom) Fig. 7

8

Unscrew rubber bellow locking ring.

9

Unscrew lower U joint bolt and remove the steering column by prying out the U joint with a screw driver.

Fig. 6

CAUTION : The steering column is of collapsible type. Hence hammering of it or application of thrust in axial direction of the column should be avoided as it will damage the shear pins.

6

INDEX

Fig. 7

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MECHANICAL STEERING INSTALLATION : 1

Proceed in reverse order of removal.

2

Tighten all fasteners to specified torque Fig. 8 & 9

Fig. 8 REMOVAL AND INSTALLATION OF STEERING LOCK CUM IGNITION SWITCH REMOVAL (Steering wheel and combination switch and steering column already removed) 1

Unscrew mounting screws by chiseling.Fig. 10

2

Remove the assembly steering lock cum ignition switch.

NOTE : Steering lock cum ignition switch can also be removed as per the above procedure while steering wheel is still fitted in the car.

MECHANICAL STEERING

Fig. 9

INSTALLATION : 1

Proceed in reverse order of removal.

2

Use new mounting screws.

3

Tighten mounting screws to 1.5 mkg torque. Fig.10

Fig. 10

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7

MECHANICAL STEERING REMOVAL AND INSTALLATION OF RACK AND PINION ASSEMBLY REMOVAL (Steering wheel, combi. switch and steering column already removed) 1

Apply parking brake and place wheel chocks at the rear or put the car on the hoist.

2

Loosen wheel nuts of front wheels Fig.11

3

Remove the front wheels

4

Raise the hoist to Jack up.

Fig. 11 5

Unscrew tie rod ball joint nyloc nut Fig.12

Fig. 12 6

Using puller Pt. No. 2702 5890 4602 take out ball joint from knuckle Fig. 13

7

Repeat steps 2 to 6 for the other side ball joint removal.

Fig. 13 8

INDEX

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MECHANICAL STEERING 8

Cut cable tie for clutch cable.

9

Remove steering gear box (rack and pinion) mounting bolts both RH & LH on fire wall Fig. 14

10

Lower the assembly rack and pinion and take out the cover.

11

Push the assembly out towards LH side approx. half the length and lower towards RH side.

12

Take out the complete assembly from RH side by moving it towards steering knuckle

INSTALLATION : 1

Cable

Proceed in reverse order of removal

PRECAUTIONS :

Mounting

Fig. 14

Replace damaged/worn out parts Adjust tie rod length to a nominal value of 1266 + 15 mm and lock it by lock nuts Fig. 15 Replace Nyloc nuts

LOCK NUT

Tighten steering gear box mounting screws (both RH & LH) to 5 mkg torque Tighten ball joints of tie-rod in steering knuckle to (4-5 mkg torque). Clamp the clutch cable with new cable tie.

1266 + 1 5 mm.

PROCEDURE FOR WHEEL ALIGNMENT Wheel alignment on Indica MPFI involves adjusting camber and toe on front wheels. The caster is in built on Indica MPFI .

MECHANICAL STEERING

Fig.15

Following precautions are to be taken before commencing wheel alignment.

•

Ensure no tyre wear on any wheels. If so replace the tyres.

•

Car should be unladen and parked on level surface.

•

Front and rear tyres should be inflated to correct pressure (30 and 28 psi respectively).

1. Bring the tyre in straight ahead position.

•

Ensure that the silent bushes in the front/rear suspension are in satisfactory condition.

2. Lock the steering wheel in straight ahead position with suitable fixture, so that it does not disturb the tie rod location.

•

Ensure that the front rear & suspension fasteners are tightened to the specified torque.

•

Also ensure that there is no visible damage to any of the suspension parts like lower link bushes and struts.

•

Ensure that there is no play in steering linkages and suspension ball joints.

INDEX

3. Check the camber and toe out, if not found within the specification then adjust it as per the following sequence and procedure.

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9

MECHANICAL STEERING First adjust the camber 1. Loosen the two strut mounting bolts. 2. Rotate the eccentric pin on Top of the strut till required camber value is achieved (For the values, see next page) If not check eccentric pin for excessive wear. If so, replace with new one.

While removal & re-fitment of steering rack and pinion assembly or replacing the tie rods on the vehicle, the following procedure should be followed before going in for the actual wheel alignment as given above. 1.

Steering rack & pinion gear comes with 1266 mm (nominal) length between centres of the ball joints at the end. Ensure that number of threads of outer ball joint exposed out of the tie rod tube are equal on both sides of the tube.

2.

Fix the steering rack & pinion gear on the fire wall. Assemble the steering column with steering wheel. (Do not tighten the steering wheel to full torque.)

3.

Bring the front tyre in straight ahead position.

4.

Rotate steering gear from lock to lock. Measure 4.27 number of turns approx (Mech.stg.) Bring the steering gear to the centre by rotating through half of the total number of turns (measured).

5.

Fix the outer ball joints into the steering arm of steering knuckle.

3. First tighten the eccentric pin flanged nut to 8 mkg torque & then tighten the bottom bolt to 8 mkg torque. 4. Apply 2 drops of Anabond 124 at nut end. Now adjust the toe out 1. Loosen the tie rod end check nuts. 2. Adjust the toe out values by rotating the tie rod ends. While adjusting toe out, adjust the length of both the tie rods by rotating them in the opposite direction such that their lengths remain equal at all times (For the values, see next page). NOTE : If toe is excessively out of limit, first adjust toe, then the camber and then adjust toe again. Not following the sequence i.e. first camber and then toe out will lead to incorrect wheel alignment even though individual adjustments are done correctly.

WHEEL ALIGNMENT VALUES (Unladen condition)

6.

FRONT WHEELS: Parameter

Power Steering

If steering wheel spokes are not centralised, remove the steering wheel & refit, so that spokes & mascot are correctly positioned. Tighten the steering wheel nut to specified torque.

Further carry out the camber & toe in adjustments as explained above.

10 30’ to20 30’ (Inbuilt)

Castor (Inbuilt)

Step 3,4,5 are particularly useful in centralisation of steering linkages and could be even adopted during normal wheel alignment process in case values are not achieved or excessive wheel lock angle is observed.

Camber

45’ to ± 15’ i.e. 30’ to 60’ (+ve) Difference between LH & RH is 20’ Toe-out 0’ to -15’ on each wheel or 0 to 3 mm (-ve) (Total toe) REAR WHEELS: Wheel alignment is also required for the rear wheels. Rear camber (Inbuilt)

10 + 30’

Toe in (per wheel)

00 to 30’

10

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INDEX

GROUP INDEX

COLLAR GEAR MOUNT 5

BUSHING, RUBBER MOUNT 4

NYLOC NUT 25

SECTION - BB

INNER BALL JOINT 19

BELLOW (PINION) 17

PINION COVER 13

B

HOUSING 1

RUBBER MOUNT 6

NEEDLE ROLLER BEARING 3

A

A

PINION 7 B

RETAINER RING 9 PINION BEARING 8

OIL SEAL 14

SECTION - CC

BRACKET (SUPPORT END) 24

RACK 10

BELLOW STRAP (PINION) 21

BELLOW CLIP 23

LOCK NUT

OUTER BALL JOINT 20

RACK TUBE 2

BELLOW STRAP (SUPPORT) 22

C

C

SECTION - AA

YOKE COVER 12

NYLOCK NUT 25

LOCK NUT

OUTER BALL JOINT 20

INNER BALL JOINT 19

SPRING 16

YOKE 11

RACK BUSH 15

BELLOW (SUPPORT) 18

BELLOW CLIP 23

MECHANICAL STEERING

DISASSEMBLY OF RACK & PINION

MECHANICAL STEERING

Fig. 16 Exploded view of steering gear (Rack and Pinion)

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11

MECHANICAL STEERING DISASSEMBLY OF RACK AND PINION : (Fig 16) TO DISMANTLE : (Steering Gear (Rack & Pinion) assembly already removed from the car).

INSPECTION OF DISMANTLED PARTS

•

Examine the Housing set which consists of Case Strg. Gear (1), Needle Roller Bearing (3) and Rack Tube (2). If damage to any of the above components is evident then Housing set must be replaced as a set.

•

Examine the Rubber Mount (6). If damage is evident, replace the part.

•

Hold the Steering Gear by the Rack tube on a soft jaw vice.

•

Remove the Bracket (24).

•

Remove both the Outer Ball joints and Lock nuts from the steering gear.(20)

•

Examine the Rubber Bushing (4) and Collar gear mount (5). If damage is evident, replace the parts.

•

Remove the Bellow strapping parts (21/22) and clips (23) on either sides using a plier via IBJ Rod and dispose them.

•

•

Remove the Bellows (17/18).

Examine the Rack-bush (15) for excessive wear leading to loose fit with Rack. If any of the above is evident, remove the Rack Bush by knocking it out of the Rack Tube using a mandrel gently.

•

Loosen the Inner Ball Joints (19) from the Rack by arresting the Rack teeth with 21 mm double end spanner. It is to be noted that gear should be free and not held / mounted on the housing / rack tube while loosening the IBJ.

•

Examine the Rack and Pinion set which consists of Rack, Pinion, Ball bearing and Retainer ring. If damage to any of the above items is evident then the rack and Pinion set must be replaced as a set.

•

Loosen the Yoke Cover (12) using tool and dispose the Yoke cover. Remove the Spring (16) and Yoke (11) from the housing.

•

Examine the Bellow (17 & 18) for crack and Torn condition. If any of the above is observed, replace the bellows.

•

Loosen the Pinion Cover (13) using the Tool and Remove the Pinion bearing Sub Assembly (7,8,9). Dispose the Pinion cover along with the oil seal (14).

•

Examine the Yoke for excessive wear and damage. If fit between Yoke bore on Case Steering Gear and Yoke is slack in either of designs, replace the Yoke by new one. If damage is evident, replace the Yoke.

•

Remove the Rack (10) via Rack Tube or Via Housing side.

•

Examine the Yoke Spring (16). If found to be damaged or found to be solid (Compressed Set) replace the part.

•

Examine Inner Ball Joints and Outer Ball joints for service failures. If Axial play is more than 0.1 mm at + 100 gms / If damage to the joints is evident, replace the parts.

•

In case of accident vehicle and also during regular overhaul, the Rack, Pinion and Housing set should be checked for visual cracks, breakage and bend. Check Rack and Pinion for micro cracks. If any one of the above is evident, replace the parts.

NOTE : Dismantling of housing assembly for repair is not recommended.

12

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MECHANICAL STEERING TO REASSEMBLE :

•

Clean all components before use.

•

Slide the Rubber Mount (6) over Rack Tube (2) of the Housing set Fig. 17.

HOUSING SET

RUBBER MOUNT (6)

Fig. 17

•

Place the gear on a fixture to orient the cast mounting as shown in Fig. 18. Press the Bushing Rubber Mounts (4). The eyes of the Housing set by hand and then press the collar gear mounts (5) to the Bushings by a Nylon mallet.

•

If the Housing set is reused, then hand tap the threads (M38 x 1.5 to suit Pinion cover) and (M33 x 1.0 to suit Yoke cover) and to remove the Loctite solution applied during the previous assembly.

COLLAR GEAR MOUNT (5)

PRESS THE BUSHING & COLLAR IN THIS WAY

MECHANICAL STEERING

Fig.18

•

Assemble the Rack-bush (15) by using the Guide bush via larger diameter of the tube. Ensure the "3 ears" of the Rack Bush is located well inside the slots of Rack-tube. Ensure that the Ears are outward and Rack-Bush as a whole to be inside the Rack Tube Fig. 19. Apply Sterak grease on the bush Inner diameter.

ADAPTER (SEE DRAWING ATTACHED)

3 SLOTS

RACK BUSH (15)

3 EARS

GENTLE BLOW

Fig. 19

INDEX

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13

MECHANICAL STEERING •

Assemble the Inner Ball Joint (19) secured against Rack to specified Torque. While tightening the IBJ, Secure the Rack in position by holding the Rack teeth with 21 mm double end spanner. It is to be noted that gear should be free and not held / mounted on the housing / Rack tube while tightening the IBJ. After tightening, Stake the IBJ - Rack intersection plane with the staking tool Fig. 20.

•

Smear Shell Sterak Grease on Rack on Outer diameter and on all tooth root and surfaces.

•

Insert the Rack with IBJ into the Housing set via Housing.

•

Assemble the Inner Ball Joint to the other end of Rack and secure it against Rack to specified torque. Follow the same procedure to tighten IBJ and staking as mentioned in paragraph 6.0 above.

•

Pull the Rack together with IBJ to Butt/Touch against inner face of Housing Fig. 21. Apply 20 gm of Sterak grease in to Case Steering Gear.

•

Insert Pinion-Bearing Sub assembly with the Rack held as mentioned above.

RACK (10)

STAKE HERE

INNER BALL JOINT (19)

Fig. 20

IBJ BUTT AGAINST HOUSING FACE

Fig. 21

•

Apply few drops of loctite 542 on pinion cover thread and assemble the Pinion Cover (13) and torque to 8-10 Kg.m. Fig. 22. OIL SEAL (14) PINION COVER (13)

Fig. 22 14

INDEX

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MECHANICAL STEERING •

Apply Molykote grease on Oil Seal (14) and press it in to the groove of Pinion Cover Fig. 23. OIL SEAL (14)

PINION COVER (13)

Fig. 23

•

Turn the Housing in such a way that the Yoke Bore is upright. Then insert the Yoke (11) and Spring (16) as shown in Fig. 24.

YOKE COVER (12)

SPRING (16) YOKE (11)

MECHANICAL STEERING

Fig. 24

•

Apply 2 to 3 drops of Loctite to the Yoke Cover threads (12) and Assemble it Yoke bore Fig. 25 and tighten it to a torque of 70 Kg.cm. Now unscrew the Yoke cover by 30 0 to 45 0 approximately to achieve free Pinion torque of 8 to 15 kgf. cm.

YOKE COVER (12)

Fig. 25

INDEX

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15

MECHANICAL STEERING •

Assemble the Bellow (17) on the Housing side and secure the bellow with Bellow strap (21) and Clip (23) as shown in Fig. 26. Scoop Silicon Grease using Fore-finger and apply on groove of IBJ prior to Bellow assembly, to enable Bellow to rotate relative to IBJ.

BELLOW CLIP (23)

BELLOW (17) BELLOW WIRE (21)

Fig. 26

•

Assemble Bellow Support End (18) over Rubber mount (6) and secure with Bellow Strap (22) and Clip (23) as shown in Fig. 27. Scoop Silicon Grease using Fore-finger and apply on groove of IBJ prior to Bellow assembly, to enable Bellow to rotate relative to IBJ.

•

Fit the Outer Ball joints (20) on either sides on Inner Ball Joints.

BELLOW (18)

BELLOW WIRE (22)

Fig. 27

16

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MECHANICAL STEERING TROUBLESHOOTING GUIDE Sr. No Problem

Causes

1.

Abnormal Noise (A clicking noise heard during a turn, or when changing directions)

Some component is loose in the steering linkges and is shifting under load.

2.

Road Wander

Tyre pressure incorrect or unequal left to right Components in steering linkage loose or worn Wheel bearings improperly adjusted or wornout. Front end alignment out of specification. Steering gear mounting bolts loose on frame. Steering gear improperly adjusted.

3.

No Recovery

Tyre pressure low Front end alignment incorrect. Steering column binding. Steering gear improperly adjusted.

4.

Shimmy

Excessively worn or unevenly worn tyres Improperly mounted tyre or wheel. Wheel bearings improperly adjusted or worn Components in steering linkage loose or worn Wheels or brake drums out of balance Front end alignment incorrect

5.

Oversteering or Darting

Front end components binding or loose. Steering column binding Steering gear improperly adjusted

6.

High steering Effort in One Direction

Unequal tyre pressure Car overloaded

7.

High Steering Effort in Both Directions

Low tyre pressure Car overloaded Components of steering system binding Oversize tyres

8.

Lost Motion (Lash) at the steering wheel

Steering wheel loose on the shaft Loose connection between the steering gear and steering column. Steering gear lose on firewall Components in steering linkage loose or worn. Steering gear improperly adjusted.

INDEX

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MECHANICAL STEERING

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17

MECHANICAL STEERING

INTRODUCTION :

The steering system installed on Indica MPFI is of rack and pinion type. When the steering wheel is turned, the motion is transmitted to pinion through steering shaft and joints. As the pinion teeth are in mesh with rack, the motion gets transferred to rack and changed to linear motion. Thus the steering turning force is transmitted to steering knuckles through tie rods which turn the wheels. This section gives details of mechanical steering system which might be available in some vehicle versions.

MECHANICAL STEERING

INDEX

GROUP INDEX

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i

MECHANICAL STEERING CONTENTS Sr. No.

Description

Page No.

1.

Specifications

1

2.

Tightening Torques

1

3.

List of Special Tools

1

4.

Exploded view : a) Steering System

2

5.

General Description

3

6.

Steering Wheel & Column

5

a) Removal & Installation of steering wheel

5

b) Removal & Installation of combination switch

5

c) Removal & Installation of steering column

6

d) Removal & Installation of steering lock cum Ignition switch

7

6.

Removal & Installation of Rack & Pinion assembly

8

7.

Procedure for Wheel Alignment

9

8.

Wheel Alignment Values

10

9.

Disassembly of Rack & Pinion

11

a) Inspection

12

b) Assembly of Rack & Pinion

13

Trouble shooting

17

10.

MECHANICAL STEERING

INDEX

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iii

MECHANICAL STEERING SPECIFICATIONS 1. No. of turns (lock to lock)

:

4.27

2. Free pinion rotation torque

:

8-15 kg-cm .

Sterak Grease @ Rack, Pinion, Bearing & Rack Bush

:

20 grams

Silicon Grease @ Bellow lip Inner Ball Joint

:

Smear

Lubrication : Pinion to be lubricated with sterak grease. Lubrication

TIGHTENING TORQUES Sr. No.

Description

Torque (mkg)

1)

Steering Gear box mounting screw on firewall

5

2)

Steering column mounting bolts

3)

Steering wheel nut

4)

Steering lock cum ignition switch mounting screws

5)

Ball joints of tie rod in the steeing knuckle

5

6)

Eccentric pin Nyloc nut on strut

8

7)

Bottom mounting bolt of strut

8

2.5 4 1.5

LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1)

Tie Rod End Puller.

2702 5890 46 02

2)

Steering Wheel Puller (Four spoke)

2779 5890 46 01

3)

Steering Wheel Puller (Two spoke)

2702 5890 46 01

3)

19 mm socket for OBJ nyloc nut loosening / tightening

2779 5890 46 08 N

4)

17 mm socket for IBJ nyloc nut loosening / tightening

2779 5890 46 09 N

5)

14 mm (double ended spanner) for front toe-in & toe-out adjustment

2779 5890 46 10 N

6)

29 mm (double ended spanner) for IBJ loosening / tightening

2779 5890 46 11 N

7)

21 mm (double ended spanner) for rack holding.

2779 5890 46 12 N

8)

Guide bush and mandrel

2779 5890 46 13 N

9)

Yoke cover loosening tool

2779 5890 46 14 N

10)

Pinion cover loosening tool

2779 5890 46 15 N

11)

Adaptor to rotate the pinion to check free pinion troque

2779 5890 46 16 N

12)

IBJ staking tool

2779 5890 46 17 N

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MECHANICAL STEERING

1

MECHANICAL STEERING EXPLODED VIEW OF STEERING SYSTEM

4.0

2.5

ASSY STEERING COLUMN

ASSY RUBBER BELLOW LOCKING RING

1.0

2.5 DUST SHIELD/RUBBER BELLOW

5.0

5.0

-- SPECIFIED TORQUE IN Kgm

2

INDEX

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MECHANICAL STEERING GENERAL DESCRIPTION Fig. 1 STEERING WHEEL

A rack and pinion steering gear is used on Indica MPFI Its design is simple, light and responsive. It uses minimum linkage parts. The rack and pinion steering gear takes the place of centre link in a ball and nut type steering gear. The gear housing containing a helical teeth rack is fastened to the front of the body (firewall) in engine compartment. The rack ends, under rubber bellows, are joined to the tie rods with ball joints at ends. A helical pinion on the steering shaft directly meshes with the rack. A yoke bearing (thrust pad) puts a preload on the rack directly across from the pinion.

STEERING COLUMN

MECHANICAL STEERING

COMBI SWITCH ASSEMBLY RACK & PINION STEERING GEAR ASSEMBLY

Fig.1 Mechanical Steering Assembly

INDEX

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3

MECHANICAL STEERING

STEERING WHEEL END

BALL BEARING

CAPSULE UPPER MOUNTING BRACKET

COLUMN BUSH LOWER MOUNTING BRACKET UPPER UNIVERSAL JOINT

INTERMEDIATE SHAFT ASSEMBLY

STEERING GEAR END UNIVERSAL JOINT

RUBBER BELLOW ASSEMBLY

Steering Column Assembly 4

INDEX

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MECHANICAL STEERING STEERING WHEEL AND COLUMN The steering column can be easily removed and installed. For installation, it is important that only the genuine spare parts i.e. screws, bolts and nuts are used and they are tightened to the specified torque. While removing the column assembly from the car, care must be taken in handling. Use Puller part no. 2779 5890 46 01 for steering wheel. REMOVAL AND INSTALLATION OF STEERING WHEEL : Caution: Please refer to Body Section safety precautions of Airbag and it removal.

Fig. 2

REMOVAL : 1

Park the car with front wheel in straight ahead position.

2

Apply parking brake and place wheel chocks at rear wheels.

3

Disconnect battery cables

4

Remove two screws of air bag

5

Disconnect the wiring connections.Fig. 2.Take out DAB

6

Unscrew the steering wheel nut.

7

Make alignment marks on steering wheel and shaft for guiding during refitment.

8

Remove steering wheel using puller Fig. 3.

MECHANICAL STEERING

Fig. 3 INSTALLATION : Proceed in reverse order of removal. Align the marks made on the steering wheel and shaft and then fit the steering wheel. Tighten the steering wheel nut to 4 mkg torque. REMOVAL AND INSTALLATION OF COMBINATION SWITCH : REMOVAL : 1

Disconnect battery cables

2

Before removing combi switch, remove steering wheel.

3

Unscrew three screws and remove the nacelle. Fig. 4

4

Remove lever assemblies along with connectors,

INDEX

Fig. 4

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5

MECHANICAL STEERING 5

Remove connectors from lever assys Fig. 5

6

Unscrew combi. switch block screw Fig. 6

7

Remove combi. switch block from steering column.

NOTE : Combi switch can also be removed alongwith RH/LH side levers after disconnecting the connectors. INSTALLATION : Proceed in reverse order of removal. Ensure that side levers are fitted in their respective place and correct connectors are connected. Fig. 5 CAUTION :

Fig. 5

When tightening upper tray cover, ensure that combination switch wires are not caught between covers. For installing steering wheel refer STEERING WHEEL INSTALLATION REMOVAL AND INSTALLATION OF STEERING COLUMN : REMOVAL : 1

Disconnect battery cables.

2

Remove steering wheel (Ref. STEERING WHEEL REMOVAL).

3

Remove combiswitch (Ref. COMBINATION SWITCH REMOVAL) Remove instrument cluster & dash board.

4

Disconnect wires & connectors from ignition switch.

5

Mark the location of electrical connector and remove them from the panel.

6

Remove the Ignition switch (For procedure refer ahead)

7

Remove steering column mounting nuts ( Top and Bottom) Fig. 7

8

Unscrew rubber bellow locking ring.

9

Unscrew lower U joint bolt and remove the steering column by prying out the U joint with a screw driver.

Fig. 6

CAUTION : The steering column is of collapsible type. Hence hammering of it or application of thrust in axial direction of the column should be avoided as it will damage the shear pins.

6

INDEX

Fig. 7

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MECHANICAL STEERING INSTALLATION : 1

Proceed in reverse order of removal.

2

Tighten all fasteners to specified torque Fig. 8 & 9

Fig. 8 REMOVAL AND INSTALLATION OF STEERING LOCK CUM IGNITION SWITCH REMOVAL (Steering wheel and combination switch and steering column already removed) 1

Unscrew mounting screws by chiseling.Fig. 10

2

Remove the assembly steering lock cum ignition switch.

NOTE : Steering lock cum ignition switch can also be removed as per the above procedure while steering wheel is still fitted in the car.

MECHANICAL STEERING

Fig. 9

INSTALLATION : 1

Proceed in reverse order of removal.

2

Use new mounting screws.

3

Tighten mounting screws to 1.5 mkg torque. Fig.10

Fig. 10

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7

MECHANICAL STEERING REMOVAL AND INSTALLATION OF RACK AND PINION ASSEMBLY REMOVAL (Steering wheel, combi. switch and steering column already removed) 1

Apply parking brake and place wheel chocks at the rear or put the car on the hoist.

2

Loosen wheel nuts of front wheels Fig.11

3

Remove the front wheels

4

Raise the hoist to Jack up.

Fig. 11 5

Unscrew tie rod ball joint nyloc nut Fig.12

Fig. 12 6

Using puller Pt. No. 2702 5890 4602 take out ball joint from knuckle Fig. 13

7

Repeat steps 2 to 6 for the other side ball joint removal.

Fig. 13 8

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MECHANICAL STEERING 8

Cut cable tie for clutch cable.

9

Remove steering gear box (rack and pinion) mounting bolts both RH & LH on fire wall Fig. 14

10

Lower the assembly rack and pinion and take out the cover.

11

Push the assembly out towards LH side approx. half the length and lower towards RH side.

12

Take out the complete assembly from RH side by moving it towards steering knuckle

INSTALLATION : 1

Proceed in reverse order of removal

PRECAUTIONS :

Mount-

Cable Tie

Fig. 14

Replace damaged/worn out parts Adjust tie rod length to a nominal value of 1249 + 15 mm and lock it by lock nuts Fig. 15 Replace Nyloc nuts

LOCK NUT

Tighten steering gear box mounting screws (both RH & LH) to 5 mkg torque Tighten ball joints of tie-rod in steering knuckle to (4-5 mkg torque). Clamp the clutch cable with new cable tie.

1249 + 1 5 mm.

PROCEDURE FOR WHEEL ALIGNMENT Wheel alignment on Indica MPFI involves adjusting camber and toe on front wheels. The caster is in built on Indica MPFI

MECHANICAL STEERING

Fig.15

Following precautions are to be taken before commencing wheel alignment.

•

Ensure no tyre wear on any wheels. If so replace the tyres.

•

Car should be unladen and parked on level surface.

•

Front and rear tyres should be inflated to correct pressure (28 and 24 psi respectively).

1. Bring the tyre in straight ahead position.

•

Ensure that the silent bushes in the front/rear suspension are in satisfactory condition.

2. Lock the steering wheel in straight ahead position with suitable fixture, so that it does not disturb the tie rod location.

•

Ensure that the front rear & suspension fasteners are tightened to the specified torque.

•

Also ensure that there is no visible damage to any of the suspension parts like lower link bushes and struts.

•

Ensure that there is no play in steering linkages and suspension ball joints.

INDEX

3. Check the camber and Toe in, if not found within the specification then adjust it as per the following sequence and procedure.

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9

MECHANICAL STEERING First adjust the camber 1. Loosen the two strut mounting bolts. 2. Rotate the eccentric pin on Top of the strut till required camber value is achieved (For the values, see next page) If not check eccentric pin for excessive wear. If so, replace with new one.

While removal & re-fitment of steering rack and pinion assembly or replacing the tie rods on the vehicle, the following procedure should be followed before going in for the actual wheel alignment as given above. 1.

Steering rack & pinion gear comes with 1249 mm (nominal) length between centres of the ball joints at the end. Ensure that number of threads of outer ball joint exposed out of the tie rod tube are equal on both sides of the tube.

2.

Fix the steering rack & pinion gear on the fire wall. Assemble the steering column with steering wheel. (Do not tighten the steering wheel to full torque.)

3.

Bring the front tyre in straight ahead position.

4.

Rotate steering gear from lock to lock. Measure 4.27 number of turns approx (Mech. stg.) Bring the steering gear to the centre by rotating through half of the total number of turns (measured).

5.

Fix the outer ball joints into the steering arm of steering knuckle.

3. First tighten the eccentric pin flanged nut to 8 mkg torque & then tighten the bottom bolt to 8 mkg torque. 4. Apply 2 drops of Anabond 124 at nut end. Now adjust the toe in 1. Loosen the tie rod end check nuts. 2. Adjust the Toe in values by rotating the tie rod ends. While adjusting Toe in, adjust the length of both the tie rods by rotating them in the opposite direction such that their lengths remain equal at all times (For the values, see next page). NOTE : If toe is excessively out of limit, first adjust toe, then the camber and then adjust toe again. Not following the sequence i.e. first camber and then Toe in will lead to incorrect wheel alignment even though individual adjustments are done correctly.

WHEEL ALIGNMENT VALUES (Unladen condition)

6.

FRONT WHEELS: Parameter

Power Steering

If steering wheel spokes are not centralised, remove the steering wheel & refit, so that spokes & mascot are correctly positioned. Tighten the steering wheel nut to specified torque.

Further carry out the camber & toe in adjustments as explained above.

10 + 45’

Caster (Inbuilt)

Step 3,4,5 are particularly useful in centralisation of steering linkages and could be even adopted during normal wheel alignment process in case values are not achieved or excessive wheel lock angle is observed.

Camber -10’ to +40’ Difference between LH & RH is 20’ Toe-in

1’ to16’ on each wheel or 0 to 3.7mm (total)

REAR WHEELS: Wheel alignment is also required for the rear wheels. Rear camber (Inbuilt) Toe in (per wheel)

10

INDEX

00 + 30’ 00 to 30’ (+ve)

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INDEX

GROUP INDEX

COLLAR GEAR MOUNT 5

BUSHING, RUBBER MOUNT 4

NYLOC NUT 25

SECTION - BB

INNER BALL JOINT 19

BELLOW (PINION) 17

PINION COVER 13

B

HOUSING 1

RUBBER MOUNT 6

NEEDLE ROLLER BEARING 3

A

A

PINION 7 B

RETAINER RING 9 PINION BEARING 8

OIL SEAL 14

SECTION - CC

BRACKET (SUPPORT END) 24

RACK 10

BELLOW STRAP (PINION) 21

BELLOW CLIP 23

LOCK NUT

OUTER BALL JOINT 20

RACK TUBE 2

BELLOW STRAP (SUPPORT) 22

C

C

SECTION - AA

YOKE COVER 12

NYLOCK NUT 25

LOCK NUT

OUTER BALL JOINT 20

INNER BALL JOINT 19

SPRING 16

YOKE 11

RACK BUSH 15

BELLOW (SUPPORT) 18

BELLOW CLIP 23

MECHANICAL STEERING

DISASSEMBLY OF RACK & PINION

MECHANICAL STEERING

Fig. 16 Exploded view of steering gear (Rack and Pinion)

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11

MECHANICAL STEERING DISASSEMBLY OF RACK AND PINION : (Fig 16) TO DISMANTLE : (Steering Gear (Rack & Pinion) assembly already removed from the car).

INSPECTION OF DISMANTLED PARTS

•

Examine the Housing set which consists of Case Strg. Gear (1), Needle Roller Bearing (3) and Rack Tube (2). If damage to any of the above components is evident then Housing set must be replaced as a set.

•

Examine the Rubber Mount (6). If damage is evident, replace the part.

•

Hold the Steering Gear by the Rack tube on a soft jaw vice.

•

Remove the Bracket (24).

•

Remove both the Outer Ball joints and Lock nuts from the steering gear.(20)

•

Examine the Rubber Bushing (4) and Collar gear mount (5). If damage is evident, replace the parts.

•

Remove the Bellow strapping parts (21/22) and clips (23) on either sides using a plier via IBJ Rod and dispose them.

•

•

Remove the Bellows (17/18).

Examine the Rack-bush (15) for excessive wear leading to loose fit with Rack. If any of the above is evident, remove the Rack Bush by knocking it out of the Rack Tube using a mandrel gently.

•

Loosen the Inner Ball Joints (19) from the Rack by arresting the Rack teeth with 21 mm double end spanner. It is to be noted that gear should be free and not held / mounted on the housing / rack tube while loosening the IBJ.

•

Examine the Rack and Pinion set which consists of Rack, Pinion, Ball bearing and Retainer ring. If damage to any of the above items is evident then the rack and Pinion set must be replaced as a set.

•

Loosen the Yoke Cover (12) using tool and dispose the Yoke cover. Remove the Spring (16) and Yoke (11) from the housing.

•

Examine the Bellow (17 & 18) for crack and Torn condition. If any of the above is observed, replace the bellows.

•

Loosen the Pinion Cover (13) using the Tool and Remove the Pinion bearing Sub Assembly (7,8,9). Dispose the Pinion cover along with the oil seal (14).

•

Examine the Yoke for excessive wear and damage. If fit between Yoke bore on Case Steering Gear and Yoke is slack in either of designs, replace the Yoke by new one. If damage is evident, replace the Yoke.

•

Remove the Rack (10) via Rack Tube or Via Housing side.

•

Examine the Yoke Spring (16). If found to be damaged or found to be solid (Compressed Set) replace the part.

•

Examine Inner Ball Joints and Outer Ball joints for service failures. If Axial play is more than 0.1 mm at + 100 gms / If damage to the joints is evident, replace the parts.

•

In case of accident vehicle and also during regular overhaul, the Rack, Pinion and Housing set should be checked for visual cracks, breakage and bend. Check Rack and Pinion for micro cracks. If any one of the above is evident, replace the parts.

NOTE : Dismantling of housing assembly for repair is not recommended.

12

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MECHANICAL STEERING TO REASSEMBLE :

•

Clean all components before use.

•

Slide the Rubber Mount (6) over Rack Tube (2) of the Housing set Fig. 17.

HOUSING SET

RUBBER MOUNT (6)

Fig. 17

•

Place the gear on a fixture to orient the cast mounting as shown in Fig. 18. Press the Bushing Rubber Mounts (4). The eyes of the Housing set by hand and then press the collar gear mounts (5) to the Bushings by a Nylon mallet.

•

If the Housing set is reused, then hand tap the threads (M38 x 1.5 to suit Pinion cover) and (M33 x 1.0 to suit Yoke cover) and to remove the Loctite solution applied during the previous assembly.

COLLAR GEAR MOUNT (5)

PRESS THE BUSHING & COLLAR IN THIS WAY

MECHANICAL STEERING

Fig.18

•

Assemble the Rack-bush (15) by using the Guide bush via larger diameter of the tube. Ensure the "3 ears" of the Rack Bush is located well inside the slots of Rack-tube. Ensure that the Ears are outward and Rack-Bush as a whole to be inside the Rack Tube Fig. 19. Apply Sterak grease on the bush Inner diameter.

ADAPTER (SEE DRAWING ATTACHED)

3 SLOTS

RACK BUSH (15)

3 EARS

GENTLE BLOW

Fig. 19

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13

MECHANICAL STEERING •

Assemble the Inner Ball Joint (19) secured against Rack to specified Torque. While tightening the IBJ, Secure the Rack in position by holding the Rack teeth with 21 mm double end spanner. It is to be noted that gear should be free and not held / mounted on the housing / Rack tube while tightening the IBJ. After tightening, Stake the IBJ - Rack intersection plane with the staking tool Fig. 20.

•

Smear Shell Sterak Grease on Rack on Outer diameter and on all tooth root and surfaces.

•

Insert the Rack with IBJ into the Housing set via Housing.

•

Assemble the Inner Ball Joint to the other end of Rack and secure it against Rack to specified torque. Follow the same procedure to tighten IBJ and staking as mentioned in paragraph 6.0 above.

•

Pull the Rack together with IBJ to Butt/Touch against inner face of Housing Fig. 21. Apply 20 gm of Sterak grease in to Case Steering Gear.

•

Insert Pinion-Bearing Sub assembly with the Rack held as mentioned above.

RACK (10)

STAKE HERE

INNER BALL JOINT (19)

Fig. 20

IBJ BUTT AGAINST HOUSING FACE

Fig. 21

•

Apply few drops of loctite 542 on pinion cover thread and assemble the Pinion Cover (13) and torque to 8-10 Kg.m. Fig. 22. OIL SEAL (14) PINION COVER (13)

Fig. 22 14

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MECHANICAL STEERING •

Apply Molykote grease on Oil Seal (14) and press it in to the groove of Pinion Cover Fig. 23. OIL SEAL (14)

PINION COVER (13)

Fig. 23

•

Turn the Housing in such a way that the Yoke Bore is upright. Then insert the Yoke (11) and Spring (16) as shown in Fig. 24.

YOKE COVER (12)

SPRING (16) YOKE (11)

MECHANICAL STEERING

Fig. 24

•

Apply 2 to 3 drops of Loctite to the Yoke Cover threads (12) and Assemble it Yoke bore Fig. 25 and tighten it to a torque of 70 Kg.cm. Now unscrew the Yoke cover by 30 0 to 45 0 approximately to achieve free Pinion torque of 8 to 15 kgf. cm.

YOKE COVER (12)

Fig. 25

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15

MECHANICAL STEERING •

Assemble the Bellow (17) on the Housing side and secure the bellow with Bellow strap (21) and Clip (23) as shown in Fig. 26. Scoop Silicon Grease using Fore-finger and apply on groove of IBJ prior to Bellow assembly, to enable Bellow to rotate relative to IBJ.

BELLOW CLIP (23)

BELLOW (17) BELLOW WIRE (21)

Fig. 26

•

Assemble Bellow Support End (18) over Rubber mount (6) and secure with Bellow Strap (22) and Clip (23) as shown in Fig. 27. Scoop Silicon Grease using Fore-finger and apply on groove of IBJ prior to Bellow assembly, to enable Bellow to rotate relative to IBJ.

•

Fit the Outer Ball joints (20) on either sides on Inner Ball Joints.

BELLOW (18)

BELLOW WIRE (22)

Fig. 27

16

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MECHANICAL STEERING TROUBLESHOOTING GUIDE Sr. No Problem

Causes

1.

Abnormal Noise (A clicking noise heard during a turn, or when changing directions)

Some component is loose in the steering linkges and is shifting under load.

2.

Road Wander

Tyre pressure incorrect or unequal left to right Components in steering linkage loose or worn Wheel bearings improperly adjusted or wornout. Front end alignment out of specification. Steering gear mounting bolts loose on frame. Steering gear improperly adjusted.

3.

No Recovery

Tyre pressure low Front end alignment incorrect. Steering column binding. Steering gear improperly adjusted.

4.

Shimmy

Excessively worn or unevenly worn tyres Improperly mounted tyre or wheel. Wheel bearings improperly adjusted or worn Components in steering linkage loose or worn Wheels or brake drums out of balance Front end alignment incorrect

5.

Oversteering or Darting

Front end components binding or loose. Steering column binding Steering gear improperly adjusted

6.

High steering Effort in One Direction

Unequal tyre pressure Car overloaded

7.

High Steering Effort in Both Directions

Low tyre pressure Car overloaded Components of steering system binding Oversize tyres

8.

Lost Motion (Lash) at the steering wheel

Steering wheel loose on the shaft Loose connection between the steering gear and steering column. Steering gear lose on firewall Components in steering linkage loose or worn. Steering gear improperly adjusted.

INDEX

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MECHANICAL STEERING

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17

POWER STEERING LEi & LSi

LX & LXi

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POWER STEERING

INTRODUCTION :

Power steering fitted on Indica LEi & LSi MPFI is for lighter steering effort and easy manoeuvrability. The system consists of power steering gearbox, hydraulic pump and hydraulic tank suitably mounted and connected by piping. Pump drive is through poly ‘V’ belt from engine. Power assistance is available during normal operating conditions. In case of any failure in hydraulic system, the steering can still be operated mechanically with increased steering effort for bringing the car to an authorised service outlet.

POWER STEERING

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i

POWER STEERING CONTENTS Sr. No.

Description

Page No.

1)

Technical Specifications

1

2)

List of Special Tools

2

3)

Layout Of Power Steering Assembly

3

4)

Exploded Views : a)

Hydraulic power steering lines

4

b)

Rack and Pinion Assembly

5

c)

Assembly power steering pump

6

d)

Power steering reservoir

7

5)

Power Rack & Pinion Steering System

8

6)

Power Rack & Pinion Steering Gear - Operation

9

7)

Procedure for filling and bleeding Hydraulic System

12

8)

Minor repairs on Power Rack & Pinion Steering Gear

13

a)

Replacement of Outer Ball Joint (OBJ) assembly

13

b)

Replacement of Bellows

14

c)

Replacement of Inner Ball Joint (IBJ) Assembly

15

d)

Replacement of Feed Pipes

16

e)

Replacement of Input Shaft Seal

17

9)

On car Service - Inspection and Maintenance

18

10)

Power Steering Gear - Exploded View

19

11)

Power Steering System - Hydraulic tests using Diagnostic gauge

20

12)

Trouble shooting guide

22

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POWER STEERING

iii

POWER STEERING TECHNICAL SPECIFICATIONS

POWER STEERING GEAR Type

:

End Take Off-Rack & Pinion Steering Gear

Rack travel

:

134 mm

No. of steering wheel turns lock to lock

:

3.27

Flow rate

:

7 lpm to 5 lpm

Maximum operating pressure

:

70

Free Pinion Rotation Torque

:

8 -15 kgf - cm

bar

POWER STEERING PUMP Type

:

Vane Type, drooping flow characteristics.

Cartridge capacity

:

7.2 cc/rev

Controlled Flow

:

7 lpm to 5 lpm

Relief Pressure

:

70 bar

Operating Speed

:

500 to 8000 RPM

Operating temperature

:

-30o C to + 120o C

POWER STEERING RESERVOIR Type

:

Transparent Plastic Reservoir with replaceable filter cartridge(for non ABS) Metallic Reservoir with replaceable filter cartridge (for ABS)

Capacity

:

At Max. level - 375 ml At Min. level - 300 ml

Hydraulic fluid

:

At Max. level- 320 ml (for non ABS) At Min. level - 250 ml (for non ABS)

POWER STEERING

Automatic Transmission Fluid

Lubricants : Sterak Grease @ Rack & Pinion & Rack Bush

:

10 grams

Silicon Grease @ Bellow LIP-IBJ

:

Smear

INDEX

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1

POWER STEERING LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1)

Fixture to position steering gear assembly firmly during repair

2779 5890 46 02 N

2)

Sputnik Torque wrench to loosen / tighten IBJ assembly

2779 5890 46 03 N

3)

Bellow dolly (2 nos.) to assemble new bellows in to the housing/rack

2779 5890 46 04 N

4)

Strap removal tool

2779 5890 46 05 N

5)

Peening punch to stake the IBJ against a notch on both ends of rack

2779 5890 46 06 N

6)

Feed pipe torque wrench to loosen / tighten the flare nut of feed pipe

2779 5890 46 07 N

7)

Seal Pressing tool

2702 5890 46 05

2

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POWER STEERING

STEERING WHEEL

STEERING COLUMN

COMBI SWITCH ASSEMBLY POWER STEERING

POWER RACK & PINION STEERING GEAR ASSEMBLY

Fig.1 Layout of power steering assembly

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3

POWER STEERING HYDRAULIC POWER STEERING LINES

(FOR ABS)

22

1.0 21

0.8

1.0

16 14

17

15

2.5

6 12

18

2 12

19 15

3.5 16

11 10 18

1

3 1.0

4

2 LIST OF PARTS No. 1 1 2 3 4 5 5 6

Description RUBBER HOSE (SUCTION LINE) RUBBER HOSE (SUCTION)-(ABS) SPRING BAND CLAMP FORM-A 15X23D CLAMP HEX FL SCREW M6X10 - 8.8 ASSY.RETURN LINE (P/STG)-RHD (ABS) ASSY RETURN LINE (POWER STG) SPRING BAND CLAMP FORM A 15X19D

9 10 11 12 14 15 16 17 18 19 21 22

ASSY. RETURN PIPE LINE ASSY.HIGH PRESSURE HOSE (COMPLETE)-RHD SEALING WASHER 14X20 IS3175 - CU PIPE UNION BOLT 10 M14X1.5 O’ RING (HP LINE) SLEEVE CLAMP (FOR 10 DIA PIPE) HEX FL NUT AM6 HEX FL SCREW M6X12 - 8.8 ASSY.BRACKET (HP LINE CLAMPING) SPRING WASHER B8 IS3063 SS8451-8C HEX SCREW M8 X 14 - 8.8

Fig.(i) 4

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POWER STEERING RACK AND PINION ASSY (POWER STEERING) FEED PIPE ASSEMBLY - LONG BELLOW KIT FEED PIPE ASSEMBLY - SHORT GEAR MOUNT COLLER

BELLOW

MOUNTING CLAMP RUBBER MOUNT BUSH

BELLOW STRAP

RUBBER MOUNT

INNER BALL JOINT ASSEMBLY

BELLOW STRAP

OUTER BALL JOINT ASSEMBLY

BELLOW

BELLOW CLIP

INNER BALL JOINT ASSEMBLY

5.0

5.0

OUTER BALL JOINT ASSEMBLY

BELLOW CLIP -- SPECIFIED TORQUE IN Kgm

Fig.(ii) INDEX

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5

POWER STEERING

Fig.(iii)

6

INDEX

GROUP INDEX

ASSY.POWER STEERING PUMP HOUSING ASSY. HOUSING SUB ASSY.(QTY/KIT - 1) FLOW CONTROL SPRING (QTY/KIT - 1)

VALVE ASSY.QTY/KIT - 1) O’ RING (QTY/KIT - 1) PRESSURE PORT CONNECTOR (QTY/KIT - 1) CARTRIDGE ASSY. PRESSURE PLATE (QTY/KIT - 1)

1 2 3 4

5 6 7 8 9

ITEM NO DESCRIPTION

DOWEL PIN (QTY/KIT - 2) VANES (QTY/KIT - 10) ROTOR (QTY/KIT - 1) CAM(QTY/KIT - 1) END COVER ASSY.(QTY/KIT - 1) SEAL KIT DOUBLE LIP SEAL (QTY/KIT - 1) O’ RING (FOR PR PLATE ID,QTY/KIT - 1) O’ RING (FOR PR PLATE ID,QTY/KIT - 1) GASKET (QTY/KIT - 1) BOLT FOR END COVER

10 11 12 13 14 15 16 17 18 19 20

SPRING WASHER B8 IS3073 THIN HD.CAP SCREW M8 X 16

26 28

O’ RING 20 X 2 NITRILE SUCTION HOUSE CONNECTOR

25 27

BALL BEARING RETAINING RING

24

SHAFT

22 23

RETAINING WASHER

21

POWER STEERING

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PLASTIC RESERVOIR 1 PLASTIC RESERVOIR & MOUNTING STRAP ASSY. 2 SHELL 3 FILTER AND END COVER ASSY. 4 VALVE SEAT 5 SPRING (FOR BY PASS VALVE) 6 WASHER

7 8 9 10 11 12

SCREW STAINER ...O-RING ...RESERVOIR CAP COVER TIE STRAP MOUNTING STRAP

1 2 3 4

METALLIC RESERVOIR FOR ABS RESERVOIR ASSY. SHELL FILTER CAP ASSY.

POWER STEERING

Fig.(iv)

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7

POWER STEERING

ALTERNATOR BELT TENSIONER BOLT STEERING WHEEL

1

COLUMN ASSEMBLY JOINT

7 PRESSURE LINE

8

RESERVOIR

SUCTION LINE 8 PUMP ENGINE

PULLEY

RETURN LINE

INTERMEDIATE JOINT

5

2 POWER RACK & PINION STG. GEAR

BELLOW CLIP BELLOW

BELLOW STRAP 3

6

4 FEED PIPE - SHORT FEED PIPE - LONG

LOCK NUT

9

BALL PIN NUT

Fig. 2 Schematic layout of a typical belt driven power steering system

POWER RACK & PINION STEERING SYSTEM GENERAL DESCRIPTION Fig. 2 The Hydraulic Power Steering reduces the driver’s effort needed to turn the steering wheel. This is achieved by utilising the hydraulic pressure generated by the hydraulic pump which is driven by the engine.

RESERVOIR Hydraulic oil for the Power steering system is stored in the Reservoir. The Reservoir generally is located at a higher level above Pump to ensure feed by gravitational flow. POWER STEERING PUMP

The power steering offers the following advantages :-

Pump is driven by engine 5PK poly ‘V’ belt.

•

Reduces steering effort and driver fatigue

•

The Power Steering Pump provides the hydraulic assistance for the Power Steering Gear to operate.

Provides precise steering control.

•

Absorbs steering shocks, hydraulically preventing them from being transmitted to the steering wheel.

•

Provides absolute control and greater safety, quickly & effortlessly in demanding emergencies like sudden tyre failures or car pull due to malfunctioning brakes.

8

INDEX

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POWER STEERING ROTARY CONTROL VALVE ASSY FEED PIPE - SHORT INPUT SHAFT

TORSION BAR I/P SHAFT SEAL

FEED PIPE - LONG

BEARING ROLLER

BELLOW PINION ASSEMBLY

BELLOW CLIP

INNER BALL JOINT ASSY

BELLOW STRAP

PINION BALL- BEARING

RACK ASSY

SEAL PINION SHAFT NEEDLE ROLLER BRG

LOCK STOP ASSY

RACK TUBE (CYLINDER) OUTER BALL JOINT

Fig. 3 Schematic sketch - power rack and pinion gear.

POWER RACK & PINION STEERING GEAR Fig. 3 The Power Rack & Pinion Steering Gear comprise of : Manual steering mechanism 1.

Manual steering mechanism is based on proven, reliable, smooth and lashfree Rack & Pinion mechanism. The Pinion is supported on Ball & Needle Roller Bearings and the Rack on anti friction bush to ensure high efficiency and smooth operation and the mechanism is designed to operate manually in the event of hydraulic power failure.

Rotary control valve (Hydraulic control valve) 2.

The Rotary Control Valve combines simplicity of construction with desirable performance characteristics that provides responsive steering control. The input shaft and the valve sleeve constitute the two members of the Rotary Control Valve.

Power cylinder (Rack Tube) all in a single compact package. 3.

and pinned on housing and the Piston swaged to the Rack. The bore of the steel tube is honed for smooth Piston movement. The two sides of the Cylinder (RH & LH) are connected to the Rotary Control Valve by external feed pipes. OPERATION POWER STEERING

What happens during steering manoeuvre ? When the driver turns the steering wheel, he transmits force from the wheel to steering gear input shaft. Input shaft rotation is transmitted to the Pinion through Torsion bar which is pinned at one end to the Input shaft and pressed firmly into the Pinion at the other end. The Pinion tends to push the Rack linearly through the Rack tube bore. But the linear movement of the Rack which is connected to the steered road wheels through link mechanism is resisted by the load on the steered wheels.

Power Cylinder : The built in hydraulic cylinder is constituted by the strong steel tube press fitted

INDEX

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9

POWER STEERING POWER RACK & PINION STEERING GEAR - OIL FLOW

LH CYLINDER RH CYLINDER

OIL IN

ROTARY VALVE POSITION

RH CYLINDER INPUT SHAFT TORSION BAR

OIL IN

VALVE SLEEVE LH CYLINDER

LH CYLINDER RH CYLINDER

SHORT FEED PIPE TO RH CYLINDER

OIL IN

LONG FEED PIPE TO LH CYLINDER

VALVE ASSY

SECTION - M (ENLARGED) OIL IN

NEUTRAL

A

A BELLOW

OIL OUT

RACK

IBJ

RACK TUBE (CYLINDER)

Fig. 4

PRESSURE OIL IN

PRESSURE OIL IN

ROTARY VALVE POSITION

RIGHT TURN

CW ROTATION

PRESSURE OIL IN

PRESSURE OIL IN RETURN OIL

Fig. 5 10

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POWER STEERING

PRESSURE OIL IN

ROTARY VALVE POSITION

PRESSURE OIL IN

LEFT TURN CCW ROTATION

PRESSURE OIL IN

PRESSURE OIL RETURN OIL

Fig. 6 This resistance offered by the steered wheels on the Pinion, leads to a definite twist on the Torsion bar depending on the input torque level. The Torsion bar twist disturbs the neutral position of the Rotary Control Valve (input shaft and valve sleeve). The disturbed Rotary Control Valve directs the oil flow from the pump to the appropriate side of the cylinder.

POWER STEERING

The Piston Rack pressurised by the oil, moves in the required direction overcoming the resistance offered by the steered wheels and produces the steering action. The resistance in the rotation direction of Pinion is relieved by movement of Piston Rack by hydraulic force and the reaction of Torsion bar returns the rotary valve to its neutral position. The oil flow diagram in neutral, right turn and left turn positions of the steering gear are shown in. Fig. 4, 5 & 6.

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11

POWER STEERING PROCEDURE FOR FILLING AND BLEEDING THE HYDRAULIC SYSTEM Apply parking brake and set the Gear shift lever in neutral. Raise the front wheel clear off the ground and support with safety stand. Check for proper connection and tightness of end fittings/hose clips in hydraulic lines. Fill the reservoir nearly full with recommended Power Steering fluid. Crank the engine for 10 seconds if possible without allowing it to start. If the engine does start, shut off immediately. Check and refill Reservoir. Repeat atleast 3 times, each time checking and refilling till the level in the reservoir is stabilised. CAUTION : Do not allow the oil to run down significantly or run out of the reservoir. This may induce air into the system. Start the engine and check for any leakage in the system and if noticed, take corrective action. Turn the steering wheel so that the lock stops are lightly contacted at each lock, 3 or 4 times till oil in the reservoir is free from any bubbles or foaming. If bubbles or foaming is present, it indicates that air is getting sucked into the system. Check the power steering lines fittings/hose clips and correct, if necessary. If the system is bled properly there should not be any appreciable change in oil level, when the engine is started or stopped repeatedly. Finally check and top up (if required) the fluid to the specified level in the Reservoir. CAUTION : Don’t load the system until it is bled properly. Severe damages could occur otherwise. Always use recommended oil from closed containers. Any dirty oil in the system will result in damage to Pump/Gear.

12

INDEX

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POWER STEERING DISENGAGEMENT OF OBJ FROM STEERING ARM INNER BALL JOINT END

OBJ LOCK NUT OUTER BALL JOINT

STEERING ARM BALL PIN NUT

REMOVAL OF OBJ FROM IBJ END

SPANNER LOCATION

Fig. 7

MINOR REPAIRS ON POWER RACK & PINION & PINION STEERING GEAR STEERING GEAR This section covers only minor repairs that do not require complete dismantling of steering gear assembly. CAUTION : The minor repairs should be handled only by proper trained personnel who have proper equipment, tools, instructions and know-how and authorised to perform the work properly and safely. REPLACEMENT OF OUTER BALL JOINT (OBJ) ASSEMBLY.

REMOVAL OF OUTER BALL JOINTS Fig. 7 Raise the front of the car and support it on a safety stand in the proper location. Remove the front wheels Unscrew the ball pin nut of the Outer ball joint (RH side & LH side) and using puller part no. 2702 5890 4602, remove the Outer ball joint from the steering arm (knuckle arm). Hold the Inner ball joint with 14mm spanner and loosen the lock nut with 17mm spanner to free the ball joint. Now unscrew the Outer ball joint out of the Inner ball joint (Tie rod) assembly Discard the Outer ball joint assembly.

NOTE :

ASSEMBLY OF OUTER BALL JOINTS

The outer ball joint assemblies must be replaced if either of the following conditions are detected.

Screw in the new Outer ball joint assembly on the Inner ball joint (Tie rod)

1.

Any binding in articulation of the ball pin.

2.

Any axial play between the ball and cup of Outer ball joint Assy, more than 0.1 mm at + 100 gms.

Align the steering gear in mid position to straight ahead position (SAP) of the steered wheels.

The replacement of Outer ball joint can be done on the vehicle itself without removing the steering gear from the vehicle as explained below :

INDEX

Connect the Outer ball joints with the steering arm Tighten the ball nut to specified torque. Install the front wheels and lower the front of the car. Carry out wheel alignment. Now tighten the outer ball joint lock nut to specified torque.

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13

POWER STEERING

POWER STEERING

ASSEMBLY OF BELLOW BELLOW STRAP BELLOW CLIP

GROOVE TO LOCATE SMALL END OF BELLOW HOUSING

BELLOW CLIP

BELLOW

DOLLY PULL OUT

Fig. 8

REPLACEMENT OF BELLOWS : Fig. 8 For better access and convenience to replace the bellows properly, remove the steering gear assembly from the car as per procedure in the Mechanical Steering Group of this Manual. CAUTION :

Pull out the bellows away from the ends of the steering gear box along with clip. Discard the bellow/strap & clip. Clean the outer surface at the ends of the steering gear and Inner ball joint assembly.

ASSEMBLY OF BELLOWS

1.

Plug the ports tight with protective caps in the steering gear.

2.

Use only Special Tools and do not hammer to remove outer ball joints from steering arm (knuckle arm)

3.

Take care to avoid damage to bellows, feed pipes and input shaft when drawing out the steering gear assembly from the car.

Mount the steering gear on a mock up bracket.

REMOVAL OF BELLOWS Remove the Outer ball joint assembly after loosening the lock nut. Unscrew out the lock nut (Refer Replacement of Outer ball joint for removal procedure). Remove the bellows straps and discard.

14

INDEX

Clean the outer surface of the dolly (Taper guide tool) and insert it on the Inner ball joint Assy. Apply grease (dow corning) on the groove of both the tie rods. Assemble the bellow clip on the small end of the bellow. Keeping the rack in mid gear position slide the bellows on the dolly big end first till the small end of bellow locates on the greased groove. Assemble the big end of the bellows over the ends of the steering gear (Housing & Rack tube) ensuring no twist to the bellows. Using the strapping gun, strap the big end of the bellow firmly to ensure proper sealing.

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POWER STEERING

REMOVAL OF INNER BALL JOINT ASSEMBLY

INNER BALL JOINT RACK SPUTNIC WRENCH

ASSEMBLY OF IBJ

NOTCH FOR IBJ STAKING

INNER BALL JOINT

Fig. 9

CAUTION :

REMOVAL OF INNER BALL JOINTS Fig. 9

If the strapping is not sound means possibility of rusty gear/entry of dust/water ingress/lack of lubrication.

Remove the steering gear assembly from the car (Refer Steering group of this Workshop Manual).

Slide the rack to right and left by turning the Input shaft to be certain that the bellows are not deformed or twisted.

CAUTION : 1.

Plug the ports tight with protective caps in the steering gear.

Screw in the lock nut and Outer ball joint assembly on the Inner ball joint. Dismount the steering gear assembly from the mock up bracket.

2.

Use only Special Tools and not hammer to remove Outer ball joints from steering arm (knuckle arm)

3.

Take care to avoid damage to bellows, feed pipes and input shaft When drawing out the steering gear assembly from the car.

Reinstall the steering gear on the car.

REPLACEMENT OF INNER BALL JOINTS ASSEMBLY (IBJ’S). NOTE : The Inner ball joint assembly must be replaced if either of the following conditions is detected. 1.

Any binding in articulation of the Ball rod (tie rod)

2.

Any axial play between the ball and cup of Inner ball joint assembly, more than 0.1 mm at + 100 gms.

INDEX

WARNING : Improper tightening of Inner ball joint assemblies will cause accident. Mount the steering gear assembly on a mock up bracket. Remove the outer ball joints and bellows on the LH side and RH side of the steering gear (Refer Replacement of Outer ball joint / Bellows for removal procedure).

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15

POWER STEERING

POWER STEERING

FEED PIPE LONG FEED PIPE SHORT

FLARE NUT A/F 11

Fig. 10 Hold the rack suitably to take care not to damage the rack surface. Using sputnik wrench, unscrew the Inner ball joint assembly from the ends of the rack.

ASSEMBLY OF INNER BALL JOINT Screw in the new Inner ball joint assembly to the ends of the rack by hand. Hold the rack suitably taking care not to damage the surface. Using Sputnik wrench, tighten the Inner ball joint assembly to 8 kg-m torque. Stake the Inner ball joint (RHS & LHS) using a punch against the notch on both the ends of the rack. Reassemble the bellows and Outer ball joint (Refer Replacement of Outer ball joint/Bellows). Dismount the steering gear from the mock up bracket. Reinstall the steering gear on the car.

REPLACEMENT OF FEED PIPES (SHORT/ LONG) Fig. 10 CAUTION : Do not attempt to repair any bent or damaged feed pipes. Whenever feed pipes are removed discard the

INDEX

Remove the steering gear assembly from the car.

CAUTION :

Discard the Inner ball joint assembly.

16

same and replace with new ones only.

1.

Plug the ports tight with protective caps in the steering gear.

2.

Use only Special Tools and not hammer to remove Outer ball joints from steering arm.

3.

Take care to avoid damage to bellows, feed pipes and Input shaft when drawing out the steering gear assembly from the car. Carefully unscrew the flare nuts at the ends of the short/long feed pipes connected to housing and rack tube ends using 11 mm spanner. Discard the feed pipes. Blow clean the inside of the new feed pipes (short/ long) with compressed air. Install the feed pipes (short/long) by screwing the flare nuts at the ends to housing and rack tube by hand. Now tighten the flare nuts to 1.7 kg-m torque. Reinstall the steering gear assembly on the car.

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POWER STEERING

REMOVAL OF INPUT SHAFT SEAL

ASSEMBLY OF INPUT SHAFT SEAL

CIRCLIP

PRESSING TOOL PART NO. 2702 5890 4605.

INPUT SHAFT SEAL

INPUT SHAFT SEAL SEAL GUIDE TOOL

PRESSURE PORT RETURN PORT

Fig. 11

REPLACEMENT OF INPUT SHAFT SEAL Fig. 11

Disconnect the air pressure supply as soon as the seal is out.

Remove the steering gear assy. from the car.

Discard the seal.

Caution :

Wipe the seal bore with a clean cloth.

1.

Plug the ports tight with protective caps.

2.

Use only Special Tools and not the hammer for removing the outer ball joints from knuckle.

Determine by inspection that seal bore is in good condition.

3.

Take care to avoid damage to bellows, feed pipe and input shaft when taking out the steering gear from the car.

Mount the steering gear assy. on a mock up bracket with Input shaft facing upwards. Using circlip plier remove the input shaft seal retaining ring. Unplug the return port and hold the clean cloth around the input shaft and apply air pressure to the return port.

Clean the seal guide tool and insert it on the input shaft covering the serration. Apply power steering fluid on the input shaft seal and slide it down the seal guide tool into the housing bore with lip facing down. Using seal pressing tool part no. 2702 5890 46 05, press the seal till it butts on the bearing face. Using circlip plier compress and engage the circlip in the bore of the housing. Now remove the circlip plier and using a drift, press the circlip until it locates in the groove of the housing bore. Reinstall the steering gear on the car.

The air pressure will force out the input shaft seal to come out of the gear and some fluid will leak out of the gear.

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17

POWER STEERING

POWER STEERING ON - CAR SERVICE - INSPECTION & MAINTENANCE 1

STEERING WHEEL

8 COLUMN ASSEMBLY JOINT.

PULLEY

RESERVOIR 7 SUCTION LINE

PUMP ENGINE

RETURNLINE

INTERMEDIATE JOINT

PRESSURE LINE

5 POWER RACK & PINION STG. GEAR

2

BELLOW CLIP

4 BELLOW 6 FEED STRAP 3 BELLOW PIPE - LONG FEED PIPE - SHORT

8

LOCK NUT

9

BALL PIN NUT

Fig. 12 Power rack & pinion steering system 1. STEERING WHEEL PLAY With Engine off and front wheels in Straight Ahead Position , check for any free play at steering wheel without moving the front wheels. There should be no free play but only the feel of the Torsion bar twist in the stg. gear. With hands off stg. wheel, the reaction of torsional twist will bring the stg. wheel back to the original position. If any play is detected, check for

replace with new one. Ensure Feed pipes do not foul with each other (or) on any part of the vehicle. 5. PUMP/DRIVE BELT Engine driven belt drive Pump. Never run the pump dry. Check Pump belt condition and proper tension atleast once in a fortnight. Adjust tension as recommended. 6. STG. GEAR MOUNTING Check for any interference (or) condition that may cause the gear to distort due to improper mounting / tightness. Correct if required.

1. Looseness in Stg. Joints / Links 2. Yoke adjustment in stg. gear.

7. POWER STEERING OIL

2. INNER BALL JOINT (TIE ROD) SWING RESISTANCE After disconnecting Outer ball joint from stg. arm give ten hard swings to Inner ball joint to feel swing resistance, If swing is tight replace the Inner ball joint. If swing is smooth and there is no play between the ball and cup of Inner ball joint, it may be used. 3. BELLOW / STRAP / CLIP Check Bellow for Crack (or) Damage, Replace if any. Check for proper crimping of Bellow by Strap/ Clip.

Use only genuine. Power Stg. oil. Never run the Engine without oil in the Reservior. Check oil level with Engine running and maintain between Min. & Max. mark. Use specified oil. Follow the oil and filter change schedule. 8. HYDRAULIC LINES Check the Hydraulic lines (Hoses/Pipes) of the system for damage, Correct as required. for leak proof connection and smooth flow without restriction. 9. OUTER BALL JOINTS

CAUTION : Defective Bellow and loose crimping means possibility of rusty gear, entry of dust or lack of grease. 4. FEED PIPES Check Feed pipes for damage (or) bend. If any, 18

INDEX

Check the boot condition for crack/damage. Check for play in the ball joint. If any of the above exist, replace with new one. Check Outer ball joint lock nut & Ball pin nut tightness.

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POWER STEERING POWER STEERING GEAR - EXPLODED VIEW :

NOTE : INSTALL NEW SEALS WHENEVER THE GEAR IS DISMANTLED FOR REPAIR.

LIST OF PARTS No. DESCRIPTION 1 HOUSING & TUBE ASSY 2. SEAL - RACK (HOUSING) 3. BALL BEARING 4. SEAL - PINION SHAFT 5. BEARINGNEEDLE ROLLER 6. RACK & PISTON ASSY. 7. PISTON SEAL RING 8. ‘O’ RING 9. LOCK STOP 10 RETAINING RING 11 LINER 12 ‘O’ RING 13 SEAL - RACK (L/S) 14 PISTON & VALVE ASSY. 14A VALVE SEAL RING 15 NUT - PINION 16 PINION COVER

17 ROLLER BEARING 18 SEAL - INPUT SHAFT 19 CIRCLIP 20 YOKE 21 YOKE SPRING 22 YOKE COVER 23 INNER BALL JOINT 24 BELLOW 25 BELLOW CLIP 26 BELLOW STRAP 27 RUBBER MOUNT BUSH 28 REAR MOUNT COLLAR 29 RUBBER MOUNTING 30 MOUNTING CLAMP 31 FEED PIPE ASSY. - LONG 32 FEED PIPE ASSY - SHORT 33 AFTER BALL JOINT ASSY. 33A OBJ LOCK NUT 33B NYLOC NUT (OBJ BALL PIN)

Fig. 13

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19

POWER STEERING

POWER STEERING POWER STEERING SYSTEM - HYDRAULIC TESTS USING DIAGNOSTIC GAUGE

Diagnostic Gauge Power Stg. Pump

Pressure Line

Column Assembly

Intermediate Joint

Suction line

Engine

Return Line

Rack & Pinion Power Stg. Gear

Fig. 14 GENERAL

2. Steering Gear - Internal leakage

The Diagnostic Gauge is designed to conduct on vehicle hydraulic tests in Power Steering System for a detailed trouble shooting when all other aspects checked prove satisfactory.

PREPARATION OF HYDRAULIC SYSTEM

The Diagnostic Gauge comprises of a PRESSURE GAUGE, FLOW METER, SHUT OFF VALVE AND HOSES provided with quick coupling for easy connection. Fig. 14

Check and top up oil in Reservoir. Bleed the system as per procedure (Refer page 6).

Using this Diagnostic Gauge, we can check the following and compare to specification of the system. 1. Pump Performance Check a. Flow b. Relief Pressure

Install Diagnostic Gauge in the pressure line (fluid supply line from Pump to Steering Gear).

Place a thermometer in the Reservoir to record temperature. With the shut off valve of Diagnostic Gauge fully open, warm up the hydraulic system by partially closing the shut off valve until the pressure gauge reads 100 PSI (7 bar). When the temperature reads 51.70 C and 57.20 C open the valve. The system is now warmed up and ready for conducting the hydraulic test.

c. Pump response 20

INDEX

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POWER STEERING Test No. 1

Test No. 2

PUMP PERFORMANCE

PUMP RESPONSE TEST

Keep an eye on the Pressure Gauge and slowly close the Shut off valve of Diagnostic Gauge. System pressure not to exceed the relief pressure specified (Refer vehicle manual) for the system.

Keeping an eye on the flow meter, look for instant return of flow rate to recommended flow range from zero when shut off valve is opened from the closed position both at idling and governed speed. Conduct the test once at idling speed and three times at Engine governed speed.

CAUTION : Do not keep the shut off valve closed for more than 5 seconds at a time to avoid damage to the pump. Measure and record in table below the flow, pressure and temperature at idling and governed speed with shut off valve in fully opened and closed condition (with hands off the steering wheel). Engine Speed

Shut off PressureFlow Temperature Comment valve condition Idling Open A Speed Closed B Governed Open A Speed Closed B Compare minimum/maximum flow and maximum pressure (relief pressure) recorded with specification and refer appropriate comments below for corrective action. If it meets the specification, proceed to Test No. 2. COMMENTS

If the flow rate does not return immediately the Pump is malfunctioning and can result in momentary loss of power assist. The Pump needs to be repaired or replaced. Test No. 3 STEERING GEAR INTERNAL LEAKAGE TEST First conduct Pump performance test and confirm that the Pump is working satisfactorily. With shut off valve open and at steady idling speed of Engine, turn the steering wheel to any wheel lock end and apply force at the rim of the steering wheel to be sure that the control valve is fully closed. The Pressure gauge should now read maximum pressure (relief pressure) specified for the pump. If it reads appreciably less than the relief pressure, it indicates reduction in power assistance because of excessive internal leakage. Repair or replace the Steering gear. Repeat this test at the opposite wheel lock.

A. (i)steady state fluid pressure (with hands off steering wheel) should be equal to or less than that specified for the system. If it reads higher than the specification, check the feed and return line circuits and hoses between Pump and Gear box for clogging/deformation. Check the filter for any clogging. (ii) If the measured flow is less than the specification the Pump needs to be repaired (or) replaced. B. (i)If maximum system pressure (relief pressure) recorded is lower than the specification, it may not be developing enough pressure to assist steering. The pump needs to be repaired or replaced.

CAUTION : Don’t hold the steering wheel in the full turn position (lock end) for more than 5 sec. to avoid damaging the Pump.

Note : 1) When hydraulic tests are completed and fluid lines are reconnected check fluid lever and bleed the system. 2) For power steering wheel alignment values refer page 9 of mechanical steering group.

CAUTION: With shut off valve closed, the flow drops to zero and should not be closed for more than five seconds.

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21

POWER STEERING

POWER STEERING TROUBLE SHOOTING GUIDE : GENERAL

•

Power Steering System trouble shooting requires correct approach and analysis.

•

First key to diagnose a steering problem is to understand exactly what the problems is

•

Save a lot of time and work by talking to the customer/driver, understand and verify the problem reported.

•

Walk around the vehicle, looking for anything that may be an obvious cause of the problem.

•

Check the following 1. Are tyre sizes, tyre variety and air pressure correct to original specification ? 2. Is the steering wheel an original equipment ? 3. Has the suspension been modified in any way that would affect steering? 4. Is the steering fluid in reservoir filled to proper level ? 5. Is the power steering pump belt properly adjusted ? 6. Is the engine idle speed correct and steady ? 7. Has the steering aggregates been disturbed off its original settings ? 8. Any record of accident/heavy impact load that would affect steering ?

The above preliminary checks help to analyse the problem and guide for corrective action, as required. Most steering problems can be charted out to common complaints as given below :

COMMON COMPLAINTS

Hard Steering

Steering Wheel kick/Shock/ Vibration

Road wander / Lash in Steering

22

INDEX

Poor Self Centering

Direction Pull

Noise / Vibration

Reduced Wheel Turns

GROUP INDEX

External leaks

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POWER STEERING COMPLAINT

HARD STEERING

CONDITION

AS MAY BE NARRATED BY THE CUSTOMER

• Won’t turn

• Lock up/stuck up

• Not enough Power assist

• Won’t turn unless moving

• High effort to steer

• Sticky/binding

PROBABLE DEFECT

CORRECTIVE ACTION

Present during cold start only

Some power steering pumps have temporary state, when pump element vanes are sticky

Increase engine speed briefly to correct the problem

Sensitive to steering wheel speed.

Air drawn in due to insufficient fluid per filling and bleeding procedure

Add fluid and bleed the system

More prevalent when steering fast

Air being sucked in through cracks or loose fittings/hose / pipes in suction line

Replace/correct the crack/ loose fitting , hoses, pipes in suction line fill and bleed the system as per procedure

Present only in one direction of turn

Present in both the direction of turn

INDEX

Flow From the pump is less than minimum recommended for steering gear.

Repair (or) replace the Pump.

Steady state fluid pressure (with hands off steering wheel) at idling with shut off valve fully open, is high, due to clogging/deformation of feed and return hydraulic lines

Clean/replace the clogged/ deformed hydraulic lines as required.

Unequal tyre pressure

Inflate both steered wheels to equal specified pressure.

Feed pipe to concerned cylinder is deformed

Replace the deformed feed pipe

Excessive internal leakage in one direction of turn only (verify with internal leakage test)

Repair or replace the steering gear

Low tyre pressure

Inflate both steered wheels to equal specified pressure.

Low hydraulic fluid

Check and rectify external leak if any. Top up the oil and

GROUP INDEX

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POWER STEERING

23

POWER STEERING

Improper rotation or binding in column related parts

Low pressure or flow from Pump

Check pump performance. Repair or replace as required.

Faulty steering joints

Replace the joints

Faulty steering link components like inner/outer ball joints etc.

Determine by inspection. Identify and replace the defective steering link component.

Rack pad adjustment too tight

Adjust rack guide to specification

Bent rack shaft

Replace steering gear assembly.

Stickiness in the Steering gear assembly

Replace Steering gear assembly.

Feed pipes to both the cylinders deformed

Replace the Feed pipes

Excessive internal leakage

Repair or replace the Steering gear as required.

Restriction in return line or line too small in diameter

Clear restriction/kinks, if hoses are same as OE. If not replace the return line with specified one. Fill and bleed the system as per procedure. Check specifications and replace with recommended size tyres

Oversize tyres

Present as intermittent loss of power assistance

24

INDEX

bleed the system (if required) Determine by Inspection what interference or condition is causing binding and correct the problem.

Pump drive belt slip or worn out belt

Adjust belt tension or replace belt and adjust as required

Pump malfunctioning as no immediate return of flow rate on opening the load valve from closed position.

Repair or replace the pump as required

GROUP INDEX

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POWER STEERING COMPLAINT

AS MAY BE NARRATED BY THE CUSTOMER

STEERING WHEEL

• Kick back

• Bump steer

KICK/ SHOCK/VIBRATION

• Rough Steering

• Vibration in steering wheel

CONDITION Prevalent when turning at low speeds, particularly at rough roads or turning at engine idle speed while car is stationery.

Vibration / shock / kick felt when turning the steering wheel to lock.

PROBABLE DEFECT

CORRECTIVE ACTION

Engine idling speed low/erratic tending to stall when the steering wheel is turned affecting steady minimum flow from pump.

Adjust the engine speed for steady idling rpm.

Air in the system or Power Steering oil too low.

If oil level is too low, look for external leak. If any, correct & fill oil and bleed the system.

Looseness or lash in steering system that may be drifting under load when turning.

Determine by inspection from steering wheel to steered wheels, links/joints/mountings for looseness/wear/ crack. Renew/ replace the affected part (s).

Improperly adjusted Steering Gear. May be Rack guide (Yoke) has backed off excessively or worn.

Adjust the Rack guide to Specification. If problem is not corrected, replace the Steering gear.

Front shock absorber/ suspension strut malfunctioning.

Replace the defective shock absorber/suspension strut.

Pump stops momentarily due to belt slipping on drive pulley.

Adjust the belt tension to specification.

COMPLAINT

POWER STEERING

AS MAY BE NARRATED BY THE CUSTOMER

REDUCED WHEEL TURN

• Very high turning

• Not enough turn from centre to lock

radius required

• Wheel cut restricted CONDITION No. of turns not equal from centre to lock (with Power Off condition).

PROBABLE DEFECT Steering Gear mid position not aligned to straight ahead condition of steered wheels. Bend in steering links due to heavy impact load/accidents.

INDEX

GROUP INDEX

• Unequal number of turns from centretolock CORRECTIVE ACTION Allign the Steering Gear mid position to straight ahead condition of steered wheels. Do the wheel alignment to the specification. Determine by inspection the affected steering link and replace with new one. Do not attempt to straighten the bend on the links.

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25

POWER STEERING COMPLAINT DIRECTIONAL PULL

AS MAY BE NARRATED BY THE CUSTOMER

• Vehicle pulls to one side

• A constant force needed to hold steering

CONDITION Pulling felt while braking only

Pulling prevalent while accelerating only

Constant force is required to hold steering wheel COMPLAINT ROAD WANDER / LASH IN STEERING

CONDITION Vehicle wanders requiring constant correction at steering wheel

26

INDEX

PROBABLE DEFECT

CORRECTIVE ACTION

Unequal braking force on steered wheels

Check and adjust the brakes of steered wheels. Replace the brakes if necessary

Uneven or badly worn tyres

Replace the tyre

Deflection in suspension or steering links

Determine by inspection the suspension and steering links and replace affected parts

Wheel bearings improperly adjusted

Check and adjust to specifications

Unequal tyre pressure on front tyres

Inflate the front tyres to equal pressure

Improper wheel alignment

Check and correct wheel alignment

Motoring (automatic steering) due to unbalanced control valve in Steering gear

Replace the Steering gear

AS MAY BE NARRATED BY THE CUSTOMER

• Lash in steering • Lost motion in steering

• Constant correction is needed at steering wheel to keep the vehicle from wandering

PROBABLE DEFECT

CORRECTIVE ACTION

Uneven or extreme tread wear

Replace tyres with new one

Unequal tyre pressure on steered wheels

Correct tyre pressure to specification

Lash in steering due to any looseness or wear or cracked components from steering wheel to road wheels (Steering wheel, steering column, joints, inner/ outer ball joints)

Determine by inspection to identify the cause for lash and tighten or Replace the affected component as necessary

Steering gear rack guide adjustment improper/disturbed Backed off excessively.

Adjust rack guide to specification

Wheel alignment out of specification

Correct wheel alignment to specification

Wheel bearings not adjusted properly or worn out

Adjust or replace the bearings as necessary

GROUP INDEX

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POWER STEERING COMPLAINT

AS MAY BE NARRATED BY THE CUSTOMER

POOR SELF CENTERING

• Steering does not return smoothly

• Steered wheels don’t return to straight ahead

• Poor self centering position CONDITION

PROBABLE DEFECT

Resistance or binding felt preventing smooth/quick return of steered wheels

Poor tyre condition/uneven tyre wear/mismatched tyres

Replace with good recommended tyres, inflate to specified pressure

Tyre pressure low or unequal

Correct tyre pressure to specification

Improper wheel alignment

Correct wheel alignment to specification

Binding in steering column

Determine by inspection after disconnecting column from Steering Gear, the cause for binding and correct / renew affected components

Rubbing/interference of any part with any other part during steering movement. Improper mounting causing distortion to Steering gear.

Determine by inspection the cause for rubbing/interference and correct the same Remove the Steering gear and determine by inspection what interference or condition is causing the gear to distort and correct the problem.

Deformed/damaged Feed pipes on Steering Gear

Replace the Feed pipes

Input torque high due to improper adjustment of Steering gear.

Remove the Steering gear. Check and adjust Rack guide adjustment to specification. If the problem is not corrected, replace the Steering gear.

Binding in Steering axle (Upper/ lower links)

Determine by inspection and renew/replace Steering axles/ links/bushes / ball joints

Insufficient oil flow to steering gear for adequate steering speed.

Repair or replace the Pump if flow is less.

INDEX

GROUP INDEX

CORRECTIVE ACTION

NEXT

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POWER STEERING

27

POWER STEERING COMPLAINT NOISE AND VIBRATION

AS MAY BE NARRATED BY THE CUSTOMER

• Humming noise while •

CONDITION

• Clicking sound while

steering Squealing noise

steering

• Hissing noise • Rattling noise

PROBABLE DEFECT

CORRECTIVE ACTION

Humming noise that increases with engine speed

This is not a defect. The noise is due to pulsation of fluid when the pump is running which is normal

-

Hissing noise when turning right or left

This is not a defect. The noise is due to actuation of Flow Control Valve during steering operation which is normal.

-

Noise evident when wheels are held on full lock.

This is not a defect. This noise is from the relief valve in the Pump

Caution : Do not hold the wheels at full lock for more than 5 seconds

Gratting noise from pump

Cavitation caused by air bubbles in the fluid, due to low or insufficient oil in system

Check fluid level in reservoir. If low top up the oil. Correct external leaks, if any. Determine by inspection, possibility of air suction through loose pipe fittings, hose clamping. Tighten or replace as necessary. Check Pump shaft seal for leakages, if any. Fill and bleed the system.

Squealing noise from pump

Low belt tension or worn out belt

Tighten the belt or replace as necessary

Abnormally loud noise from pump

Pump internals excessively worn out or damaged

Replace the pump

Rattling or chattering noise

Loose pump pulley

Tighten or replace the pulley. If shaft is found damaged, replace the Pump

Loose or worn steering columns/ intermediate joints

Tighten or replace the parts as necessary

Loose inner or outer ball joints

Tighten to replace the parts as necessary

Rack guide adjustments improper or disturbed.

Adjust to specification if not corrected, replace the Steering gear

Clicking noise heard during a turn or when changing direction

Some component is loose and shifting under load

Determine by inspection, tighten or replace if necessary

Vibrating Noise

Unclamped/Rubbing/damaged/ deformed pipe lines

Determine by inspection and correct or replace if necessary

28

INDEX

GROUP INDEX

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POWER STEERING COMPLAINT EXTERNAL LEAKS

AS MAY BE NARRATED BY THE CUSTOMER

• Loss of steering fluid • Frequent adding of fluid is required

• Oil wetness CONDITION Leak through fittings/ sealing washers

Leak through hoses

Leak through Reservoir

Leak through Pump hardened or cracked seal.

Leak through Steering Gear Assy.

INDEX

PROBABLE DEFECT

• Oil puddle under vehicle after parking

• Leak at steering gear / pump/reservoir CORRECTIVE ACTION

Improper tightness of fittings

Tighten and clamp suitably to avoid loosening under vibration

End fitting/Sealing washer is damaged or cracked due to improper tightening

Replace the end fittings/sealing washer & tighten properly

Loose connection

Tighten & clamp suitably

Heat or age cracks

Replace the hose with new one

Twisting or Abrasion wear due to improper routing/fouling/kinking/ twist

Replace the hose & route and clamp suitably

Foaming or oil throwing out due to air in the system

Check proper connection of suction line. Fill and bleed the system.

Reservoir is overfilled.

Drain the oil in reservoir to proper level

Broken or cracked bracket/cover/ shell of reservoir due to improper clamping/vibration

Replace the reservoir assembly with new and clamp properly

Through shaft seal, due to defective seal Fill and bleed the system. If it still leaks, replace the pump.

Remove the seal. If seal bore is OK, replace with new seal.

Leak through Pump assembly housing/ cover/ joint face seals/ “O” rings

Replace the seals/ “O” rings. If it still leaks, replace the pump.

Leak through Input shaft seal

Remove input shaft seal. If seal bore is OK, replace the seal with new one.

Leak from Cylinder (Rack tube) through Rack seal into right/ left bellows.

Replace the Rack seal using special tools taking care not to cause any damage/scorings to inner walls of Cylinder (Rack tube)

Leak through pinion seal in valve housing into RH bellows.

Replace pinion seals using special tools.

Leak through feed pipes connection to Rack tube at flare nut.

Tighten the connection properly.

Cracked/damaged feed pipes

Replace feed pipes.

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POWER STEERING

29

POWER STEERING

INTRODUCTION :

Power steering fitted on Indica LX & LXi MPFI is for lighter steering effort and easy manoeuvrability. The system consists of power steering gearbox, hydraulic pump and hydraulic tank suitably mounted and connected by piping. Pump drive is through poly ‘V’ belt from engine. Power assistance is available during normal operating conditions. In case of any failure in hydraulic system, the steering can still be operated mechanically with increased steering effort for bringing the car to an authorised service outlet.

POWER STEERING

INDEX

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i

POWER STEERING CONTENTS Sr. No.

Description

Page No.

1)

Technical Specifications

1

2)

List of Special Tools

2

3)

Layout Of Power Steering Assembly

3

4)

Exploded Views : a)

Hydraulic power steering lines

4

b)

Rack and Pinion Assembly

5

c)

Assembly power steering pump

6

d)

Power steering reservoir

7

5)

Power Rack & Pinion Steering System

8

6)

Power Rack & Pinion Steering Gear - Operation

9

7)

Procedure for filling and bleeding Hydraulic System

12

8)

Minor repairs on Power Rack & Pinion Steering Gear

13

a)

Replacement of Outer Ball Joint (OBJ) assembly

13

b)

Replacement of Bellows

14

c)

Replacement of Inner Ball Joint (IBJ) Assembly

15

d)

Replacement of Feed Pipes

16

e)

Replacement of Input Shaft Seal

17

9)

On car Service - Inspection and Maintenance

18

10)

Power Steering Gear - Exploded View

19

11)

Power Steering System - Hydraulic tests using Diagnostic gauge

20

12)

Trouble shooting guide

22

INDEX

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POWER STEERING

iii

POWER STEERING TECHNICAL SPECIFICATIONS

POWER STEERING GEAR Type

:

End Take Off-Rack & Pinion Steering Gear

Rack travel

:

134 mm

No. of steering wheel turns lock to lock

:

3.27

Flow rate

:

7 lpm to 5 lpm

Maximum operating pressure

:

70

Free Pinion Rotation Torque

:

8 -15 kgf - cm

bar

POWER STEERING PUMP Type

:

Vane Type, drooping flow characteristics.

Cartridge capacity

:

7.2 cc/rev

Controlled Flow

:

7 lpm to 5 lpm

Relief Pressure

:

70 bar

Operating Speed

:

500 to 8000 RPM

Operating temperature

:

-30o C to + 120o C

POWER STEERING RESERVOIR Type

:

Transparent Plastic Reservoir with replaceable filter cartridge(for non ABS) Metallic Reservoir with replaceable filter cartridge (for ABS)

Capacity

:

At Max. level - 375 ml At Min. level - 300 ml

Hydraulic fluid

:

At Max. level- 320 ml (for non ABS) At Min. level - 250 ml (for non ABS)

POWER STEERING

Automatic Transmission Fluid

Lubricants : Sterak Grease @ Rack & Pinion & Rack Bush

:

10 grams

Silicon Grease @ Bellow LIP-IBJ

:

Smear

INDEX

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1

POWER STEERING LIST OF SPECIAL TOOLS Sr. No.

Description

Part No.

1)

Fixture to position steering gear assembly firmly during repair

2779 5890 46 02 N

2)

Sputnik Torque wrench to loosen / tighten IBJ assembly

2779 5890 46 03 N

3)

Bellow dolly (2 nos.) to assemble new bellows in to the housing/rack

2779 5890 46 04 N

4)

Strap removal tool

2779 5890 46 05 N

5)

Peening punch to stake the IBJ against a notch on both ends of rack

2779 5890 46 06 N

6)

Feed pipe torque wrench to loosen / tighten the flare nut of feed pipe

2779 5890 46 07 N

7)

Seal Pressing tool

2702 5890 46 05

2

INDEX

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POWER STEERING

STEERING WHEEL

STEERING COLUMN

COMBI SWITCH ASSEMBLY POWER STEERING

POWER RACK & PINION STEERING GEAR ASSEMBLY

Fig.1 Layout of power steering assembly

INDEX

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3

POWER STEERING HYDRAULIC POWER STEERING LINES

(FOR ABS)

22

1.0 21

0.8

1.0

16 14

17

15

2.5

6 12

18

2 12

19 15

3.5 16

11 10 18

1

3 1.0

4

2 LIST OF PARTS No. 1 1 2 3 4 5 5 6

Description RUBBER HOSE (SUCTION LINE) RUBBER HOSE (SUCTION)-(ABS) SPRING BAND CLAMP FORM-A 15X23D CLAMP HEX FL SCREW M6X10 - 8.8 ASSY.RETURN LINE (P/STG)-RHD (ABS) ASSY RETURN LINE (POWER STG) SPRING BAND CLAMP FORM A 15X19D

9 10 11 12 14 15 16 17 18 19 21 22

ASSY. RETURN PIPE LINE ASSY.HIGH PRESSURE HOSE (COMPLETE)-RHD SEALING WASHER 14X20 IS3175 - CU PIPE UNION BOLT 10 M14X1.5 O’ RING (HP LINE) SLEEVE CLAMP (FOR 10 DIA PIPE) HEX FL NUT AM6 HEX FL SCREW M6X12 - 8.8 ASSY.BRACKET (HP LINE CLAMPING) SPRING WASHER B8 IS3063 SS8451-8C HEX SCREW M8 X 14 - 8.8

Fig.(i) 4

INDEX

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POWER STEERING RACK AND PINION ASSY (POWER STEERING) FEED PIPE ASSEMBLY - LONG BELLOW KIT FEED PIPE ASSEMBLY - SHORT GEAR MOUNT COLLER

BELLOW

MOUNTING CLAMP RUBBER MOUNT BUSH

BELLOW STRAP

RUBBER MOUNT

INNER BALL JOINT ASSEMBLY

BELLOW STRAP

OUTER BALL JOINT ASSEMBLY

BELLOW

BELLOW CLIP

INNER BALL JOINT ASSEMBLY

5.0

5.0

OUTER BALL JOINT ASSEMBLY

BELLOW CLIP -- SPECIFIED TORQUE IN Kgm

INDEX

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5

POWER STEERING

Fig.(iii)

6

INDEX

GROUP INDEX

ASSY.POWER STEERING PUMP HOUSING ASSY. HOUSING SUB ASSY.(QTY/KIT - 1) FLOW CONTROL SPRING (QTY/KIT - 1)

VALVE ASSY.QTY/KIT - 1) O’ RING (QTY/KIT - 1) PRESSURE PORT CONNECTOR (QTY/KIT - 1) CARTRIDGE ASSY. PRESSURE PLATE (QTY/KIT - 1)

1 2 3 4

5 6 7 8 9

ITEM NO DESCRIPTION

DOWEL PIN (QTY/KIT - 2) VANES (QTY/KIT - 10) ROTOR (QTY/KIT - 1) CAM(QTY/KIT - 1) END COVER ASSY.(QTY/KIT - 1) SEAL KIT DOUBLE LIP SEAL (QTY/KIT - 1) O’ RING (FOR PR PLATE ID,QTY/KIT - 1) O’ RING (FOR PR PLATE ID,QTY/KIT - 1) GASKET (QTY/KIT - 1) BOLT FOR END COVER

10 11 12 13 14 15 16 17 18 19 20

SPRING WASHER B8 IS3073 THIN HD.CAP SCREW M8 X 16

26 28

O’ RING 20 X 2 NITRILE SUCTION HOUSE CONNECTOR

25 27

BALL BEARING RETAINING RING

24

SHAFT

22 23

RETAINING WASHER

21

POWER STEERING

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POWER STEERING

INDEX

GROUP INDEX

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7

POWER STEERING

ALTERNATOR BELT TENSIONER BOLT STEERING WHEEL

1

COLUMN ASSEMBLY JOINT

7 PRESSURE LINE

8

RESERVOIR

SUCTION LINE 8 PUMP ENGINE

PULLEY

RETURN LINE

INTERMEDIATE JOINT

5

2 POWER RACK & PINION STG. GEAR

BELLOW CLIP BELLOW

BELLOW STRAP 3

6

4 FEED PIPE - SHORT FEED PIPE - LONG

LOCK NUT

9

BALL PIN NUT

Fig. 2 Schematic layout of a typical belt driven power steering system

POWER RACK & PINION STEERING SYSTEM GENERAL DESCRIPTION Fig. 2 The Hydraulic Power Steering reduces the driver’s effort needed to turn the steering wheel. This is achieved by utilising the hydraulic pressure generated by the hydraulic pump which is driven by the engine.

RESERVOIR Hydraulic oil for the Power steering system is stored in the Reservoir. The Reservoir generally is located at a higher level above Pump to ensure feed by gravitational flow. POWER STEERING PUMP

The power steering offers the following advantages :-

Pump is driven by engine 5PK poly ‘V’ belt.

•

Reduces steering effort and driver fatigue

•

The Power Steering Pump provides the hydraulic assistance for the Power Steering Gear to operate.

Provides precise steering control.

•

Absorbs steering shocks, hydraulically preventing them from being transmitted to the steering wheel.

•

Provides absolute control and greater safety, quickly & effortlessly in demanding emergencies like sudden tyre failures or car pull due to malfunctioning brakes.

8

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POWER STEERING ROTARY CONTROL VALVE ASSY FEED PIPE - SHORT INPUT SHAFT

TORSION BAR I/P SHAFT SEAL

FEED PIPE - LONG

BEARING ROLLER

BELLOW PINION ASSEMBLY

BELLOW CLIP

INNER BALL JOINT ASSY

BELLOW STRAP

PINION BALL- BEARING

RACK ASSY

SEAL PINION SHAFT NEEDLE ROLLER BRG

LOCK STOP ASSY

RACK TUBE (CYLINDER) OUTER BALL JOINT

Fig. 3 Schematic sketch - power rack and pinion gear.

POWER RACK & PINION STEERING GEAR Fig. 3 The Power Rack & Pinion Steering Gear comprise of : Manual steering mechanism 1.

Manual steering mechanism is based on proven, reliable, smooth and lashfree Rack & Pinion mechanism. The Pinion is supported on Ball & Needle Roller Bearings and the Rack on anti friction bush to ensure high efficiency and smooth operation and the mechanism is designed to operate manually in the event of hydraulic power failure.

Rotary control valve (Hydraulic control valve) 2.

The Rotary Control Valve combines simplicity of construction with desirable performance characteristics that provides responsive steering control. The input shaft and the valve sleeve constitute the two members of the Rotary Control Valve.

Power cylinder (Rack Tube) all in a single compact package. 3.

and pinned on housing and the Piston swaged to the Rack. The bore of the steel tube is honed for smooth Piston movement. The two sides of the Cylinder (RH & LH) are connected to the Rotary Control Valve by external feed pipes. OPERATION POWER STEERING

What happens during steering manoeuvre ? When the driver turns the steering wheel, he transmits force from the wheel to steering gear input shaft. Input shaft rotation is transmitted to the Pinion through Torsion bar which is pinned at one end to the Input shaft and pressed firmly into the Pinion at the other end. The Pinion tends to push the Rack linearly through the Rack tube bore. But the linear movement of the Rack which is connected to the steered road wheels through link mechanism is resisted by the load on the steered wheels.

Power Cylinder : The built in hydraulic cylinder is constituted by the strong steel tube press fitted

INDEX

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9

POWER STEERING POWER RACK & PINION STEERING GEAR - OIL FLOW

LH CYLINDER RH CYLINDER

OIL IN

ROTARY VALVE POSITION

RH CYLINDER INPUT SHAFT TORSION BAR

OIL IN

VALVE SLEEVE LH CYLINDER

LH CYLINDER RH CYLINDER

SHORT FEED PIPE TO RH CYLINDER

OIL IN

LONG FEED PIPE TO LH CYLINDER

VALVE ASSY

SECTION - M (ENLARGED) OIL IN

NEUTRAL

A

A BELLOW

OIL OUT

RACK

IBJ

RACK TUBE (CYLINDER)

Fig. 4

PRESSURE OIL IN

PRESSURE OIL IN

ROTARY VALVE POSITION

RIGHT TURN

CW ROTATION

PRESSURE OIL IN

PRESSURE OIL IN RETURN OIL

Fig. 5 10

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POWER STEERING

PRESSURE OIL IN

ROTARY VALVE POSITION

PRESSURE OIL IN

LEFT TURN CCW ROTATION

PRESSURE OIL IN

PRESSURE OIL RETURN OIL

Fig. 6 This resistance offered by the steered wheels on the Pinion, leads to a definite twist on the Torsion bar depending on the input torque level. The Torsion bar twist disturbs the neutral position of the Rotary Control Valve (input shaft and valve sleeve). The disturbed Rotary Control Valve directs the oil flow from the pump to the appropriate side of the cylinder.

POWER STEERING

The Piston Rack pressurised by the oil, moves in the required direction overcoming the resistance offered by the steered wheels and produces the steering action. The resistance in the rotation direction of Pinion is relieved by movement of Piston Rack by hydraulic force and the reaction of Torsion bar returns the rotary valve to its neutral position. The oil flow diagram in neutral, right turn and left turn positions of the steering gear are shown in. Fig. 4, 5 & 6.

INDEX

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11

POWER STEERING PROCEDURE FOR FILLING AND BLEEDING THE HYDRAULIC SYSTEM Apply parking brake and set the Gear shift lever in neutral. Raise the front wheel clear off the ground and support with safety stand. Check for proper connection and tightness of end fittings/hose clips in hydraulic lines. Fill the reservoir nearly full with recommended Power Steering fluid. Crank the engine for 10 seconds if possible without allowing it to start. If the engine does start, shut off immediately. Check and refill Reservoir. Repeat atleast 3 times, each time checking and refilling till the level in the reservoir is stabilised. CAUTION : Do not allow the oil to run down significantly or run out of the reservoir. This may induce air into the system. Start the engine and check for any leakage in the system and if noticed, take corrective action. Turn the steering wheel so that the lock stops are lightly contacted at each lock, 3 or 4 times till oil in the reservoir is free from any bubbles or foaming. If bubbles or foaming is present, it indicates that air is getting sucked into the system. Check the power steering lines fittings/hose clips and correct, if necessary. If the system is bled properly there should not be any appreciable change in oil level, when the engine is started or stopped repeatedly. Finally check and top up (if required) the fluid to the specified level in the Reservoir. CAUTION : Don’t load the system until it is bled properly. Severe damages could occur otherwise. Always use recommended oil from closed containers. Any dirty oil in the system will result in damage to Pump/Gear.

12

INDEX

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POWER STEERING DISENGAGEMENT OF OBJ FROM STEERING ARM INNER BALL JOINT END

OBJ LOCK NUT OUTER BALL JOINT

STEERING ARM BALL PIN NUT

REMOVAL OF OBJ FROM IBJ END

SPANNER LOCATION

Fig. 7

MINOR REPAIRS ON POWER RACK & PINION & PINION STEERING GEAR STEERING GEAR This section covers only minor repairs that do not require complete dismantling of steering gear assembly. CAUTION : The minor repairs should be handled only by proper trained personnel who have proper equipment, tools, instructions and know-how and authorised to perform the work properly and safely. REPLACEMENT OF OUTER BALL JOINT (OBJ) ASSEMBLY.

REMOVAL OF OUTER BALL JOINTS Fig. 7 Raise the front of the car and support it on a safety stand in the proper location. Remove the front wheels Unscrew the ball pin nut of the Outer ball joint (RH side & LH side) and using puller part no. 2702 5890 4602, remove the Outer ball joint from the steering arm (knuckle arm). Hold the Inner ball joint with 14mm spanner and loosen the lock nut with 17mm spanner to free the ball joint. Now unscrew the Outer ball joint out of the Inner ball joint (Tie rod) assembly Discard the Outer ball joint assembly.

NOTE :

ASSEMBLY OF OUTER BALL JOINTS

The outer ball joint assemblies must be replaced if either of the following conditions are detected.

Screw in the new Outer ball joint assembly on the Inner ball joint (Tie rod)

1.

Any binding in articulation of the ball pin.

2.

Any axial play between the ball and cup of Outer ball joint Assy, more than 0.1 mm at + 100 gms.

Align the steering gear in mid position to straight ahead position (SAP) of the steered wheels.

The replacement of Outer ball joint can be done on the vehicle itself without removing the steering gear from the vehicle as explained below :

INDEX

Connect the Outer ball joints with the steering arm Tighten the ball nut to specified torque. Install the front wheels and lower the front of the car. Carry out wheel alignment. Now tighten the outer ball joint lock nut to specified torque.

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13

POWER STEERING

POWER STEERING

ASSEMBLY OF BELLOW BELLOW STRAP BELLOW CLIP

GROOVE TO LOCATE SMALL END OF BELLOW HOUSING

BELLOW CLIP

BELLOW

DOLLY PULL OUT

Fig. 8

REPLACEMENT OF BELLOWS : Fig. 8 For better access and convenience to replace the bellows properly, remove the steering gear assembly from the car as per procedure in the Mechanical Steering Group of this Manual. CAUTION :

Pull out the bellows away from the ends of the steering gear box along with clip. Discard the bellow/strap & clip. Clean the outer surface at the ends of the steering gear and Inner ball joint assembly.

ASSEMBLY OF BELLOWS

1.

Plug the ports tight with protective caps in the steering gear.

2.

Use only Special Tools and do not hammer to remove outer ball joints from steering arm (knuckle arm)

3.

Take care to avoid damage to bellows, feed pipes and input shaft when drawing out the steering gear assembly from the car.

Mount the steering gear on a mock up bracket.

REMOVAL OF BELLOWS Remove the Outer ball joint assembly after loosening the lock nut. Unscrew out the lock nut (Refer Replacement of Outer ball joint for removal procedure). Remove the bellows straps and discard.

14

INDEX

Clean the outer surface of the dolly (Taper guide tool) and insert it on the Inner ball joint Assy. Apply grease (dow corning) on the groove of both the tie rods. Assemble the bellow clip on the small end of the bellow. Keeping the rack in mid gear position slide the bellows on the dolly big end first till the small end of bellow locates on the greased groove. Assemble the big end of the bellows over the ends of the steering gear (Housing & Rack tube) ensuring no twist to the bellows. Using the strapping gun, strap the big end of the bellow firmly to ensure proper sealing.

GROUP INDEX

NEXT

PREVIOUS

POWER STEERING

REMOVAL OF INNER BALL JOINT ASSEMBLY

INNER BALL JOINT RACK SPUTNIC WRENCH

ASSEMBLY OF IBJ

NOTCH FOR IBJ STAKING

INNER BALL JOINT

Fig. 9

CAUTION :

REMOVAL OF INNER BALL JOINTS Fig. 9

If the strapping is not sound means possibility of rusty gear/entry of dust/water ingress/lack of lubrication.

Remove the steering gear assembly from the car (Refer Steering group of this Workshop Manual).

Slide the rack to right and left by turning the Input shaft to be certain that the bellows are not deformed or twisted.

CAUTION : 1.

Plug the ports tight with protective caps in the steering gear.

Screw in the lock nut and Outer ball joint assembly on the Inner ball joint. Dismount the steering gear assembly from the mock up bracket.

2.

Use only Special Tools and not hammer to remove Outer ball joints from steering arm (knuckle arm)

Reinstall the steering gear on the car.

3.

Take care to avoid damage to bellows, feed pipes and input shaft When drawing out the steering gear assembly from the car.

REPLACEMENT OF INNER BALL JOINTS ASSEMBLY (IBJ’S). NOTE :

WARNING :

The Inner ball joint assembly must be replaced if either of the following conditions is detected.

Improper tightening of Inner ball joint assemblies will cause accident.

1.

Any binding in articulation of the Ball rod (tie rod)

2.

Any axial play between the ball and cup of Inner ball joint assembly, more than 0.1 mm at + 100 gms.

Mount the steering gear assembly on a mock up bracket.

INDEX

Remove the outer ball joints and bellows on the LH side and RH side of the steering gear (Refer Replacement of Outer ball joint / Bellows for removal procedure).

GROUP INDEX

NEXT

PREVIOUS

15

POWER STEERING

POWER STEERING

FEED PIPE LONG FEED PIPE SHORT

FLARE NUT A/F 11

Fig. 10 Hold the rack suitably to take care not to damage the rack surface. Using sputnik wrench, unscrew the Inner ball joint assembly from the ends of the rack.

ASSEMBLY OF INNER BALL JOINT Screw in the new Inner ball joint assembly to the ends of the rack by hand. Hold the rack suitably taking care not to damage the surface. Using Sputnik wrench, tighten the Inner ball joint assembly to 8 kg-m torque. Stake the Inner ball joint (RHS & LHS) using a punch against the notch on both the ends of the rack. Reassemble the bellows and Outer ball joint (Refer Replacement of Outer ball joint/Bellows). Dismount the steering gear from the mock up bracket. Reinstall the steering gear on the car.

REPLACEMENT OF FEED PIPES (SHORT/ LONG) Fig. 10 CAUTION : Do not attempt to repair any bent or damaged feed pipes. Whenever feed pipes are removed discard the

INDEX

Remove the steering gear assembly from the car.

CAUTION :

Discard the Inner ball joint assembly.

16

same and replace with new ones only.

1.

Plug the ports tight with protective caps in the steering gear.

2.

Use only Special Tools and not hammer to remove Outer ball joints from steering arm.

3.

Take care to avoid damage to bellows, feed pipes and Input shaft when drawing out the steering gear assembly from the car. Carefully unscrew the flare nuts at the ends of the short/long feed pipes connected to housing and rack tube ends using 11 mm spanner. Discard the feed pipes. Blow clean the inside of the new feed pipes (short/ long) with compressed air. Install the feed pipes (short/long) by screwing the flare nuts at the ends to housing and rack tube by hand. Now tighten the flare nuts to 1.7 kg-m torque. Reinstall the steering gear assembly on the car.

GROUP INDEX

NEXT

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POWER STEERING

REMOVAL OF INPUT SHAFT SEAL

ASSEMBLY OF INPUT SHAFT SEAL

CIRCLIP

PRESSING TOOL PART NO. 2702 5890 4605.

INPUT SHAFT SEAL

INPUT SHAFT SEAL SEAL GUIDE TOOL

PRESSURE PORT RETURN PORT

Fig. 11

REPLACEMENT OF INPUT SHAFT SEAL Fig. 11

Disconnect the air pressure supply as soon as the seal is out.

Remove the steering gear assy. from the car.

Discard the seal.

Caution :

Wipe the seal bore with a clean cloth.

1.

Plug the ports tight with protective caps.

2.

Use only Special Tools and not the hammer for removing the outer ball joints from knuckle.

Determine by inspection that seal bore is in good condition.

3.

Take care to avoid damage to bellows, feed pipe and input shaft when taking out the steering gear from the car.

Mount the steering gear assy. on a mock up bracket with Input shaft facing upwards. Using circlip plier remove the input shaft seal retaining ring. Unplug the return port and hold the clean cloth around the input shaft and apply air pressure to the return port.

Clean the seal guide tool and insert it on the input shaft covering the serration. Apply power steering fluid on the input shaft seal and slide it down the seal guide tool into the housing bore with lip facing down. Using seal pressing tool part no. 2702 5890 46 05, press the seal till it butts on the bearing face. Using circlip plier compress and engage the circlip in the bore of the housing. Now remove the circlip plier and using a drift, press the circlip until it locates in the groove of the housing bore. Reinstall the steering gear on the car.

The air pressure will force out the input shaft seal to come out of the gear and some fluid will leak out of the gear.

INDEX

GROUP INDEX

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17

POWER STEERING

POWER STEERING ON - CAR SERVICE - INSPECTION & MAINTENANCE 1

STEERING WHEEL

8 COLUMN ASSEMBLY JOINT.

PULLEY

RESERVOIR 7 SUCTION LINE

PUMP ENGINE

RETURNLINE

INTERMEDIATE JOINT

PRESSURE LINE

5 POWER RACK & PINION STG. GEAR

2

BELLOW CLIP

4 BELLOW 6 FEED STRAP 3 BELLOW PIPE - LONG FEED PIPE - SHORT

8

LOCK NUT

9

BALL PIN NUT

Fig. 12 Power rack & pinion steering system 1. STEERING WHEEL PLAY With Engine off and front wheels in Straight Ahead Position , check for any free play at steering wheel without moving the front wheels. There should be no free play but only the feel of the Torsion bar twist in the stg. gear. With hands off stg. wheel, the reaction of torsional twist will bring the stg. wheel back to the original position. If any play is detected, check for

replace with new one. Ensure Feed pipes do not foul with each other (or) on any part of the vehicle. 5. PUMP/DRIVE BELT Engine driven belt drive Pump. Never run the pump dry. Check Pump belt condition and proper tension atleast once in a fortnight. Adjust tension as recommended. 6. STG. GEAR MOUNTING Check for any interference (or) condition that may cause the gear to distort due to improper mounting / tightness. Correct if required.

1. Looseness in Stg. Joints / Links 2. Yoke adjustment in stg. gear.

7. POWER STEERING OIL

2. INNER BALL JOINT (TIE ROD) SWING RESISTANCE After disconnecting Outer ball joint from stg. arm give ten hard swings to Inner ball joint to feel swing resistance, If swing is tight replace the Inner ball joint. If swing is smooth and there is no play between the ball and cup of Inner ball joint, it may be used. 3. BELLOW / STRAP / CLIP Check Bellow for Crack (or) Damage, Replace if any. Check for proper crimping of Bellow by Strap/ Clip.

Use only genuine. Power Stg. oil. Never run the Engine without oil in the Reservior. Check oil level with Engine running and maintain between Min. & Max. mark. Use specified oil. Follow the oil and filter change schedule. 8. HYDRAULIC LINES Check the Hydraulic lines (Hoses/Pipes) of the system for damage, Correct as required. for leak proof connection and smooth flow without restriction. 9. OUTER BALL JOINTS

CAUTION : Defective Bellow and loose crimping means possibility of rusty gear, entry of dust or lack of grease. 4. FEED PIPES Check Feed pipes for damage (or) bend. If any, 18

INDEX

Check the boot condition for crack/damage. Check for play in the ball joint. If any of the above exist, replace with new one. Check Outer ball joint lock nut & Ball pin nut tightness.

GROUP INDEX

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POWER STEERING POWER STEERING GEAR - EXPLODED VIEW :

NOTE : INSTALL NEW SEALS WHENEVER THE GEAR IS DISMANTLED FOR REPAIR.

LIST OF PARTS No. DESCRIPTION 1 HOUSING & TUBE ASSY 2. SEAL - RACK (HOUSING) 3. BALL BEARING 4. SEAL - PINION SHAFT 5. BEARINGNEEDLE ROLLER 6. RACK & PISTON ASSY. 7. PISTON SEAL RING 8. ‘O’ RING 9. LOCK STOP 10 RETAINING RING 11 LINER 12 ‘O’ RING 13 SEAL - RACK (L/S) 14 PISTON & VALVE ASSY. 14A VALVE SEAL RING 15 NUT - PINION 16 PINION COVER

17 ROLLER BEARING 18 SEAL - INPUT SHAFT 19 CIRCLIP 20 YOKE 21 YOKE SPRING 22 YOKE COVER 23 INNER BALL JOINT 24 BELLOW 25 BELLOW CLIP 26 BELLOW STRAP 27 RUBBER MOUNT BUSH 28 REAR MOUNT COLLAR 29 RUBBER MOUNTING 30 MOUNTING CLAMP 31 FEED PIPE ASSY. - LONG 32 FEED PIPE ASSY - SHORT 33 AFTER BALL JOINT ASSY. 33A OBJ LOCK NUT 33B NYLOC NUT (OBJ BALL PIN)

Fig. 13

INDEX

GROUP INDEX

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19

POWER STEERING

POWER STEERING POWER STEERING SYSTEM - HYDRAULIC TESTS USING DIAGNOSTIC GAUGE

Diagnostic Gauge Power Stg. Pump

Pressure Line

Column Assembly

Intermediate Joint

Suction line

Engine

Return Line

Rack & Pinion Power Stg. Gear

Fig. 14 GENERAL

2. Steering Gear - Internal leakage

The Diagnostic Gauge is designed to conduct on vehicle hydraulic tests in Power Steering System for a detailed trouble shooting when all other aspects checked prove satisfactory.

PREPARATION OF HYDRAULIC SYSTEM

The Diagnostic Gauge comprises of a PRESSURE GAUGE, FLOW METER, SHUT OFF VALVE AND HOSES provided with quick coupling for easy connection. Fig. 14

Check and top up oil in Reservoir. Bleed the system as per procedure (Refer page 6).

Using this Diagnostic Gauge, we can check the following and compare to specification of the system. 1. Pump Performance Check a. Flow b. Relief Pressure

Install Diagnostic Gauge in the pressure line (fluid supply line from Pump to Steering Gear).

Place a thermometer in the Reservoir to record temperature. With the shut off valve of Diagnostic Gauge fully open, warm up the hydraulic system by partially closing the shut off valve until the pressure gauge reads 100 PSI (7 bar). When the temperature reads 51.70 C and 57.20 C open the valve. The system is now warmed up and ready for conducting the hydraulic test.

c. Pump response 20

INDEX

GROUP INDEX

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POWER STEERING Test No. 1

Test No. 2

PUMP PERFORMANCE

PUMP RESPONSE TEST

Keep an eye on the Pressure Gauge and slowly close the Shut off valve of Diagnostic Gauge. System pressure not to exceed the relief pressure specified (Refer vehicle manual) for the system.

Keeping an eye on the flow meter, look for instant return of flow rate to recommended flow range from zero when shut off valve is opened from the closed position both at idling and governed speed. Conduct the test once at idling speed and three times at Engine governed speed.

CAUTION : Do not keep the shut off valve closed for more than 5 seconds at a time to avoid damage to the pump. Measure and record in table below the flow, pressure and temperature at idling and governed speed with shut off valve in fully opened and closed condition (with hands off the steering wheel). Engine Speed

Shut off PressureFlow Temperature Comment valve condition Idling Open A Speed Closed B Governed Open A Speed Closed B Compare minimum/maximum flow and maximum pressure (relief pressure) recorded with specification and refer appropriate comments below for corrective action. If it meets the specification, proceed to Test No. 2. COMMENTS

If the flow rate does not return immediately the Pump is malfunctioning and can result in momentary loss of power assist. The Pump needs to be repaired or replaced. Test No. 3 STEERING GEAR INTERNAL LEAKAGE TEST First conduct Pump performance test and confirm that the Pump is working satisfactorily. With shut off valve open and at steady idling speed of Engine, turn the steering wheel to any wheel lock end and apply force at the rim of the steering wheel to be sure that the control valve is fully closed. The Pressure gauge should now read maximum pressure (relief pressure) specified for the pump. If it reads appreciably less than the relief pressure, it indicates reduction in power assistance because of excessive internal leakage. Repair or replace the Steering gear. Repeat this test at the opposite wheel lock.

A. (i)steady state fluid pressure (with hands off steering wheel) should be equal to or less than that specified for the system. If it reads higher than the specification, check the feed and return line circuits and hoses between Pump and Gear box for clogging/deformation. Check the filter for any clogging. (ii) If the measured flow is less than the specification the Pump needs to be repaired (or) replaced. B. (i)If maximum system pressure (relief pressure) recorded is lower than the specification, it may not be developing enough pressure to assist steering. The pump needs to be repaired or replaced.

CAUTION : Don’t hold the steering wheel in the full turn position (lock end) for more than 5 sec. to avoid damaging the Pump.

Note : 1) When hydraulic tests are completed and fluid lines are reconnected check fluid lever and bleed the system. 2) For power steering wheel alignment values refer page 9 of mechanical steering group.

CAUTION: With shut off valve closed, the flow drops to zero and should not be closed for more than five seconds.

INDEX

GROUP INDEX

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21

POWER STEERING

POWER STEERING TROUBLE SHOOTING GUIDE : GENERAL

•

Power Steering System trouble shooting requires correct approach and analysis.

•

First key to diagnose a steering problem is to understand exactly what the problems is

•

Save a lot of time and work by talking to the customer/driver, understand and verify the problem reported.

•

Walk around the vehicle, looking for anything that may be an obvious cause of the problem.

•

Check the following 1. Are tyre sizes, tyre variety and air pressure correct to original specification ? 2. Is the steering wheel an original equipment ? 3. Has the suspension been modified in any way that would affect steering? 4. Is the steering fluid in reservoir filled to proper level ? 5. Is the power steering pump belt properly adjusted ? 6. Is the engine idle speed correct and steady ? 7. Has the steering aggregates been disturbed off its original settings ? 8. Any record of accident/heavy impact load that would affect steering ?

The above preliminary checks help to analyse the problem and guide for corrective action, as required. Most steering problems can be charted out to common complaints as given below :

COMMON COMPLAINTS

Hard Steering

Steering Wheel kick/Shock/ Vibration

Road wander / Lash in Steering

22

INDEX

Poor Self Centering

Direction Pull

Noise / Vibration

Reduced Wheel Turns

GROUP INDEX

External leaks

NEXT

PREVIOUS

POWER STEERING COMPLAINT

HARD STEERING

CONDITION

AS MAY BE NARRATED BY THE CUSTOMER

• Won’t turn

• Lock up/stuck up

• Not enough Power assist

• Won’t turn unless moving

• High effort to steer

• Sticky/binding

PROBABLE DEFECT

CORRECTIVE ACTION

Present during cold start only

Some power steering pumps have temporary state, when pump element vanes are sticky

Increase engine speed briefly to correct the problem

Sensitive to steering wheel speed.

Air drawn in due to insufficient fluid per filling and bleeding procedure

Add fluid and bleed the system

More prevalent when steering fast

Air being sucked in through cracks or loose fittings/hose / pipes in suction line

Replace/correct the crack/ loose fitting , hoses, pipes in suction line fill and bleed the system as per procedure

Present only in one direction of turn

Present in both the direction of turn

INDEX

Flow From the pump is less than minimum recommended for steering gear.

Repair (or) replace the Pump.

Steady state fluid pressure (with hands off steering wheel) at idling with shut off valve fully open, is high, due to clogging/deformation of feed and return hydraulic lines

Clean/replace the clogged/ deformed hydraulic lines as required.

Unequal tyre pressure

Inflate both steered wheels to equal specified pressure.

Feed pipe to concerned cylinder is deformed

Replace the deformed feed pipe

Excessive internal leakage in one direction of turn only (verify with internal leakage test)

Repair or replace the steering gear

Low tyre pressure

Inflate both steered wheels to equal specified pressure.

Low hydraulic fluid

Check and rectify external leak if any. Top up the oil and

GROUP INDEX

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POWER STEERING

23

POWER STEERING

Improper rotation or binding in column related parts

Low pressure or flow from Pump

Check pump performance. Repair or replace as required.

Faulty steering joints

Replace the joints

Faulty steering link components like inner/outer ball joints etc.

Determine by inspection. Identify and replace the defective steering link component.

Rack pad adjustment too tight

Adjust rack guide to specification

Bent rack shaft

Replace steering gear assembly.

Stickiness in the Steering gear assembly

Replace Steering gear assembly.

Feed pipes to both the cylinders deformed

Replace the Feed pipes

Excessive internal leakage

Repair or replace the Steering gear as required.

Restriction in return line or line too small in diameter

Clear restriction/kinks, if hoses are same as OE. If not replace the return line with specified one. Fill and bleed the system as per procedure. Check specifications and replace with recommended size tyres

Oversize tyres

Present as intermittent loss of power assistance

24

INDEX

bleed the system (if required) Determine by Inspection what interference or condition is causing binding and correct the problem.

Pump drive belt slip or worn out belt

Adjust belt tension or replace belt and adjust as required

Pump malfunctioning as no immediate return of flow rate on opening the load valve from closed position.

Repair or replace the pump as required

GROUP INDEX

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POWER STEERING COMPLAINT

AS MAY BE NARRATED BY THE CUSTOMER

STEERING WHEEL

• Kick back

• Bump steer

KICK/ SHOCK/VIBRATION

• Rough Steering

• Vibration in steering wheel

CONDITION Prevalent when turning at low speeds, particularly at rough roads or turning at engine idle speed while car is stationery.

Vibration / shock / kick felt when turning the steering wheel to lock.

PROBABLE DEFECT

CORRECTIVE ACTION

Engine idling speed low/erratic tending to stall when the steering wheel is turned affecting steady minimum flow from pump.

Adjust the engine speed for steady idling rpm.

Air in the system or Power Steering oil too low.

If oil level is too low, look for external leak. If any, correct & fill oil and bleed the system.

Looseness or lash in steering system that may be drifting under load when turning.

Determine by inspection from steering wheel to steered wheels, links/joints/mountings for looseness/wear/ crack. Renew/ replace the affected part (s).

Improperly adjusted Steering Gear. May be Rack guide (Yoke) has backed off excessively or worn.

Adjust the Rack guide to Specification. If problem is not corrected, replace the Steering gear.

Front shock absorber/ suspension strut malfunctioning.

Replace the defective shock absorber/suspension strut.

Pump stops momentarily due to belt slipping on drive pulley.

Adjust the belt tension to specification.

COMPLAINT

POWER STEERING

AS MAY BE NARRATED BY THE CUSTOMER

REDUCED WHEEL TURN

• Very high turning

• Not enough turn from centre to lock

radius required

• Wheel cut restricted CONDITION No. of turns not equal from centre to lock (with Power Off condition).

PROBABLE DEFECT Steering Gear mid position not aligned to straight ahead condition of steered wheels. Bend in steering links due to heavy impact load/accidents.

INDEX

GROUP INDEX

• Unequal number of turns from centretolock CORRECTIVE ACTION Allign the Steering Gear mid position to straight ahead condition of steered wheels. Do the wheel alignment to the specification. Determine by inspection the affected steering link and replace with new one. Do not attempt to straighten the bend on the links.

NEXT

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25

POWER STEERING COMPLAINT DIRECTIONAL PULL

AS MAY BE NARRATED BY THE CUSTOMER

• Vehicle pulls to one side

• A constant force needed to hold steering

CONDITION Pulling felt while braking only

Pulling prevalent while accelerating only

Constant force is required to hold steering wheel COMPLAINT ROAD WANDER / LASH IN STEERING

CONDITION Vehicle wanders requiring constant correction at steering wheel

26

INDEX

PROBABLE DEFECT

CORRECTIVE ACTION

Unequal braking force on steered wheels

Check and adjust the brakes of steered wheels. Replace the brakes if necessary

Uneven or badly worn tyres

Replace the tyre

Deflection in suspension or steering links

Determine by inspection the suspension and steering links and replace affected parts

Wheel bearings improperly adjusted

Check and adjust to specifications

Unequal tyre pressure on front tyres

Inflate the front tyres to equal pressure

Improper wheel alignment

Check and correct wheel alignment

Motoring (automatic steering) due to unbalanced control valve in Steering gear

Replace the Steering gear

AS MAY BE NARRATED BY THE CUSTOMER

• Lash in steering • Lost motion in steering

• Constant correction is needed at steering wheel to keep the vehicle from wandering

PROBABLE DEFECT

CORRECTIVE ACTION

Uneven or extreme tread wear

Replace tyres with new one

Unequal tyre pressure on steered wheels

Correct tyre pressure to specification

Lash in steering due to any looseness or wear or cracked components from steering wheel to road wheels (Steering wheel, steering column, joints, inner/ outer ball joints)

Determine by inspection to identify the cause for lash and tighten or Replace the affected component as necessary

Steering gear rack guide adjustment improper/disturbed Backed off excessively.

Adjust rack guide to specification

Wheel alignment out of specification

Correct wheel alignment to specification

Wheel bearings not adjusted properly or worn out

Adjust or replace the bearings as necessary

GROUP INDEX

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POWER STEERING COMPLAINT

AS MAY BE NARRATED BY THE CUSTOMER

POOR SELF CENTERING

• Steering does not return smoothly

• Steered wheels don’t return to straight ahead

• Poor self centering position CONDITION

PROBABLE DEFECT

Resistance or binding felt preventing smooth/quick return of steered wheels

Poor tyre condition/uneven tyre wear/mismatched tyres

Replace with good recommended tyres, inflate to specified pressure

Tyre pressure low or unequal

Correct tyre pressure to specification

Improper wheel alignment

Correct wheel alignment to specification

Binding in steering column

Determine by inspection after disconnecting column from Steering Gear, the cause for binding and correct / renew affected components

Rubbing/interference of any part with any other part during steering movement. Improper mounting causing distortion to Steering gear.

Determine by inspection the cause for rubbing/interference and correct the same Remove the Steering gear and determine by inspection what interference or condition is causing the gear to distort and correct the problem.

Deformed/damaged Feed pipes on Steering Gear

Replace the Feed pipes

Input torque high due to improper adjustment of Steering gear.

Remove the Steering gear. Check and adjust Rack guide adjustment to specification. If the problem is not corrected, replace the Steering gear.

Binding in Steering axle (Upper/ lower links)

Determine by inspection and renew/replace Steering axles/ links/bushes / ball joints

Insufficient oil flow to steering gear for adequate steering speed.

Repair or replace the Pump if flow is less.

INDEX

GROUP INDEX

CORRECTIVE ACTION

NEXT

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POWER STEERING

27

POWER STEERING COMPLAINT NOISE AND VIBRATION

AS MAY BE NARRATED BY THE CUSTOMER

• Humming noise while •

CONDITION

• Clicking sound while

steering Squealing noise

steering

• Hissing noise • Rattling noise

PROBABLE DEFECT

CORRECTIVE ACTION

Humming noise that increases with engine speed

This is not a defect. The noise is due to pulsation of fluid when the pump is running which is normal

-

Hissing noise when turning right or left

This is not a defect. The noise is due to actuation of Flow Control Valve during steering operation which is normal.

-

Noise evident when wheels are held on full lock.

This is not a defect. This noise is from the relief valve in the Pump

Caution : Do not hold the wheels at full lock for more than 5 seconds

Gratting noise from pump

Cavitation caused by air bubbles in the fluid, due to low or insufficient oil in system

Check fluid level in reservoir. If low top up the oil. Correct external leaks, if any. Determine by inspection, possibility of air suction through loose pipe fittings, hose clamping. Tighten or replace as necessary. Check Pump shaft seal for leakages, if any. Fill and bleed the system.

Squealing noise from pump

Low belt tension or worn out belt

Tighten the belt or replace as necessary

Abnormally loud noise from pump

Pump internals excessively worn out or damaged

Replace the pump

Rattling or chattering noise

Loose pump pulley

Tighten or replace the pulley. If shaft is found damaged, replace the Pump

Loose or worn steering columns/ intermediate joints

Tighten or replace the parts as necessary

Loose inner or outer ball joints

Tighten to replace the parts as necessary

Rack guide adjustments improper or disturbed.

Adjust to specification if not corrected, replace the Steering gear

Clicking noise heard during a turn or when changing direction

Some component is loose and shifting under load

Determine by inspection, tighten or replace if necessary

Vibrating Noise

Unclamped/Rubbing/damaged/ deformed pipe lines

Determine by inspection and correct or replace if necessary

28

INDEX

GROUP INDEX

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POWER STEERING COMPLAINT EXTERNAL LEAKS

AS MAY BE NARRATED BY THE CUSTOMER

• Loss of steering fluid • Frequent adding of fluid is required

• Oil wetness CONDITION Leak through fittings/ sealing washers

Leak through hoses

Leak through Reservoir

Leak through Pump hardened or cracked seal.

Leak through Steering Gear Assy.

INDEX

PROBABLE DEFECT

• Oil puddle under vehicle after parking

• Leak at steering gear / pump/reservoir CORRECTIVE ACTION

Improper tightness of fittings

Tighten and clamp suitably to avoid loosening under vibration

End fitting/Sealing washer is damaged or cracked due to improper tightening

Replace the end fittings/sealing washer & tighten properly

Loose connection

Tighten & clamp suitably

Heat or age cracks

Replace the hose with new one

Twisting or Abrasion wear due to improper routing/fouling/kinking/ twist

Replace the hose & route and clamp suitably

Foaming or oil throwing out due to air in the system

Check proper connection of suction line. Fill and bleed the system.

Reservoir is overfilled.

Drain the oil in reservoir to proper level

Broken or cracked bracket/cover/ shell of reservoir due to improper clamping/vibration

Replace the reservoir assembly with new and clamp properly

Through shaft seal, due to defective seal Fill and bleed the system. If it still leaks, replace the pump.

Remove the seal. If seal bore is OK, replace with new seal.

Leak through Pump assembly housing/ cover/ joint face seals/ “O” rings

Replace the seals/ “O” rings. If it still leaks, replace the pump.

Leak through Input shaft seal

Remove input shaft seal. If seal bore is OK, replace the seal with new one.

Leak from Cylinder (Rack tube) through Rack seal into right/ left bellows.

Replace the Rack seal using special tools taking care not to cause any damage/scorings to inner walls of Cylinder (Rack tube)

Leak through pinion seal in valve housing into RH bellows.

Replace pinion seals using special tools.

Leak through feed pipes connection to Rack tube at flare nut.

Tighten the connection properly.

Cracked/damaged feed pipes

Replace feed pipes.

GROUP INDEX

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POWER STEERING

29

WHEEL AND TYRES

GROUP INDEX

NEXT

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WHEELS AND TYRES

INTRODUCTION :

Wheels and tyres assembly is an important part in the vehicle, it has effect on performance of the vehicle. It is responsible to transfer the required road feel to the driver and passengers.Hence it is required to follow correct workshop practices.

WHEELS AND TYRES

INDEX

GROUP INDEX

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i

WHEELS AND TYRES CONTENTS Sr. No. 1.

Description Technical specification a. Tyres

1

b. Wheels

1

2.

Tightening Torque

3.

Exploded Views :

4.

Page No.

1

a. Steel Wheel Rim

2

b. Alloy Wheel Rim

3

Replacement Instruction a. Tyres

4

b. Wheels

4

5.

How to measure wheel runout

4

6.

Matched Tyres and Wheels

5

7.

Inflation of tyres

5

8.

Tyre rotation

5

9.

Tyre mounting and demounting

6

10.

Balancing wheels a. General procedure

7

b. Off-vehicle balancing

7

WHEELS AND TYRES

INDEX

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iii

WHEELS AND TYRES SPECIFICATION TYRES : This vehicle is equipped with 175/60 R14 tubeless tyres for LX & LXi versions, and with 165/65 R13 tubeless tyres for LEi & LSi versions.The tyre is designed to operate satistactorily with loads upto the full rated load capacity when inflated to the recommended inflation pressures.Heavy cornering, excessively rapid acceleration, and unnecessary sharp braking incerase tyre wear.

WHEELS : Standard equipment wheels are as follows: 5J x 14 stylised steel rim for LX & LXi versions, & 4.50J x 13 for LEi & LSi versions.

TIGHTENING TORQUE Sr. No.

Description

Torque

1.

Wheel Bolts

80 Nm 8 kg m 59 Lb. ft

WHEELS AND TYRES

INDEX

GROUP INDEX

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1

WHEELS AND TYRES STEEL WHEEL RIM

8.0

ASSEMBLY WHEEL RIM COVER TUBE VALVE TR 414

BALANCE WEIGHTS 5 gms TO 80 gms IN STEPS OF 5 gms WHEEL RIM (5J X14) (for LX & LXi versions) TYRE 175/60 R14 (for LX & LXi versions)

WHEEL RIM (4.50J X13) (for LEi & LSi versions)

TYRE 165/65 R13 (for LEi & LSi versions)

ASSEMBLY KNOB (SPARE WHEEL) WHEELS AND TYRES

- SPECIFIED TORQUE IN Kgm

2

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WHEELS AND TYRES ALLOY WHEEL RIM

ASSEMBLY ALLOY WHEEL RIM

WHEEL CAP - ALLOY RIM

8.0

TUBE VALVE TR 414 WHEEL MOUNTING PIN

WHEELS AND TYRES

TYRE 175/60 R14 (for LX & LXi versions) TYRE 165/65 R13 (for LEi & LSi versions)

BALANCE WEIGHT 5gms TO 140 gms IN STEPS OF 5 gms

- SPECIFIED TORQUE IN Kgm

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3

WHEELS AND TYRES Replacement of Tyres :

How to measure wheel runout :

When replacement is necesary, the original equipment type tyre should be used. Replacement tyres should be of the same size, load range and construction as those originally on the vehicle. Use of any other size or type tyre may affect ride, handling, speedometer/ odometer calibration, vehicle ground clearance and tyre clearance to the body chassis. It is recommended that new tyres be installed in pairs on the same axle. If necessary to replace only one tyre, it should be paired with the tyre having the most tread, to equalise braking traction. Also do not mix different types of tyres (viz. radial, bias etc) on the same vehicle, because it badly affects the handling of the vehicle.

To measure wheel runout, it is necessary to use an accurate dial indicator. The tyre may be on or off the wheel.The wheel should be installed on a wheel balancer for proper measurement. Take measurements of both lateral runout and radial runout at both inside and outside of the rim flange. With the dial indicator set in place securely, turn the wheel on full revolution slowly and record every reading of the indicator. (fig 1) When the measured runout exceeds the specification and correction by the balancer adjustment is impossible, replace the wheel. If the reading is affected by welding, paint or scratch, it should be ignored.

Replacement of wheels : Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, air leak through welds, have elongated bolt holes, if wheel bolts will not stay tight, or if they are heavily rusted. Wheels with greater runout than specification may cause vibrations.

Radial runout limit Steel wheel / alloy wheel

Lateral runout limit

1.14 mm (0.045 in)

1.4 mm (0.055 in)

Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim with offset and mounting configuration. A wheel of improper size or type may affect wheel and bearing life, brake cooling, speedometer/odometer calibration, vehicle ground clearance and tyre clearance to body and chassis.

WHEELS AND TYRES

2 1.Radial Runout 2.Lateral Runout

1

* Ignore high points due to welds, scratches, etc. Fig 1. 4

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WHEELS AND TYRES Matched tyres and wheels :(Provisional) Tyres and wheels are match mounted at the assembly plant. This means that the radially stiffest part of the tyre or “high spot” marked in RED on tyre is matched to the smallest radius or “low spot” of the steel wheel rim. In case of alloy rims valve is to be matched with YELLOW spot on the tyre. The YELLOW spot is an indication of low point of static imbalance of tyres. This is done to provide the smoothest possible ride. The colour spots on the tyres are originally marked by paint dot on the out board sidewall. This paint dot will eventually washoff the tyre. The “low spot” of the wheel is originally marked by paint dot on the wheel rim. If properly assembled, the wheel rims’ paint dot should be aligned with the tyres’ paint dot as shown in the fig2. Whenever a tyre is dismounted from its wheel it should be remounted so that the tyre and wheel are matched. If the tyre’s paint dot cannot be located, a line should be marked on the tyre and wheel before dismounting to assure that it is remounted in the same position.

Inflation of tyres :

Paint

Paint

Fig 2 Valve caps should be on the valves to keep dust and water out. Lower than recommended pressure can cause : 1. Tyre squeal on turns. 2. Hard steering

The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering tread wear, tyre life and resistance to bruises.

3. Rapid and uneven wear on the edges of the tread

Tyre pressure with tyres cold, (after vehicle set for three hours or more or driven less than one mile) should be checked monthly or before any extended trip. It is normal for tyre pressure to increase (0.28 bar, 4 psi) when the tyres become hot during driving. Do not bleed or reduce tyre pressure after driving. Bleeding reduces the “Cold inflation Pressure”.

5. Tyre cord breakage

Front

Rear

LX & LXi (14” Rim)

28 psi

24 psi

LEi & LSi (13” Rim)

30 psi

28 psi

Higher than recommended pressure can cause : 1. Hard ride 2. Tyre brushing or carcass damage 3. Rapid tread wear at center of tyre Unequal pressure on same axle can cause : 1. Uneven braking 2. Vehicle pull 3. Reduced handling 4. Swerve on acceleration

INDEX

4. Tyre rim bruises and rupture

6. High tyre temperature 7. Reduced handling 8. High fuel consumption

WHEELS AND TYRES

Tyre Rotation : To equalise wear, rotate tyres according to Fig 3 periodically. Set tyre pressure. NOTE : Due to their design, radial tyres tend to wear faster in the shoulder area, particularly in front positions.

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5

WHEELS AND TYRES This makes regular rotation necessary. Do not use spare steel wheel rim for tyre rotation, when vehicle is fitted with alloy wheel rims.

Trye Rotation with Steel Wheel Rim

Wheel Removal :

Front

1. Loosen wheel bolts (M12 x 1.5) by approximately 180 deg (half a rotation). 2. Hoist vehicle.

Trye Rotation with Alloy Wheel Rim

3. Remove bolts and then wheel. Front

Wheel bolts must be tightened in sequence given in Fig 4 and to proper torque to avoid bending wheel or brake disc.

(Spare Wheel with Steel Wheel Rim)

Fig 3 (RHD)

NOTE : 3

1

1. Clean all parts and remove any build up of corrosion of any parts, before installation of the wheel. 2. Never heat any part to loosen tight wheel, it will shorten life of wheel and bearings.

Tyre Mounting and Demounting : Use a tyre changing machine to mount or demount tyres. Follow equipment manufacturer’s instructions. Do not use hand tools or tyre irons alone to change tyres as they may damage tyre beads or wheel rim.Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, old rubber and light rust. WHEELS AND TYRES

4

2

Fig 4

After mounting, inflate to specified pressure so that beads are completely sealed. Warning : Do not stand over tyre when inflating. Bead may break when bead snaps over rim’s safety hump and cause serious personal injury. Do not exceed specifed pressure when inflating. If specifed pressure will not seat beads, deflate, relubricate and reinflate. Install valve core and inflate to proper pressure.

6

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WHEELS AND TYRES Balancing Wheels :

ADD BALANCE WEIGHTS HERE

Dynamic balance, as shown in Fig 5. is the equal distribution of weight of each side of the wheel center line so that when the tyre spins there is no tendency for the assemble to move from side to side. Wheels that are dynamically unbalanced may cause shimmy.

General Balance Procedures :

CORRECTIVE WEIGHTS C / L OF SPINDLE HEAVY SPOT WHEEL TRAMP

Deposits of mud, etc.must be cleaned from inside of rim. Warning : Remove stones from tread, clean the tyre and rim before balancing for safety to achieve better results.

Fig 5.

Each tyre should be inspected for any damage, then balanced according to equipment manufacturer’s recommendation.

Off-Vehicle Balancing : Most electronic off vehicle balancers are more accurate than the on-vehicle spin balancers. They are easy to use and give a dynamic (two plane) balance. Although they do not correct for drum or disc unbalance as does on vehicle spin balancing, this is overcome by their accuracy.

Notes :WHEELS AND TYRES

1) Permissible imbalance for assembly tyre with rim, 95 gmcm Max. 2) Total balance weight should be within 80 gm on each side. 3) Do not use more than one balance weight on one side.

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7

BODY

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BODY

INTRODUCTION :

The body skin panels of Indica MPFI are made of 0.7 mm thick coated steel sheet.The four doors and bonnet consist of inner and outer panels to ensure rigidity.The body shell design particularly ensures maximum safety of the occupants during full frontal as well as offset impacts. Side impact bars have been incorporated in the doors. There are specially formed impact initiators.They ensure that in the event of a collision the collapse begins at predetermined locations and progresses in a predicted manner. This all goes to make the car totally safe.

BODY

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i

BODY CONTENTS Sr. No.

Description

A.

Tightening torques

B.

Precautions :

C.

Page No.

1

1.

Instructions to be followed while removing, installing & handling air bag modules

2

2.

Safety Precautions

2

3.

General Precautions

3

Removal and fitment : 1.

Hood latch cable

4

2.

Bonnet lock

5

3.

Bonnet hood

5

4.

Hood Insulation

7

5.

Fixing of wind screen glass & tail gate glass

8

6.

Outer Rear view mirror

9

7.

Front door trim

9

8.

Front door latch

10

9.

Front door lock

10

10.

Front window glass, window glass channel and window winding mechanism

11

11.

Assembly of glass guide channels, window regulator & window glass of front door 13

12.

Door lock linkages

15

13.

Rear door trim

16

14.

Rear door

18

15

Rear door latch19

16.

Supplementary Restraint System

20

17.

Steering Wheel

21

18.

Driver air bag

21

19.

Co-driver air bag

22

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BODY

iii

BODY CONTENTS Sr. No.

Description

Page No.

20.

Safety belts with pretensioners & load limiters

22

21.

Dash board

23

22.

Roof trim

25

23.

Front seat

25

24.

Rear seat

27

25.

Front console housing

27

26.

Tail gate

28

27.

Tail gate latch cable

30

28.

Fuel flap cable

31

29.

Inner panel trims

32

30.

Seat belts

33

31.

Front bumper

34

32.

Front eyebrow

35

33.

Valance cover

35

34.

Rear eyebrow

35

35.

Rear bumper

36

36.

Side panels

37

37.

Rear spoiler

37

38.

Sill Cover

38

D.

Body repairs

39

E.

Body sealant application

42

F.

Paint care

47

iv

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BODY A.

TIGHTENING TORQUES :

Sr. Description No.

Torque (mkg)

1.

Bonnet lock mounting bolts (Hex. M6 X 12)

-

1

2.

Bonnet hood hinge mounting screws (Hex.M6 X12)

-

1

3.

Front door latch mounting screws (Csk.Soc M6 X16)

-

1

4.

Rear door latch (Csk.Soc M6 X12)

-

1

5.

Front/Rear door Check strap mounting screws (Hex.M6 X 20)

-

1

6.

Front /Rear door striker mounting screws (Hex.M8 X20)

-

2.5

7.

Window glass channel bracket mounting bolts (Hex.M6 X12)

-

1

8.

Window glass divisional channel mounting bolts (Hex. M6 X12) -

1

9.

Front door hinge fixing screws (Csk. M8 X20)

-

2.8

10

Glass mounting bracket (Hex. M6 X 12)

-

1

11.

Glass holding bracket mounting bolts (Hex. M6 X12)

-

1

12.

Antiglare inside rear view mirror (Csk. M6 X16)

-

1

13.

Tail gate hinge mounting bolts (Hex. M8 X 25)

-

2.8

14.

Tail gate striker mounting bolts (Hex. M8 X 12)

-

2.8

15.

Tail gate latch mounting bolts (Hex. M6 X 12)

-

1

16.

Tail gate balancer mounting bolts (Hex.M6 X 12)

-

1

17.

Front seat mounting bolts (Hex. M10 X 25)

-

4.9

18.

Rear seat mounting bolt (Hex. M8 X18)

-

2.5

19.

Rear seat latch striker mounting bolt (Hex. M6 X 16)

-

1

20.

Dashboard mounting bolts (Flanged gimlet M6 X 20)

-

1

21.

Front seat & rear seat belt bolt (7/16” UNF)

-

7

22.

Outer rear view mirror mounting screws

-

0.75

23.

Driver Airbag mounting (Soc head capscrew)

-

2.5

Csk. : Countersunk

BODY

Soc. : Socket Hex. : Hexagonal

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1

BODY B.

not even connect multimeter or other electrical measuring equipments to the inflators.

PRECAUTIONS

1. Instructions to be followed while removing, installing and handling of air bag modules.

11. Do not try to open, repair or dismantle the air bag module. 12. Do not expose the module to heat or fire.

(Ensure that the battery is disconnected while working with the air bag /belt pre-tensioners)

13. Always store inactivated modules in a dry, cool and secure area.

1. Always handle air bag modules with care.

• Follow the above mentioned instructions for the 2.

3.

Always wear safety glasses when repairing an air bag Supplementary Restraint System (SRS) vehicle and when handling air bag module. Carry a live air bag module with air bag deployment door pointed away from your self and others. This will reduce the risk of injury in the event of an accidental deployment.

4. Do not keep a live air bag module with the deployment door faced down. 5.

belt pre-tensioners as well.

2. SAFETY PRECAUTIONS Some important precautions need to be taken while handling air bag units. They are as follows : Service

•

The inflator is intended not to fire below the threshold current. To avoid inadverdent triggering of the air bag, NEVER apply a current through the squib except with the specified test equipment and procedures

•

The system has backup power for about 30 seconds after the battery is disconnected. Wait for at least ONE minute after disconnecting the battery before servicing the vehicle to prevent accidental deployment and personal injury.

•

Never dispose the air bag module un-deployed without proper instructions as this may result in possible injury. All deployments must follow special instructions to be safe. All units shall be activated (deployed) prior to disposal. It is recommended that the module assembly be dismantled for recycling of the individual components. The gas generator after activation can be scrapped as metal or depending on design, recycled for reclamation of steel and aluminium. The air bag modules or their components must not be adapted or installed in any other vehicle other than the specific vehicle for which they are designed and manufactured. Any attempt to adapt or install air bag modules or their components in any other vehicle can result in personal injury to the occupants in the event of accidents.

Do not lift the module by connected wires and cable harnesses.

6. After deployment, the air bag surface can contain propellent residue. Wash your hands with soap and water afterwards. 7. Never probe the connectors on the air bag module Doing so can result in air bag deployment which will lead to personal injury. 8. Air bag modules with discolored or damaged deployed doors must be replaced & should not be repainted. 9. To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any air bag Supplementary Restraint System (SRS) components. To deplete the backup power supply energy, disconnect the battery ground cable and wait for one minute. Be sure to disconnect auxillary batteries and power supplies (if equipped) as well. 10. Do not apply or connect electric current to the module except as specified for installation. Do 2

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BODY •

Vehicles should not be fitted with additional protective devices like bull bars etc.

• If the air bag cover has opened during transport or handling, the air bag must be returned to the supplier.

Storage •

Store air bag module in a dry, cool and secure area.

•

Deployed air bags are safe to handle and may be stored as scrap material or in accordance with company policy.

•

Do not attempt to refold the bag into the cover. Deployment protection may be compromised or injury may be induced. This is because foreign objects could enter the bag, or the vehicle specific bag-folding pattern could be altered from its original optimised design.

Fire •

In case modules catch fire and are trapped inside keep away and be alert for possible flying objects.

• If the modules are not trapped and exposed to heat then move them to a cooler environment, preferably outside the building to a secure environment, and away from people.

3.

GENERAL PRECAUTIONS

• Do not try to open or dismantle the air bag or pretensioner module.

• Do not expose these pyrotehnic modules to open flames or temperatures in excess of + 85º C

• Do not cut, drill, braze or solder the gas generator assembly.

•

Do not allow assemblies to come into contact with electrical current (for e.g. multimeter etc.) except as designed.

•

Never hammer on any SRS part - it might get damaged internally.

BODY

• Dropped modules may get damaged. In such cases contact the supplier for further course of action.

• Do not carry the air bag or pre-tensioner module with the cable assembly connected :- long cables can pick up Electrostatic Charge particularly if dragged on the floor and could lead to deployment of air bag.

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3

BODY WHEEL ARCH

HOOD LATCH CABLE

A 4 A

2

3 FIRE WALL

1 HOOD RELEASE LEVER

HOOD LATCH BOWDEN CLIP SECTION A-A

Fig 1.

C. REMOVAL AND FITMENT :

FITMENT :

1.

a)

Insert the loose end of the cable into the passenger cabin through the opening in the firewall (2).

b)

Fit the end of the cable to the hood latch release lever (1).

c)

Route the cable to pass along the wheel arch and under the member radiator support top, as shown in Fig 1.

c) Pull out the cable through the firewall (2) from the engine house side

d)

Fit the loose end of the cable to the hood latch (3).

d) Remove the end of the cable from the hood latch (3).

e)

Finally strap the cable to the bowden clip (ref. section A - A)and snap the bowden clip to the member radiator support (4) as shown in Fig 1 and section A - A.

HOOD LATCH CABLE

REMOVAL : (RHD) Fig 1. a) Open the hood (bonnet) and support it on the stay rod. b) Remove the end of the cable from the hood latch release lever (1) in the passenger cabin.

e) Unclip the bowden clip (4) and pull the cable free from the vehicle.

4

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BODY 2.

BONNET LOCK

REMOVAL : a)

Remove the 2 Nos. of Mounting screws. Fig 2.

b)

Pull out the cable from the hook.

c)

Take out the lock plate.

FITMENT : a)

Insert the cable in the hook.

b)

Also insert the cable cover in the groove. Fig 3

c)

Fix the mounting plate on front tie member.

d)

Tighten the 2 mounting screws to specified torque.

e)

Operate the bonnet opening lever from inside and ensure that the bonnet pops up properly, if not loosen the mounting bolts and move the lock in the oval slots provided in the mounting holes, so that it opens properly.

f)

Apply the recommended grease to the sliding plates and cable.

Fig 2

Fig 3

3.

BONNET HOOD :

REMOVAL : a)

Remove the pipe connection for windshield washer from the connector. Fig 4 BODY

Fig 4

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5

BODY b)

Unscrew and remove the 4 mounting bolts (2 in LH and 2 in RH) i.e Bolt no. 1, 2, 3 & 4 Fig 6

c)

Remove the stay rod from the plastic grommet.

d)

Lift and take out the bonnet.

FITMENT : For installation follow the same procedure in reverse order but tighten all the mounting screws to the specified torque.

1 2 3 4

STAY ROD

Ensure that the bonnet hood is locking smoothly and also ensure that the flushness is maintained. Check the condition of stay rod grommet and replace if damaged. Check the condition of hood inside lining and replace if soiled or torn.

Fig 5 NOTE : Hinges if damaged should be replaced and for removing the hinges unscrew the 4 mounting bolts (2 in LH and 2 in RH) 5, 6, 7 & 8 and then fit it back Fig 6.

5 6 7 STAY ROD

8

Fig 6 6

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BODY

PANEL HOOD INNER

1

2

HOOD INSULATION

Fig 7

4.

c) Finally fix the 14 numbers of hood insulation clips (2) at the location (shown in the fig) to hold the hood insulation to the inner panel firmly.

HOOD INSULATION :

REMOVAL : FIG.7 a) Open the bonnet and support it on the stay rod. b) Remove the 14 clips that support the hood insulation to the hood shell and remove it.

BODY

FITMENT : a) Hold the hood insulation on the hood panel inner and align the 2 number of holes marked (1) with the cutout on the hood inner panel. b) Fix the hood insulation to the inner panel using the plug (1) (2678 8870 6326)

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7

BODY 5. FIXING OF WIND SCREEN GLASS & TAIL GATE GLASS

Materials Required : 1.

Cleaner Betaseal 43518 - for glass & body shell.

The glasses are directly pasted to sheet metal flanges using sealant. We give below the Equipment / materials required and the procedure for fixing the Wind screen and Tailgate glasses.

2.

Primer Betaseal 43520A - for glass.

3.

Primer Betaseal 43533AT - for body shell.

4.

Sealant Betaseal 58702 - for glass.

Equipments required :

Procedure for fixing Wind Screen glass :

1.

Pneumatic applicator gun with holding arrangement for sealant cans.

2.

Vacuum cups for holding glasses.

Before fixing the Wind screen glass following preparation needs to be done on glass and body shell flange area.

3.

C-Clamp for holding tail gate glass. Sr. No.

Preparation on Glass (Windshield & Tailgate)

Preparation on Body shell

1.

Clean the glass with cleaner Betaseal 43518. Allow it to dry completely. Assemble the rubber mould to the glass.

Clean the Body shell flange area conforming to glass with Cleaner Betaseal 43518. Allow it to dry completely.

2.

Apply a thin & even (Approx. 0.5 mm thick wet layer) of Primer Betaseal 43520A on glass. Allow it to dry for minimum 2 minutes.

Apply a thin and even coat (Approx 0.5 mm thick wet layer) of Primer Betaseal 43533AT on painted surface. Allow it to dry for minimum 2 minutes.

3.

Fill up the mould groove with Sealant Betaseal 58702 with the applicator gun. (This sealant at later stage spreads on glass and mating shell flange area, when glass is fixed.)

FIXING WINDSHIELD GLASS

FIXING TAILGATE GLASS

After the above preparation mount the glass on the body flange from outside. This operation should be done within 15 minutes of the application of sealant on the glass.

Repeat the above procedure for Tail gate glass. For Tail gate glass, after fixing, use ‘C’ clamps both at LHS/RHS side for holding the glass with flange.

After mounting the glass, the same has to be pulled towards inside of body with the help of vacuum cups.

Tailgate Glass Windshield glass

Slightly tap the glass all around with hand for proper seating of glass mould. Wipe off the excessive spill off of sealant with clean dry rags. Do not use iso-propanol. Keep the vacuum cups pulled for 10 to 12 minutes as mentioned above. Do not drive the car for 2 hours. FIg 8 8

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BODY 6.

OUTER REAR VIEW MIRROR :

REMOVAL : a) Pull out the inside cover plate with rubber boot of the RH side RVM. b) Unscrew the 3 mounting Phillip screws from inside by a screwdriver. Fig 10 c) Pull out the Mirror from outside the door being careful about the mirror adjusting lever . d) Similarly remove the RVM from LHS. FITMENT : a) Insert the Mirror from outside carefully. b) Tighten the 3 mounting screws from inside. c) Fit the cover plate, with rubber boot.

7.

1

3 2

Fig 10

FRONT DOOR TRIM :

REMOVAL : a) Pull out the inner cover ORVM. Fig 9 b) Remove the Door pull handle mounting screws from inside i.e 6 & 7 Fig 11 c) Remove the mounting screws of Door lock housing handle from inside i.e 4 & 5 Fig 11 d) Remove the remaining mounting screws of the Door trim i.e screws no. 1 2 & 3 Fig 11 e) Take out the Speaker cover and remove the mounting screw no. 8 Fig 11 f) Remove the lock ring and pull out the windowwinding handle. Fig 12 (only for manual winding) g) Pull out the Inner belt mould of the Door. h) Pull out and remove the inner trim from the door.

1

5 6 4

8

7

2

3 9

Fig 11

BODY

Fig 12

Fig 9

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9

BODY FITMENT : a)

Fit the Trim by pressing from all sides ensuring that all clips are fixed properly. (Replace damaged tree clips)

b)

Fit back the Door pull handle, Door lock housing, Speaker cover and the window-winding handle.

c)

Tighten all the 8 mounting screws.

d)

Fit the Inner belt mould back properly in its groove.

1

NOTE : Do not Overtighten the Door trim mounting screws.

8.

2

FRONT DOOR LATCH :

3

REMOVAL : (Trim already removed) a)

Remove 3 mounting screws at the side of the door for the latch i. e. screw nos.1, 2 & 3 Fig 13

b)

Remove the Longer linkage connecting the latch to Inner Handle from the latch groove after removing the plastic clip.

c)

Remove the Linkage from latch to link connector. Fig 14

d)

Remove the link from latch to the Door inner handle. Fig 14

e)

Also remove the linkage from latch to Door lock. Fig 14

f)

Pull out the latch from inside (without the window being removed)

Fig 13

LINK FROM INNER HANDLE TO THE LATCH

LINK FROM LATCH TO LINK CONNECTOR (PIVOT) LINK FROM DOOR LOCK TO LATCH

FITMENT : a)

Insert the latch from inside.

b)

Tighten the 3 Nos. of mounting screws on the door.

c)

Connect the linkages from link connector, Door outer handle and Door Inner handle by inserting them into the plastic grooves.

d)

Insert linkage connecting the door lock and the latch into the plastic groove in the door lock.

Fig 14

NOTE : 1.

Apply little grease on the sliding levers of the latch.

2.

Replace the latch if any of the parts is found corroded or spring is damaged.

3.

Check the links for bends/twisting.

10

INDEX

9.

FRONT DOOR LOCK :

REMOVAL : (Front Door trim already removed) a) Pull out the link connecting the door lock and the door latch from the groove from the door lock Fig 14. b) Remove the Lock ring from inside. c) Take out the lock from outside. FITMENT : a) Insert the door lock from outside. b) Lock the Door lock in the panel by inserting the lock ring from inside. c) Insert the link connecting the door lock and the door latch from the groove.

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BODY

Extended Boltable Glass Guide Channel Window Regulator

Window Glass

Rear Glass Guide Channel

Fig. 15

10. FRONT WINDOW GLASS, WINDOW GLASS CHANNEL AND WINDOW WINDING MECHANISM (Fig. 15): For removal of Window glass : BODY

REMOVAL : (Door Inner Trim already removed) a)

Pull out the Plastic membrane

b)

Raise the window glass to half the height.

c)

Remove the 2 mounting screws from the glass holding bracket by holding the glass. Fig 16

Fig 16

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11

BODY d)

Remove the outer belt and inner belt of window glass. Fig 17

e)

Pull out the glass from outside along with the glass holding bracket. INNER BELT

OUTER BELT

Fig 17 For removal of Window winding mechanism, a)

Unscrew and remove the 3 Nos. of mounting bolts of the glass mechanism channel Fig 18. (In case of power regulator, also disconnect the connector)

b)

Also remove the 3 Nos. of mounting screws of the Window winding regulator Fig 18.

c)

Pull out the regulator along with the bracket through the Panel hole from inside.

Window winding regulator screws

Fig 18 For removal of Extended Boltable Window Glass Guide Channel a)

Remove the 2 Nos. of mounting bolts of the window glass channel bracket i.e bolt no. 1 & 2 Fig. 19

b)

Take out the glass channel from inside.

Positioning Holes 1

3

For removal of glass guide rear channel, a)

Remove the 2 nos. of mounting bots of the window glass channel bracket i.e. bolt no. 3 & 4. Fig. 19.

b)

Take out the glass channel from inside.

2

4

Fig 19 12

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BODY 11.

ASSEMBLY OF GLASS GUIDE CHANNELS, WINDOW REGULATOR & WINDOW GLASS OF FRONT DOOR

1.

Position the holes on the outer panel and the extended boltable glass guide channel as shown in Fig. 19 After positioning of the channel mounting screw 1 & 2 to be tightened.

2.

The rear glass guide channel Fig. 19 is to be assembled with the mounting screws 3 & 4 kept loose.

3.

The glass run mould (GRM, single section) to be fitted without wrinkles.

4.

The window regulator to be assembled by using the cutout on the inner panel. The mounting screws 5, 6, 7 to be tightened and 8,9, 10 to be kept loose as shown in Fig. 20 (For power regulator connector to be connected to winding motor)

5.

8

Insert the glass and slide it inside the GRM to ensure its free movement.

5

9

6

7

10 Fig 20 6.

Fit the glass to the slider by using the special screw 11 & 12 as shown in the Fig. 21 and keep the mounting screws loose.

BODY

11

12

Fig 21

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13

BODY 7.

Take the glass to the top position and push the glass towards the B- pillar by using the slots provided on the slider. (This ensures the parallel shifting of the glass with respect to channel). Then tighten the glass to the regulator slider through the slots provided on the inner panel as shown in Fig. 22

Fig 22 8.

Take the glass to the middle position; tighten the window regulator mounting screws 8, 9 & 10 as shown in Fig. 23 (Ensure the bottom mounting of window regulator at the center of the slot provided on the inner panel for screw no. 10)

8

9

10

Fig 23 9.

Take the glass to bottom most position and tighten the mounting screws 3 & 4 as shown in Fig. 24 (Mounting screw 4 has to be tighten by pushing it towards the A-pillar)

3

4 Fig 24 14

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BODY 12. DOOR LOCK LINKAGES (Fig. 25): REMOVAL : a)

Remove the 2 mounting screws of the Door lock plate from inside panel i.e screw nos. 1 & 2 Fig 26

b)

Disconnect the 2 linkages (i.e Link-1 from lock plate to latch) and the other (i.e Link-2 from lock plate to Link connector) Fig 26

c)

Remove the Links from the respective plastic clips and pull out the linkages along with the door lock plate. Fig 26

FITMENT : a)

Fix the Linkages on to their respective holes inside the door panel (Longer linkage in the outside hole and Shorter in the inside hole).

b)

Align the linkages properly and insert the linkages in the respective plastic clips (Longer linkage in the Top clip and the Shorter one in the bottom clip).

c)

Fig 25

LINK-1 2

1

Tighten the mounting screws 1 & 2.

LINK-2 3

4 5

Fig 26

BODY

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15

BODY 13. REAR DOOR TRIM : REMOVAL : a)

Remove the 3 Nos. of mounting screws i.e screw no. 1, 2 & 3 Fig 27a

b)

Remove the lock ring of the window winding handle. Fig 28 and remove the handle.

c)

Remove inner belt mould of door. Fig 27

d)

Pull out the Rear Door trim along with the Treeclips.

e)

Disconnect the wiring harness connector from window winding switch. (if fitted)

FITMENT : Repeat the same procedure as of the removal in the reverse order.

Fig 27 a

For removal of Window glass : HOUSING DOOR PULL

REMOVAL :

DOOR PULL OUTER FRONT DOOR

3

( Door Inner Trim already removed)

1

a)

Pull out the Plastic membrane

b)

Raise the window glass to half the height.

c)

Remove the 2 mounting screws from the glass holding bracket on the w/w mechanism (channel) slider by holding the glass.

DOOR PULL INNER FRONT DOOR

b

2 c

3

4 2 1

2

Without power window

4 1

3

with power window

Fig 27a

LOCK NUT

WINDOW WINDING HANDLE

Fig 28 16

INDEX

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BODY d)

Remove the inner belt mould and outer waist seal of window glass Fig.29

e)

Pull out the glass from outside along with the glass holding bracket.

For removal of Window glass divisional channel, a)

Remove the mounting screw (i.e screw no. 1, 2 & 3) of the window glass channel bracket Fig 30

b)

Pull out the glass channel from inside.

3

2

1

FITMENT : a)

Insert the glass support channel from inside panel such that the longer arm is towards the opening side of the Door.

b)

Tighten the mounting screw (i.e screw no. 1, 2 & 3) as shown.

c)

Slide the Rubber beading with bush on to the Channel guide.

1. OUTER WAIST SEAL 2. INNER BELT MOULD 3. QUARTER GLASS

Fig 29

2

3

FRONT OF CAR

GLASS DIVISIONAL CHANNEL

1

BODY

Fig 30

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17

BODY 14. REAR DOOR : 1

REMOVAL : a)

Disconnect the electrical connector to the door

b)

Remove the door side hinge by removing spl. screw no. 1 (Hinge fixing). Fig 31 NOTE : Never remove body side hinge.

Fig 31 c)

d)

Remove the 2 Nos. of mounting bolts of the check strap i.e bolt no. 2 & 3. and remove the check strap. Fig 32 Lift the door vertically and remove it. 2

3

Fig 32 FITMENT : Follow the reverse procedure of Removal for Fitment. Removal of Striker ( Both For Front and Rear Door) : a) Unscrew the 2 mounting screws 4 & 5 with 5 mm Allen key. Fig 33 b) Pull out the striker.

4

4

5

5

FOR FRONT DOOR

FOR REAR DOOR

Fig 33 18

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BODY 15. REAR DOOR LATCH : REMOVAL : (Trim already removed)

3

a)

Remove 3 mounting screws 1, 2 & 3 at the side of the door for the latch. Fig 33a

b)

Remove the Longer linkage connecting the latch to Inner Handle (Link No. 1) from the latch groove after removing the plastic clip. Fig 33b

c)

Remove the Linkage from latch to link connector. (Link No. 2) Fig 33b

d)

Remove the link from latch to the Door outer handle. Fig 33c

e)

Pull out the latch from inside (without the window being removed)

22222222222 2

4

1

5

FITMENT : a)

Insert the latch from inside.

b)

Tighten the 3 Nos. of mounting screws on the door.

c)

Connect the linkages from link connector, Door outer handle and Door Inner handle by inserting them into the plastic grooves.

2

1

Fig 33b

4 1

BODY

2 3

3 LINK FROM LATCH TO DOOR OUTER HANDLE

Fig 33a

Fig 33c

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19

BODY 16. SUPPLEMENTARY RESTRAINT SYSTEM DRIVER AIRBAG (standard) PASSENGER AIRBAG (if fitted) : The vehicle is fitted with an airbag for the driver, located in the steering wheel, and a passenger airbag (if fitted) is located above the glove box compartment. Vehicles fitted with airbag can be identified by the “AIRBAG” label on the steering wheel. The airbag is supplementary restraint system. It is designed to be used in addition to seat belts to help protect against head and chest injuries in certain moderate and severe frontal and front angular collisions. The airbag is not visible until it is activated. Because the system senses crash severity, some frontal/ angular collisions will not inflate the airbags. Airbags are not designed to inflate in rollover, rear side or slow speed frontal/angular crashes because the necessary protection can be achieved by the seat belt alone.

OPERATION : Sensors in the ECU detect the degree of severity of frontal/angular impact. The airbag(s) are designed to deploy if the collision suits the criteria for deployment.

•

The sensor switches close the circuit and the propellant rapidly burns in a container producing mainly nitrogen gas to fill the airbag.

•

The inflating airbag deploys out of the steering wheel in the front of the driver and passenger airbag (if fitted) of the dashboard in front of the passenger.

•

The airbag(s) deflates as the gas escapes through the vents.

•

Airbag(s) may only deploy when the ignition switch is in "ON" position. The system will however work for about 30 seconds immediately after switching “OFF” of ignition. Immediately after airbag inflation, one may notice fairly loud noise, dust or smoke and smell of the burnt propellant. This is NORMAL.

•

Passenger airbag (if fitted) switch provided on the floor console housing should always be ACTIVE. If in case the front passenger switch is unoccupied, the passenger airbag may be prevented from deploying by turning the PAB switch to INACTIVE position by using the ignition key.

20

INDEX

CAUTION : •

Airbag systems components get hot after inflation. Do not touch them after inflation.

•

The smoke could cause breathing problems for people with a history of asthma or other breathing trouble. If such a case occurs after deployment of airbag, get fresh air promptly.

•

Always turn the PAB switch to PAB in case the front passenger seat is occupied.

SRS

AIRBAG WARNING LIGHT :

The diagnostic system continually monitors the readiness of the SRS AIRBAG while the vehicle is being driven. The airbag warning light on the instrument panel will illuminate for approximately 5 seconds when the ignition is switched ON. This is normal and indicates that the system is performing a self check. The following components are monitored by the indicator : • Airbag control module • Driver airbag • Passenger airbag • Retractor Pre registrations • All related wiring If light does not illuminate when ignition is switched on remains illuminated after the initial check period & during driving a fault may exist with airbag/seat belt pre-tensioner.

PAB SWITCH

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BODY (Ensure that the battery is disconnected while working with the air bag/belt pre-tensioners).

STEERING WHEEL

DRIVER AIRBAG MODULE

17. STEERING WHEEL REMOVAL : (Driver airbag removed)

STEERING COLUMN SIDE CAPS

1. Orient the vehicle in Straight Ahead Position (SAP). 2. Remove the steering wheel mounting nut. 3. Remove the steering wheel. 4. Mark or fix a sticking tape on top and bottom part of the clock spring to ensure its center position. Fig. 35a

Fig 34

FITMENT : 1.

2.

Ensure that the vehicle is in Straight Ahead Position (SAP). Insert the steering wheel to the steering column with the clock spring slot aligning with the M clip on the clock spring & rotate the wheel statistically to break the “Center tag” on the clock spring. Bring the vehicle back to SAP ENSURE THAT THE PLASTIC BUSH IS PRESENT IN THE M CLIP SLOT ON THE STEERING WHEEL BASE PLATE.

3.

Remove the steering wheel and re-orient it in the desired SAP orientation.

4.

Align the M clip on the clock spring to the slot in the steering wheel manually and tighten the steering wheel on the steering column.

PASSENGER AIRBAG COVER

INFLATOR CONTAINER

DASHBOARD

COVER PAB MOUNTING

ASSY. CROSS MEMBER DASHBOARD

BRACKET PAB MOUNTING

Fig 35 (RHD)

18. DRIVER AIR BAG REMOVAL:

BODY

1. Disconnect battery ground cable and wait for one minute. 2. Remove side caps on steering wheel bottom cover. 3. Remove the two screws to detach air bag module from steering wheel. 4. Disconnect clock spring and horn connectors after removal of the plastic clamp provided for the inflator connector.

Fig 35 a

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21

BODY FITMENT : 1. Disconnect battery ground cable and wait for one minute. 2. Connect the air bag inflator and horn function with the clock spring. Install the plastic clamp on floating horn function base plate for inflator connector. 3. Insert the air bag module in steering wheel. Press the module fully and align the mounting tabs with respect to bottom mounting lugs provided on steering wheel. Make sure that gaps at all spokes are maintained uniformly. 4.

Tighten the screws located sidewise the steering wheel with specified torque (2.5 kg.m.)

5.

Put on the side caps on steering wheel bottom cover.

6. Connect the battery ground cable.

4. Disconnect battery ground cable and wait for one minute. 5.

Put on the air bag connector located sidewise and snap fit the PAB covers.

6.

Connect the battery ground cable.

20. SAFETY BELTS WITH PRETENSIONERS & LOAD LIMITERS FITMENT : 1. Disconnect battery ground cable and wait for one minute. 2. Connect the pre-tensioner to the wiring harness. 3. Install the retractor as per the usual recommended procedure.

19. CO-DRIVER AIR BAG REMOVAL : 1. Disconnect battery ground cable and wait for one minute. 2.

Remove both the PAB covers from within the glove box. Fig. a

3. Disconnect the air bag connector located sidewise. 4.

Remove mounting screws to dismantle air bag container assembly.These are accessible through the cutout in the glove box. Fig. b

5.

Remove air bag assembly by lifting away from the dashboard.

Fig a (RHD)

FITMENT : 1. The air bag module has two mountings- air bag cover to the dashboard, - air bag container to the dashboard mounting cross member. 2. Insert the complete air bag module into the dashboard of the vehicle & snap fit the three metal clips onto the brackets provided on the dashboard. Press the cover gently to ensure all the snaps lock into the slots in the dashboard. 3.

Tighten the air bag container with dashboard cross member mounting bracket with bolts with specified torque (1.0 kg.m.)

Fig b (RHD) 22

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BODY 4. Make sure that the load limiter belts are installed for the occupant provided with air bag. (IF THE VEHICLE IS “DRIVER AIR BAG ONLY” VERSION THE CO-DRIVER SEAT BELT SHOULD BE OF PRETENSIONER ONLY CATEGORY).

•

3

9

1

2

10

8

Observe the SRS warning lamp status for any error codes after the air bag/belt pretensioner connections. 7

4 6 5

RHD Version Fig 36

21. DASH BOARD Fig 36

1. DIGITAL CLOCK

(Steering Wheel, Driver airbag, and Floor console removed) a) Remove the A pillar trim (LH & RH) Fig 37 b)

c)

Remove the 2 bottom mounting screws of the Facia A/c control on Facia central cluster, then pull out the Facia A/c control. To remove the central cluster remove 2 mounting screws in A/c control area which are fitted on dashboard skin and remove one screw in the ash tray area which is fitted on cross member. Then pull out the central cluster. (Disconnect the connection of A/c control switches, and electrical connection of the Hazard switch.)

2. FACIA CENTRAL CLUSTER 3. SPEAKER GRILLS 4. VENTILATION CONTROLS 5. POWER SOCKET 6. POWER WINDOW SWITCH PACK 7. ACCESSORY SWITCHES 8. INSTRUMENT PANEL 9. DRIVER AIRBAG MODULE 10. PASSENGER AIR BAG MODULE

A- PILLAR TRIM

BODY

Fig 37

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23

BODY d)

Remove the digital clock by disconnecting the electrical connections. Fig 38

e)

Take out the speaker grills (LH & RH) on top of the dashboard and unscrew the 2 mounting screws. Fig 39

f)

Remove the steering wheel (For procedure refer Steering group of this manual). Follow removal procedure 1 to 4 for co-driver airbag removal.

DIGITAL CLOCK DASHBOARD SKIN

FACIACENTRAL CLUSTER STEERING NACELLE (TOP & BOTTOM)

NOTE : DO NOT REMOVE THE AIRBAG ASSEMBLY FROM DASHBOARD g)

Remove the steering nacelle by removing two screws mounted on combi- switch and one screw for fitment of top and bottom nacelle. Fig 40 (For further details, refer Mechanical Steering group)

h)

Pull out the combi switch, unscrewing the screw tightened on steering column.

i)

Remove the bezels by removing the screws mounted on dashboard skin.

j)

Remove instrument bezel by removing the screws mounted on dashboard skin and disconnect the wiring connections.

k)

Pull out the front Floor console which is located on location pin which is mounted on skin.

l)

To pull out the Tray cover, remove 3 screws mounted on dashboard skin, and disconnect the electrical connections of Facia switch, Dimmer and headlamp levelling switch (If fitted).

m)

Remove screw below the instrument cluster (bezel front) Fig 40

Power socket

Fig 38 RHD Version

Fig 39

Fitment : Follow the reverse procedure of Removal.

Fig 40 24

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BODY 22.

ROOF TRIM : Fig 41

REMOVAL : a) Remove the Grab handles (3 Nos.) after removing the 2 mounting screws each & 2 plugs of the grab handle on the driver side. Fig 41 b) Pry out the Roof lamp from the roof lamp mounting bracket. c) Unscrew the 2 mounting screws of the sunvisor (both of Driver’s side and Co-driver side) and take them out. Fig 42 d) Unscrew the 2 mounting screws and remove the Inside Antiglare Rear View Mirror. e) Remove the 7 Nos. of Tree clips. FITMENT : a) Fix the Trim on to the Roof using the adhesive (Headliner adhesive WC - 2446) b) Fit the Tree clips on to the Roof trim. c) Fit back the Rear View Antiglare mirror, Sunvisors, Grab handles in their respective places.

23. FRONT SEAT : Fig 43 REMOVAL : a) Remove the 2 front mounting bolts of the front seat. b) Similarly remove the 2 rear mounting bolts of the front seat. Fig 44 c) Take out the seat from its position. NOTE : Refer to Exploded View Fig. A FITMENT : Follow the reverse order of removal for fitting back the front seat.

SUNVISOR ANTI GLARE REAR VIEW MIRROR

Fig 42

VALENCE

FRONT SEAT (RH) FRONT SEAT RISER

Fig 43

TREE CLIP

BODY

GRAB HANDLE ANTIGLARE REAR VIEW SUNVISOR

ROOF LAMP

Fig 44

Fig 41

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25

BODY

HEAD RESTRAINT

ASSY FRONT SEAT BACK

RECLINER COVER OUTBOARD

PLATE PROTECTOR SPRING RETAINER PLATE

SIDE VALANCE OUTBOARD

STRIKER BUSH INBOARD RECLINER HANDLE CAP HANDWHEEL RECLINER MECHANISM RECLINER COVER INBOARD SIDE VALANCE INBOARD FIX CLIP ASSY FRONT SEAT CUSHION

C CLIP

Fig A. Front Seat Exploded View ASSY LATCH MOUNTING BRACKET

ASSY REAR SEAT BACK ASSY LATCH

ASSY REAR SEAT CUSHION ASSY REAR SEAT CUSHION FRONT MOUNTING

Fig B. Rear Seat Exploded View 26

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BODY 24. REAR SEAT : REMOVAL : a)

De-latch the Rear seat from 2 latches, provided on back of backrest. Fig. 45

b)

Fold the rear seat into two folds towards the front side.

c)

Remove the 4 mounting bolts on the hinges of the seat (2 each on one Hinge). Fig. 46

d)

Lift and take out the seat from its position.

REAR SEAT LATCH HANDLE (RH) DPILLAR TRIM

REAR SEAT LATCH STRIKER (RH)

FITMENT : Fit back the seat in the reverse sequence as of the removal. NOTE : Refer to Exploded View Fig. B

Fig 45

25. FLOOR CONSOLE HOUSING : FIG.47 Ensure that the battery is disconnected while working with airbag. REMOVAL : a)

Remove the Gear shift lever knob from the lever.

b)

Remove the two turn clips and separate out the power window switch kit from the console and disconnect the electrical connections.

c)

Unscrew the mounting screws 2, 3, and 5 and pull out the rear floor console.

d)

Unscrew the mounting screw 4. Remove the floor console housing housing front and disconnect the electrical connections of the PAB switch.

FITMENT : Fitment procedure is reverse of the removal procedure.

Fig 46 FLOOR CONSOLE HOUSING FRONT 2

PAB SWITCH 3 BODY

FLOOR CONSOLE HOUSING REAR

5

1

5 CONSOLE MOUNTING SCREW

GROMMET FOR CONSOLE MOUNTING

SPRING CLIP BRACKET FOR CONSOLE MOUNTING

Fig 47

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27

BODY

TAILGATE LATCH TAILGATE HINGE

TAILGATE LOCK

TAILGATE STRIKER COVER T A I L G ATE BALANCER

TAILGATE STRIKER PARCEL SHELF CABLE

Fig 48

Fig 49

26. TAIL GATE : REMOVAL : TAIL GATE TRIM : Pull out the Tail gate trim along with the Tree clips and remove parcel shelf cable Fig.48,49 & 57 FITMENT : Fit back the Tail gate trim by pressing the tree clips into the Tail gate inner panel TAIL GATE : a) Unscrew the 4 mounting bolts of the Tail gate at the top. Remove balancer from Tail gate. Fig 49 b) Disconnect the electrical connections for the Rear wiper and Heated rear window controller c) Take out the Tail gate. FITMENT : Follow the reverse procedure of Removal. TAILGATE STRIKER : a) Unscrew and Remove the 2 mounting screws of the Tail gate striker cover and take out the cover. Fig 50 b) Unscrew the 2 mounting bolts of the Tail gate striker Fig 51 c) Disconnect the cable from the hook and take out the striker. Fig 51

Fig 50

Fig 51 28

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BODY FITMENT : a)

Insert the cable in the hook of the Tail gate striker.

b)

Align the Tail gate striker with the holes on the tail gate sill and tighten the 2 mounting screws Fig. 52

c)

Fix back the striker cover and tighten the 2 mounting screws.

1 3

TAILGATE LATCH :

2

REMOVAL : a)

Remove the 3 mounting bolts i. e. bolt nos. 1, 2 & 3 of the Tail gate latch Fig 53.

b)

Disconnect the link connecting the latch and the tail gate lock Fig 54.

FITMENT :

Fig 52

a)

Insert the Tail gate latch from outside on to the Tail gate.

b)

Connect back the link connecting the lock and the latch.

c)

Tighten the 3 mounting bolts to the specified torque.

TAILGATE LOCK : (Tailgate trim already removed)

LINK CONNECTING LOCK AND THE LATCH

a)

Pull out the Tail gate trim.

b)

Disconnect the link from the tail gate latch to the tail gate lock.

c)

Slide out the Lock plate from the panel from inside.

d)

Pull out the lock from outside.

TAIL GATE TRIM TAIL GATE LOCK

FITMENT : a)

Insert the lock unit from outside into the tail gate.

b)

Slide back the lock ring on to the lock unit from inside the Tail gate panel.

Fig 53

BALANCER : REMOVAL : a)

Remove the balancer from the tail gate by pulling it out from the ball pin.

b)

Unscrew the 2 mounting bolts i. e. Bolt nos. 1 & 2 of the Balancer on LH inner side of the d-pillar Fig 54.

c)

BODY

1

Similarly remove the other side Balancer.

2

FITMENT : a)

Fit the 2 mounting bolts of the balancer on LH inner side of the d-pillar.

b)

Fix the other end of the balancer (i.e the tail gate end) on to the ball pin on the tail gate.

INDEX

Fig 54

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29

BODY

T/G SILL INNER CUTOUT 7

4

1

3

FUEL LID LATCH

CABLE

5 SECTION A-A 8 T/G SILL INNER CUTOUT 2

9 REINF. REAR QUARTER 6

Fig 55

27. TAILGATE LATCH CABLE :

FITMENT :

REMOVAL :

a)

Route the cable as shown in fig, passing through the cutout in the tailgate sill inner.

b)

Connect the end of the cable to the tailgate release lever (4) and the tailgate latch (4) through the opening in the tailgate sill. (for end connection refer section A - A)

c)

Fix the cable in place using the 5 Nos adhesive pads as shown in fig.

d)

Fit the carpet finally.

a)

First remove the carpet on the right hand side of the vehicle so that the cable routing is visible.

b)

Next remove the rubber foam pad (3) that is adhesively bonded to the floor.

c)

Disconnect the end of cable from the Tailgate release lever (4) and the latch (5) (refer section A - A for end connector)

d)

Pull the cable free from the vehicle.

30

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BODY 28. FUEL FLAP CABLE : REMOVAL : a)

Remove the Rear Bumper (refer section Rear Bumper)

b)

Remove the carpet on the right hand side of the vehicle so that the fuel flap cable routing is visible.

c)

Remove the adhesively bonded rubber foam pads (3).

d)

Disconnect the cable from the fuel flap release lever (4) and the latch (6). • Cable end connection is similar as shown in section A - A. • The Fuel flap latch can be accessed through the opening in the rear LH side.

e)

Pull out the cable.

FITMENT : a)

Route the cable as shown in Fig passing through the cutouts (7) and (8) in the Tailgate sill.

b)

Connect the cable to the fuel flap release lever (4) and fuel flap latch (6) (refer section A-A)

c)

Then fix the cable in position by the 5 No of rubber foam pads (3).

d)

Fix the carpet back in place.

BODY

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31

BODY 29. INNER PANELS (TRIMS) : A-Trim : Fig 56 For removal and Fitment of A-Trim refer Removal of Dashboard given in the previous pages. B-Trim : Fig 56 REMOVAL : a)

Pull out the seat belt top mounting screw cover.

b)

Remove all the Tree clips as shown in Fig. 56

c)

Pull out the B-pillar lower trim and then the top trim.

FITMENT : a)

Align the lower B-trim on to the panel.

b)

Slide the tree clip on to the panel through the B-trim.

c)

Align the seat belt retractor cover at the bottom and slide the tree clips.

d)

Fix the B-pillar upper trim and slide the tree clips.

e)

Fit the seat belt mounting and tighten the screw.

f)

Press the cover of the seat belt top mounting screw.

Fig 56

C - Pillar trim : Fig 58 REMOVAL : a)

Remove the Parcel shelf after removing cable Fig 58.

b)

Unscrew the 5 mounting screws (i. e. screws no. 1, 2, 3, 4 & 5)

c)

Unscrew the seat belt top mounting bolt.

d)

Pry out the C-pillar trim (both top and the inner trims).

Fig 57

1

FITMENT : a)

Fit back both the trims (top and inner trims) and tighten the 5 mounting screws.

b)

Align the seat belt top mounting and tighten the bolt.

c)

2 3 C - PILLAR INNER TRIM

5 4

Fit back the parcel shelf.

Fig 58 32

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BODY 30. SEAT BELTS : Fig. 59 Front Seat Belt Removal Fig. 60

Front seat belt

Rear seat belt

(Ensure that the battery is disconnected while working with the airbag/belt pretensioner ) 1.

Disconnect battery ground cable and wait for one minute (while working with seat belt with pretensioner and load limiters).

2.

Remove B- pillar lower trim by removing 4 plastic rivet buttons.

3.

Disconnect the pretensioners from the wiring harness.

4.

Remove lower seat belt mounting hex screw on the floor.

5.

Remove plastic cap & unscrew top seat belt mounting hex screw.

6.

Then Remove two hex screws of retracting unit at bottom of B- Pillar.

7.

To remove the buckle remove buckle mounting hex screw from side of the seats.

8.

For driver’s seat - seat belt disconnect pigtail connections from wiring harness.

Lap belt

Fig 59

Top mounting

Installation : Follow the reverse sequence of removal.

Retracting Unit

(Also refer airbag section, procedure for installation of seatbelts with pretensioners & load limiters)

Bottom mounting

Rear Seat Belt Removal Fig. 61

Fig 60

1.

Remove C- pillar upper trim

2.

Remove retracting unit mounting hex screw, top mounting hex screw & one bottom seat belt mounting hex screw on front side of rear wheel arch.

3.

Top mounting

For removal of buckle remove hex screw from floor below rear seat.

Retracting Unit Lap Belt

Important Note : Ensure to keep correct orientation of rear seat belt retracting unit on C- pillars by matching projection of retracting unit with cut out hole on C-pillar.

BODY

Installation : Follow the reverse sequence of removal. Ensure for proper retracting of seat belts after installation.

INDEX

Bottom mounting

Buckle mounting

Fig 61

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33

BODY FRONT BUMPER :

7 6

5

2

2 A

B

G

4

C

H

D

I

F

E

J

5

6 7

K

3 3 4 View from inside of bumper

Fig 62

31. FRONT BUMPER : FIG. 62 REMOVAL :

d)

Next tighten the splash guard and the Bumper to the vehicle using mounting screws (3) & (4)

e)

Match the surface of the bumper with the surface of the fender and then tighten the screws (6) & (7)

a)

Remove the front wheel arch liner on both the left hand and right hand side by removing the self tapping screws (8)

f)

b)

Next remove the bumper by unscrewing the screws marked (2),(3),(4),(5),(6), & (7) Fig 62.

Tighten all remaining screws (1),(2),(3),(5),(6) & (7) The screws should be loosely fitted.

g)

Fix the front bumper to the vehicle by using screws (2),(3),(6) & (7) Fig 62. They should be partially tightened.

h)

Next fix the front wheel arch liner (align the holes with the mounting locations on the bumper & the vehicle body) Tighten the bumper to the BIW an bumper using self tapping screws (8)

c)

Disconnect the wiring harness connection to the fog lamps (if fitted)

c)

The splash guard if required is removed by removing the screw marked (1)

FITMENT : a)

b) c)

First fix the splash guard to the BIW (vehicle body) by partially screwing the screws (1). The screws should be loosely fitted.

NOTE :

Connect the wiring harness connection to the fog lamps (if fitted)

31a. GRILL REMOVAL AND FITMENT :

Fix the front bumper to the vehicle by using screws (2),(3),(6) & (7) Fig 62. They should be partially tightened.

34

INDEX

The procedure for fitting LH / RH liner is similar.

a)

It can only be removed after removal of front bumper as it is fitted from inside.

b)

To remove unscrew 11 nos. screws (A to K)from inner side of bumper.

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BODY 32. FRONT EYEBROW : FIG A REMOVAL :

9 8

a)

Remove the 2 bolts (1,6) from inside of fender & 1 screw (9),common for front eyebrow and Valance cover.

b)

Remove lug from front bumper and then unsnap clips (2,3,4,5,6,7,8) by pulling it carefully.

7

6

5

4

3

2

1

Note : Follow the reverse procedure of removal

Fig A

33. VALANCE COVER : FIG B

5

4

3

2

7

8

1

REMOVAL : a)

Remove 5 bolts (1,2,3,4,5) & 2 screws. Unsnap clips (6,7,8) by pulling it carefully.

Note : Follow the reverse procedure of removal 6

Fig B

33. REAR EYEBROW : FIG C b)

Remove 2 bolts (1&3) & one screw (6) from body, then remove lug from rear bumper & then unsnap clips (2,4,5,) by pulling it carefully.

6

5

4

2

3

1

Note : Follow the reverse procedure of removal

BODY

Fig C

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35

BODY Energy absorber (LH)

REAR BUMPER : 5 6

10

Energy absorber (RH)

1 2 3

5

4

6

10

7 8 8 7 6 5 10

1

2

3

8 8 7 View from inside of bumper

5 6 10

4

7

Fig 63

32. REAR BUMPER :

c)

Match the bumper surface with the body side outer surface and then tigten the screws (5) & (6).

d)

Next tighten the remaining screws (1), (2),(3),(4),(7) & (8) The screws should be loosely fitted.

e)

Then fix the wheel arch liner (aligning the holes of the liner to the corresponding location in the bumper/BIW) by using self tapping screws. (Procedure for both sides liner fitments are similar).

f)

Then fix the wheel arch liner (aligning the holes of the liner to the corresponding location in the bumper/BIW) by using self tapping screws. (procedure for both sides liner fitments are similar)

g)

Removal the rub rail by unscrewing 3 screws, after removing rear bumper.

REMOVAL : a)

First remove the rear wheel arch liner by removing the self tapping screws.

b)

Next remove the rear bumper by removing the screws marked (1),(2),(3),(4),(5),(6),(7),(8) & (10) Fig 63.

c)

Disconnect the connection of wiring harness to the registration plate lamp before removing the bumper free.

FITMENT : a)

Connect the wiring harness to the registration lamps.

b)

Fix the rear bumper to the vehicle body using screws (1),(2),(3) & (4) Fig 63. Keep the screws loose (i.e. partially tightened).

36

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BODY 33. SIDE PANELS : REMOVAL : (Front bumper already removed) a)

Pry out the side repeater lamp with a screwdriver on the RH side panel.

b)

Unscrew the 2 top mounting bolts of the side panel 1 & 2 Fig 64

c)

Unscrew the side mounting bolt 3 of the side panel (Located on the front door side) Fig 65

2 1

Similarly unscrew & remove the side bottom mounting bolt of the panel (located on the front door side) d)

Pull out the side panel.

Fig 64

Repeat the same procedure to remove the LH side panel.

3

FITMENT : Follow the reverse procedure of removal. Fit back the front bumper.

4 Fig 65

34. REAR SPOILER : (Fig. 66 & 66a) REMOVAL : 1)

Remove the 5 nos. mounting screw from inner side of tailgate.

2)

Take out spoiler from tailgate shell.

3)

Disconnect the wiring harness connector (Provided for high mount lamp wiring harness connection).

BODY

FITMENT : Follow the reverse procedure of removal.

Fig 66

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37

BODY

Fig 66a

35. SILL COVER : (Fig. 67 & 67a) REMOVAL : 1)

Remove the 5 nos. mounting screw fixed to bottom sill of body.

2)

Remove 4 nos tapping screw, used to fix liner front wheel house LH/RH to body shell.

3)

Pull out the rear portion of liner front wheel house LH/RH from body to access the removal nut, used for sill cover fitment.

4)

Remove the hex nut, used to fix the sill cover to body.

5)

Remove 2 nos. of hex nut, used to fix liner rear wheel house front LH (only on LH side).

6)

Take out liner rear wheel house front LH, to access the nut removal, used for sill cover fitment.

7)

Remove the hex nut, used to fix the sill cover to body.

8)

Pull out sill cover along with clips.

sill cover (with valance cover)

sill cover (with valance cover removed)

Fig 67

FITMENT : Follow the reverse procedure of removal.

Fig 67a 38

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BODY D. BODY REPAIRS : Indica Body shell is a semi monovolume minisize hatch back, steel monocoque body. In case of minor collision Indica body shell can be repaired by use of the recommended body collision repair fixtures. The dimension given in this group should be measured and corrected only on the fixture which will ensure the performance of steering system, suspension, brakes, tyres, etc.

Repairs done without use of proper fixture and procedure could adversely affect the performance of the car. Use proper measuring tools for measuring point to point dimensions given in the sketches.

SIDE VIEW :

P

M K

N L

TABLE FOR SIDE VIEW : MEASUREMENT POSITION LENGTH (in mm) K-L L-M M-N N-P K-M L-N M-P K-N

INDEX

330 1033 221 841 1020 1026 840 1082

K :

OUTER REAR VIEW MIRROR HOLE

L :

CHECK STRAP MTG. HOLE

M :

REAR DOOR TOP HINGE MTG. HOLE

N :

CHECK STRAP MOUNTING HOLE

P :

REAR DOOR STRIKER MTG. HOLE

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BODY

39

BODY REAR VIEW :

V W Z

v X Y

TABLE FOR REAR VIEW : MEASUREMENT POSITION

LENGTH (in mm)

W-V

997

V-Y

1066

Y-V

370

V-X

682

X-Z

364

40

INDEX

V : REAR RH SUSPENSION TOWER HOLE CENTRE. v : REAR LH SUSPENSION TOWER HOLE CENTRE W : TAILGATE HINGE MTG. HOLE X : STRIKER (TAIL GATE) MOUNTING HOLE Y : BUMPER MOUNTING HOLE.

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BODY TOP VIEW :

B

C

D

c

d

E

F

A

b

f

TABLE FOR TOP VIEW : MEASUREMENT POSITION

LENGTH (in mm)

A-B

862

A-b

789

B-b

1045

b-C

1398

C-c

787

C-d

1029

c-d

834

D-d

460

d-E

534

D-F

979

D-f

1212

F-f

1110

INDEX

A :

BONNET

B :

RH SUSPENSION TOWER CENTRE (FRONT)

b :

LH SUSPENSION TOWER CENTRE (FRONT)

C :

DRAIN HOLE NEAR DRIVER SEAT FRONT RH MOUNTING

c :

DRAIN HOLE NEAR CO-DRIVER’S SEAT FRONT LH MOUNTING

D :

FUEL TANK FRONT RH MOUNTING POINT

d :

FUEL TANK FRONT LH MOUNTING POINT

F :

REAR RH SUSPENSION TOWER CENTRE

f

REAR LH SUSPENSION TOWER CENTRE

:

E :

BODY

FUEL TANK REAR MOUNTING POINT

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41

BODY E. BODY SEALANT APPLICATION: While attending to accident repairs on the car, body sealants are to be used for preventing water and dust entry into inner panels thereby avoiding rusting of the parts. Also this helps in achieving better NVH levels. UNDERBODY SPOT REPAIRS : Product recommended : DINITROL Rockote. Dinitrol rockote is an acrylic based air drying product. Surface Preparation : Before application of the product it is essential to ensure that the surface is free of any oil, dust etc. Cleaning can be done using water. To remove oil de greasers like white spirit may have to be used followed by cleaning with water. The affected area should be sprayed with Dinitrol rockote. Thickness to be applied (minimum 500 microns)

Fig 68

Allow to dry overnight. Packing : One litre containers, which can be fitted directly to spray guns. Application Equipment : Application can be done by pneumatic guns, which can be screwed onto the one litre containers. COMPLETE UNDERBODY REPAIR : Product to be used : Dinitrol 401 - Brushable sealant - Synthetic resin, rubber based Dinitrol Rockote - Acrylic underbody coating Ensure that the complete underbody is clean and dry.Apply Dinitrol 401 by brush on all the joints of the underbody Allow to dry for two hours.

Fig 69

Spray Dinitrol Rockote on the under chassis. Minimum thickness to be applied 500 microns. Surface preparation : Please ensure that the surface is free of oil, grease, and dust, Use water & degreaser to clean the underbody. Packing : Dinitrol 401 - one kg tin Dinitrol Rockote - one kg tin

42

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BODY REPAIR OF JOINTS INSIDE THE CAR CABIN, ENGINE COMPARTMENT : Fig. 70 Product recommended : Dinitrol 401 brushable paintable sealant based on synthetic resin and rubber. The material should be brushed onto the joints. Allow to dry for two hours before painting. Surface preparation : Ensure that the surface is free of oil, grease, and dust. Use water & degreaser to clean Packing : Dinitrol 401 - one kg tin

Fig 70 REPAIR OF CLINCH JOINTS : Fig. 71 & 72 Product recommended : Dinitrol 410 : Polyurethane one component paintable. Application : Fit the cartridge into a manual or compressed air operated gun and apply material onto the joints. The bead of required size can be achieved by shaping of the nozzle into the desired shape. Surface preparation : Ensure that the surface is free of oil, grease, and dust. Use water & degreaser to clean. Packing : Dinitrol 410 - 310 ml cartridge.

Fig 71

BODY

Fig 72

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43

BODY Dinitrol Rockote Characteristics : Dinitrol Rockote is a quick drying acrylic stone chip protection product. The grey elastic product efficiently protects the vehicle body from stone chips and road salt. Range of use : Dinitrol Rockote is designed for treatment of cars, buses, trucks and other vehicles, on line application as well as in the aftermarket. The product is designed to protect the most exposed parts such as doorsills, spoilers, bumpers, wheel arches, edges, under chassis etc. Application : Dinitrol Rockote can either be applied with brush, low or high pressure equipment. The spraying is recommended airless with a product temperature of 15 to 350 C Technical data dinitrol Rockote Colour

Black/Grey

Type of film

Elastic

Density at 230 C

1400 kg/m3

Viscosity at 230 C

1200 mPa s

Dry matter content

66% by weight

Rec. Film thickness

500 mm

Drying time (touch dry)

3 - 4 hrs

Effect on car paint

None

Heat resistance

>1000C

44

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BODY The locations where the above sealants are to be used are given below. Front Side Fig. 73 1.

Dashboard planum seating on the firewall

2.

Leaf screen seating on the wheel arch

3.

Member crash seating on the Wheel arch

4.

Planum seating on the Wheel arch

Fig 73 5.

Dashboard cross member seating on the Planum / Cowl panel Fig. 74

Fig 74 6.

Roof seating surface on the Front roof bow Fig. 75

7.

Fender seating on the side panels (LH & RH)

BODY

Fig 75

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45

BODY Under Chassis Fig. 76 1.

Gear shift lever mounting on floor

2.

Parking brake lever mounting on floor

3.

Rear floor mounting on the front floor

4.

Longitudinal mounting on the floor

Body Side : Fig 77 1.

Tail lamp cover mounting on side panels (LH & RH)

2.

Wheel arch seating on side panels (LH & RH)

3.

Fuel filling cap housing on Panel on LH side

4.

Rear quarter trim seating on side panels (LH & RH)

5.

Roof seating on the side panels (LH & RH)

6.

A-pillar mounting surface on the side panels (LH & RH)

7.

Roof bow seating on the side panels (LH & RH)

8.

Cross impact bar seating on the door (LH & RH) Fig 77

9.

Hinge mounting place of Front and Rear doors THUMB SEALANT

Fig 76

Fig 77 Rear side : Fig. 78 1.

Fuel filling pipe mounting on side panel

2.

Rear suspension tower on the rear panel

3.

In between the seating of Roof and Rear roof bow (2 lines - Front & Rear)

4.

Tail gate seating place on the side panels - THUMB SEALANT

Fig 78 46

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BODY E. PAINT CARE CAUSE FOR CONCERN : The Tata Indica is painted using contemporary and state of the art technology to safeguard the body shell from corrosion. However certain precautions need to be taken to ensure better care of paint finish and long term corrosion protection of Indica. The common causes of corrosion of car are :

•

Accumulation of dirt and moisture in hard to reach areas under the vehicle.

•

Paint or underbody chip off due to minor accidents or due to the impact of stones or gravel against the painted surface. Certain environmental conditions or particular locations where the vehicle is driven may accelerate the rate of corrosion. Hence special care needs to be taken to repair any damage to the paint or protective coating, as soon as possible, in such areas. Please be very careful in case of the following situations.

•

If the car is driven in areas having hot and sultry weather.

•

The roads have a presence of substances which will accelerate the rate of corrosion such as road salt, industrial fallout, saline atmosphere near coastal areas.

•

The car is subjected to dampness on certain parts of the body for a long duration of time.

Fig 79 precautions need to be taken.

•

The underbody must be thoroughly pressure washed after every three months.

•

In case the car is driven near coastal areas or on salted roads in icy cold winter conditions the underbody must be pressure washed once a month.

FOLLOWING GUIDELINES WILL HELP TO PROTECT INDICA FROM CORROSION PROPER CLEANING : In order to protect Indica from corrosion it is recommended to wash Indica thoroughly and frequently in case :

•

There is heavy accumulation of dirt and mud especially on the underbody.

•

It is driven in areas having high atmospheric pollution due to smoke, soot, dust, iron dust and other chemical pollutants.

•

It is driven in coastal areas.

BODY

In addition to regularly washing, the following

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47

BODY •

All drain holes on doors and tailgate etc. must be clear so that there is no water entrapment. Fig 81

•

Any mud on wheel arches and underbody must be removed thoroughly so that these parts are not subjected to dampness that might be present in this mud.

•

Make use of mud-flaps to protect the painted surface and wheel-arch coating from the abrasive action of mud and impacting stones.

PERIODIC INSPECTION : Regularly inspect for any damage in the paint film such as deep scratches and immediately get them repaired, as these defects tend to accelerate corrosion.

Fig 80

PROPER PARKING : Always park the vehicle in shade to protect it from harsh sunlight or in a well-ventilated garage so that there is no dampness on any part of the vehicle. WASHING INDICA Follow these tips while washing Indica. HAND WASH :

•

Always wash in shade and when the surface is at room temperature.

•

Wash with mild car wash soap like "Car Shampoo" and use a soft 100% cotton cloth to avoid scratches. Please take help of your dealer to buy the right products.

•

Please be sure to remove the wristwatch and wear soft gloves to avoid scratches due to finger rings or nails.

•

To remove stubborn stains and contaminants like tar, use turpentine or cleaners like "Stain Remover" which is safe for painted surfaces. Again your dealer can help you in selecting the right product.

•

Avoid substances like petrol, diesel, kerosene, benzene or other solvents that cause damage to paint.

•

Dry the vehicle thoroughly to prevent any damp spots.

Fig 81

INSPECT MUD LINERS FOR DAMAGES

Fig 82 48

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BODY AUTOMATIC CAR WASH : Fig 83 These machines can clean the car thoroughly. However check for following :-

•

Please feel the surface of the brushes and ensure that the brushes on the automatic car wash are in proper condition as damaged or worn bristles may develop scratches on the paint finish.

•

Please enquire and verify that the water used in the automatic car wash undergoes proper filtration as water which is reused without filtration contains dirt and contaminants, which may lead to scratches and damage.

WAXING : Fig 84 Waxing and polishing is recommended to maintain the gloss and wet-look appearance of your paint finish.

•

Use a good quality polish and wax for your Indica.

•

Re-was your Indica when the water does not slip off the surface and collects over the surface in patches.

Fig 83

FURTHER TIPS FOR THE CARE OF NEW INDICA FINISH IN THE FIRST 30 DAYS : In case the car is washed in an automatic car wash, please remember that the paint can be scratched by some type of brushes, unfiltered washing water, or the washing process itself.Scratching reduces paint durability and gloss, especially on darker colours. Wash the vehicle by hand with cool and clean water using a soft cloth or sponge. Please do not use soap but a car shampoo recommended. Please take the following precautions.

Fig 84 check immediately afterwards for any stains and clean them.

•

External contamination in the form of sap or industrial fallout may mar or develop spots on a new finish. Hence avoid parking Indica near trees, which are known to drop sap, or near factories, which give out heavy smoke.

•

Always wash in shade, avoiding direct exposure to sunlight during washing.

•

Dry wiping may lead to the formation of scratches and hence always use a soft cloth and clean water while wiping your Indica.

•

Always keep Indica parked in a well ventilated shade. Exposure to heat with entrapped moisture promotes corrosion.

The acid content in bird droppings may damage the newly painted finish and hence any bird droppings must be immediately washed off.

•

The paint finish is susceptible to damage in case petrol, brake fluid, liquid from car battery, oil, antifreeze, transmission fluid or windshield solvent

•

•

Avoid driving on gravel roads, as the possibility of paint chip off due to the impact of stones is high. If the car is driven on freshly tarred road,

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49

BODY

BODY spills onto the painted surface.. In case of such a spillage immediately rinse the affected area with water. Avoiding wiping the area as far as possible, however if wiping is required, ensure to wipe the area gently with soft cotton cloth.

•

Avoiding using sharp objects to scrap off tar or mud from a painted surface as it may develop scratches or may peel off the paint.

•

It is recommended that you wax your Indica after a wash as wax forms a protective layer over the painted surface.

•

Always keep the drain holes and channels clear so that water drains off freely and does not accumulate in crevices and box sections.

•

Any damages in the paint film such as dents and scratches are prone to corrosion and hence must be rectified immediately.

•

A higher salt contents in the air accelerates corrosion in coastal areas and hence more care should be taken in case your Indica is driven in these areas in wet season.

IN THE FIRST 90 DAYS : It is recommended not to wax or polish your Indica in the first 90 days. This will allow the paint finish to completely age and cure. When the car is ready to wax, do not use silicone containing or super polymer containing waxes or polishes, (e.g. Teflon). Indica's OEM finish does not need such extreme protection and if the vehicle is involved in an accident, the removal of such waxes would be time consuming and expensive. It is advised to use ordinary organic waxes. "TO DO" LIST FOR INDICA PAINT FINISH CARE IN RAINY SEASON CAR BODY : The exterior of the car is the only line of defence between the interior and critical components. Not only that, but most modern cars are monocoque i.e. the bodies are themselves the load bearing structures. So making sure they weather the rainy season is not only an aesthetic reason, it's a pretty good technical reason too. The main cause of body and underbody deterioration is corrosion. Modern cars come with galvanized metal, rust proofing, etc. but with our fierce monsoons, additional care needs to be taken. Following precautions must be taken :

•

Do not allow dirt to accumulate on any painted surface. Water trickles off painted surfaces but dirt settles on the damp areas and eventually eats into the paint work. Most corrosion beings on the inside, so your Indica may need more than a wash down.

•

Wheel-arch's, doorsills and doors are most susceptible to corrosion and hence special care needs to be taken to keep these areas clean.

•

Do not use household detergents to wash paint work as they are strong and may affect the metal and promote corrosion.

50

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BODY CARE OF THE UNDERBODY: Fig. 85 The underbody of the car houses many critical components and connections and hence special care has to be taken to keep it corrosion free. Following are some useful tips to keep underbody corrosion free.

•

Inspect Indica before and after the rainy season for any possible signs of corrosion.

•

Corrosion can be arrested using a rust-proofing treatment like waxing e.g. Dinitrol.

•

The exhaust system on the underbody is most susceptible to corrosion. It is recommended to re-coat it with aluminium paint in case the original coating is damaged or weathered away.

•

Periodically check the car for any scrapes on the underbody caused due to speed-breakers or due to stones.

Fig 85

Caring for the car's paint finish is a good investment as it not only helps to prevent the rusting of sheet metal parts but also enhances the value of the car following the above guidelines will help you to maintain the glossy and wet look appearance of the car.

BODY

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51

AIR CONDITIONING

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AIR CONDITIONING

INTRODUCTION :

Air conditioning is the regulation of air flow, temperature and humidity in the car for making up an environment comfortable to the occupants. The comfort of the environment in the car will not necessarily be the same as that in buildings and will be defined in terms of temperature, humidity and air flow. But this degree of comfort will vary with the outside conditions (radiation, sunlight, etc.) For maintaining a comfortable environment (climate) in the car cabin, two separate temperature regulated circuits and the corresponding controlling elements are required i.e. refrigeration and heating circuits. Tata Indica LSi, LX, LXi versions are fitted with HVAC system. This system provides for full heating, ventilation and cooling of the car interior.The controls on the dash boards can be adjusted to mix heating and cooling to get the desired effect inside the car. There is a provision for demisting of windshield and front door glasses if required. Tata Indica LEi is fitted with Heating and Demisting (HD) system,which provides full heating. There is a provision for demisting of windshield and front door glasses if required. This manual provides information on operation, maintenance, charging and trouble shooting of A. C. system.

AIR CONDITIONING

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i

AIR CONDITIONING CONTENTS Sr. No.

Description

Page No.

1.

Technical specification

1

2.

Tightening Torques

2

3.

Schematic Diagram of Airconditioning Cycle

3

4.

Layout of A. C. System (BHER)

4

5.

Main Parts of A. C. System

5

6.

HVAC controls

7

7.

Climate Box & Control Panel (BEHR HVAC)

9

8.

Removal & fitment of A. C. Components

10

9.

Trouble shooting Tips

13

10.

Precautions in Handling refrigerant

15

11.

Discharging the system refrigerant recovery

16

12.

System Charging & Evacuation

17

10.

Flushing the system

21

11.

A. C. Performance Testing

23

12.

Do’s & Don’ts & Safety Tips for A/C system

26

13.

Function & inspection of A. C. components

27

14.

Trouble shooting

28

AIR CONDITIONING

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iii

AIR CONDITIONING TECHNICAL SPECIFICATIONS : IMPORTANT SPECIFICATION

INDICA HVAC SYSTEM (BEHR)

Model Applicability

HVAC

Gas used

R-134a

Gas charge Quantity

640 + 20 gms

Compressor Lube oil used

FD 46XG (PAG) EQV ND - 8

Compressor oil top up qty when the following components are changed :

120 ml.

a. Receiver Drier

20 ml.

b. Condenser

20 ml.

c. Evaporator

20 ml.

d. All Pipes

10 ml. each

System Pressure : Car in stationary condition with engine speed at 1500 rpm. Discharge Pressure Suction Pressure

15 kg / cm2 to 20 kg / cm2 1.5 kg / cm2 to 3 kg / cm2

High - Low safety pressure switch

2 kg / cm2 to 32 kg / cm2

Medium pressure switch

Cut off at 15.5 kg / cm2 Cut in at 20.5 kg / cm2 for two speed condenser fan

AIR CONDITIONING

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1

AIR CONDITIONING TIGHTENING TORQUES : SR. NO.

JOINT

TIGHTENING TORQUE

1.

Discharge end of compressor with discharge pipe inlet

10 Nm + 10 %

2.

Discharge pipe outlet with condenser inlet

10 Nm + 10 %

3.

Condenser outlet with inlet of R. D. inlet pipe

30 Nm + 10 %

4.

R. D. inlet pipe with inlet end of R. D. bottle.

30 Nm + 10 %

5.

Outlet end of R. D. bottle with inlet of R. D. outlet pipe.

30 Nm + 10 %

6.

R. D. outlet pipe end with ilet end of R. D. to expansion valve inlet pipe.

10 Nm + 10 %

7.

Hex nut at expansion valve end.

10 Nm + 10 %

8.

Suction pipe outlet with suction end of compressor.

10 Nm + 10 %

2

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INDEX

GROUP INDEX Condenser

Compressor TRINARY PRESSURE SWITCH

HIGH TEMP HIGH PRESSURE LIQUID

ENGINE COMPARTMENT

Condenser Fan

HIGH TEMP HIGH PRESSURE GAS

LOW TEMP LOW PRESSURE VAPOUR

Expansion Valve

SCHEMATIC DIAGRAM OF AIRCONDITIONING CYCLE

CAB

Blower

Evaporator

COLD AIR

AIR CONDITIONING

AIR CONDITIONING

Fig. 1

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3

4

INDEX

Condenser fan

Magnatic Clutch

Hose discharge

GROUP INDEX Receiver Drive

Trinary Pressure Switch

Drain hose

Heater inlet with water valve

Condenser Assembly

Compressor Mounting Bracket

A. C. Compressor

Heater outlet

Hose suction

LAYOUT OF A.C. SYSTEM (BEHR)

Tube liquid

Blower motor

Servo motor

HVAC Climate Box

AIR CONDITIONING

Fig. 2

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AIR CONDITIONING MAIN PARTS OF A. C. SYSTEM

7.

1.

COMPRESSOR : It is the heart of A. C. system where, low temperature, low pressure vapour refrigerant is compressed and converted to high temperature high pressure gas.

2.

CONDENSER : It is the place where heat dissipation takes place. Hot compressed gas enters the condenser and is cooled off and converted into high pressure liquid at the condenser outlet.

3.

RECIEVER DRIER : It serves as a reservoir for excess refrigerant where it removes any traces of moisture and filters out dirt in the system.

4.

TRINARY PRESSURE SWITCH : It is used to monitor & or limit pressure conditions in a closed refrigerant cycle.

ANTI FREEZE SWITCH : It is a temperature sensing device, which protects the A. C. systems from damage. It switches off the compressor when condensed water tends to form ice on the fins of evaporator. Thus it maintains the evaporator temperature within a specified range.

High Low Pressure Settings : If the system pressure reaches impermissible levels i. e. if the pressure is less than 2 + 0.2 kg/cm 2 or if the pressure is higher than 32 + 2 kg/cm2 then the compressor is switched off. This avoids its consequential damage. Medium Pressure Settings : Due to these pressure settings, both the condenser fan and radiator fan start immediately after the A. C. is switched ON. Both the fans run at slow speed until the system pressure exceeds 20.5 kg / cm 2 Above this pressure, both the fans run at full speed. When the system pressure drops below 15.5 kg / cm 2, both the fans will run at slow speed. 5.

EXPANSION VALVE : It senses the pressure of the refrigerant coming into the evaporator as well as the temperature of the refrigerant into the evaporator. By sensing the temperature and the pressure of the gas leaving the evaporator, the expansion valve prevents the evaporator from being flooded, and thereby returning liquid refrigerant to the compressor.

6.

EVAPORATOR : It serves as heat absorption unit. Here it removes heat from inside the vehicle & dehumidifies it. The refrigerant enters the bottom of evaporator as a low pressure liquid. The warm air passing through evaporator fins causes the refrigerant to boil, it can absorb large amounts of heat. The heat is then carried off with the refrigerant to the outside of vehicle.

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AIR CONDITIONING

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5

AIR CONDITIONING Magnetic clutch : A magnetic clutch is used to connect and disconnect the compressor from the engine. ATTRACTIVE FORCE

Main components are stator, rotor, and pressure plate.

SWITCH

IRON (I)

Principle :

IRON (II)

When the current is fed to the coil (as shown fig. on the right), magnetic force is generated in iron II which attracts iron I.

BATTERY

Construction : A magnetic clutch consists of a stator, rotor with pulley, and pressure plate to engage the drive pulley and compressor magnetically. The stator is fixed on the compressor housing, and the pressure plate is attached to the compressor shaft. Two ball bearings are used between the inner surface of the rotor and the front housing of the compressor. Operation :

Fig. 3 STATOR BALL BEARING PRESSURE PLATE

SNAP RING

Whenever the engine is operating, the pulley is rotating since it is connected to the crankshaft by a belt, but the compressor does not operate until the clutch is energized. When the air conditioning system is on, the amplifier supplies current to the stator coil. The electromagnet attracts the pressure plate and pulls the plate against the friction facings on the pulley. The friction between the facing and plate causes the clutch assembly to rotate as a unit, and drive the compressor.

SNAP RING

PULLEY

Fig. 4 ATTRACTED

ELECTROMAGNET

STATOR

PULLEY

PRESSURE PLATE

Fig. 5 6

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AIR CONDITIONING HVAC CONTROLS

AIR FLOW PATTERN

Fig. 6 HEATING, VENTILATION & AIR CONDITIONING

D

E

HEATING : (IF FITTED) Controls : (For Deluxe Version) A. Temperature Control Knob : The air temperature in the car can be controlled by operating the temperature control knob at the left hand side of the control panel (A). The temperature can be increased by rotating the knob towards the red segment and decreased by rotating it towards the blue segment. The temperature adjusting dampers can be set manually to achieve desired temperature. The air mix is done at the part shown by dotted lines, to attain comfortable air conditioning. A. Temperature Control Knob :(For Heater Version) The air temperature in the car can be controlled by operating the temperature control knob at the left hand side of the control panel (A). The temperature can be increased by rotating the knob towards the max red segment and decreased by rotating it towards the min. red segment. The temperature adjusting dampers can be set manually to achieve desired comfortable temperature.

INDEX

A

C

B

Fig 7 HVAC Controls D

E

AIR CONDITIONING

A

B

C

Fig 8 Heater controls

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7

AIR CONDITIONING B. Blower Speed Regulation Knob :

HEATERCORE

The ventilation system has a three/four speed blower.The blower speeds can be regulated to any one of the following speeds by operating the knob at the centre of the control panel (B). LOW




OUT SIDE AIR

MEDIUM
HIGH
VERY HIGH COOLING COIL

This is similar for heating version

TEMP.ADJUSTDAMPER

C. Air direction control knob : The air flow can be changed by turning the switch to the desired direction (C) Towards face Towards face and feet Towards feet Towards feet and windshield Recommended for clearing fogging on windshield) Air demist / defrost windshield (Recommended for clearing heavy fog and snow)

AIR OUTLET

HOTAIR AIR OUTLET OUTLET

COOL AIR OUTLET

Fig 9 Schematic layout - Air flow


The condenser fan works only with the A. C. switched ‘ON’ and when the engine is running.The condenser fan is a two speed fan.




The A. C. compressor gets switched ‘OFF’ automatically when the engine gets over heated. The A. C. is automatically switched ‘ON’ when the engine cools down.

NOTE : If your car is has been left in the sun with the windows closed, to quicken the cooling open the windows briefly while you operate the air conditioner with the air circulation switch in fresh air mode and the fan at a higher speed. Maximum Cooling Effect :

This is similar for heating version D. A. C. ON/OFF switch The A. C. can be switched on by pressing the switch (D) on the A. C. control panel provided the blower is ‘ON’ and the engine is running. The indicator lamp will show that the A. C. is ‘ON’. (In heater version : This is absent and a dummy knob (D) is provided on control panel).

Switch ‘ON’ the A. C. and keep the blower at maximum speed. Keep air direction in face mode. All vents should be opened completely. Keep the air circulation switch in the recirculation mode and temperature control switch in the maximum cooling (Blue) position. At maximum cooling, A. C. trips OFF automatically when the desired temperature is acheived. Front Windshield Demister / Defrost :

Fresh air can be circulated by pressing switch (E) on the panel for DLX version. For DLE version rotary knob has been provided.This should be put on only when discomfort is felt, as cooling effect reduces with fresh air entry.

First start the engine and accelerate to warm up. Select defrost / demist mode on air flow direction control. Then set the blower to maximum speed and temperature control knob to maximum heat ensuring that A. C. is ON. These settings direct all air flow to the base of the front windshield and towards front door glasses. The hot air clears the frost from the windshield and door glasses. Electrical heater coil is provided for demisting of tail gate glass .

NOTE :

(In Heater version) :

The A. C. can be switched ‘ON’ only if the blower is ‘ON’. Engine fast idling control has been provided. When the A. C. is switched ‘ON’, the engine idling RPM increases marginally to adjust to the A. C. compressor load. When the thermostat cuts off the A. C. engine idling RPM decreases to normal idling.

First start the engine and accelerate to warm up. Select defrost / demist mode on air flow direction control. Then set the blower to maximum speed and temperature control knob to maximum heat .

E. Fresh Air switch

8

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AIR CONDITIONING These settings direct all air flow to the base of the front windshield and towards front door glasses. The hot air clears the frost from the windshield and door glasses. Electrical heater coil is provided for demisting of tail gate glass for deluxe models. Heater : When the heater is ON, It is desirable to switch off A. C. for quick heating effect.This will also help to save fuel. Fresh air option is preferable for using heater or as per comfort of the customer. Maximum Heating Effect : (In Heater Version) Switch ‘ON(tm) the heater and keep the blower at maximum speed. Keep air direction in face mode. All vents should be opened completely. Keep the air circulation switch in the recirculation mode and temperature control switch in the maximum heating Ventilator : The air flow can be adjusted continuously with the rotary control knob at the vents on the dash board. The air vents can be adjusted upward and downward. This is common for HVAC, AC and ventilation. NOTE : Refrigerant charged in the air conditioning circuit has been identified on the label over front body member. Use only refrigerant as given in the label for topping up or recharge, i.e. do not charge R 12 (CFC) in the vehicle earlier charged with R 134a (Non CFC) or vice versa.

AIR CONDITIONING

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9

AIR CONDITIONING CLIMATE BOX & CONTROL PANEL (BEHR HVAC) Blower Assly.

CLIMATE BOX ASSEMBLY

Evaporator Assly.

Kinematic Assembly Bowdon Cable Distribution

Heater Inlet Heater Outlet

Clip Bowdon Cable (single End)

Bowdon Cable Temperature

Distribution Box Assy. Hvac

Bowdon Cable Temperature

Cable Movement Towards Full Warm

Clip

Cabele Movement Towards Face Mode

Bowdon Cable Distribution Clip

Towards Full Warm

Towards Face Mode

Base Plate

Front Plate

CONTROL PANEL HVAC (TOP VIEW)

Fig. 9a 10

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AIR CONDITIONING REMOVAL & FITMENT OF A. C. COMPONENTS 1.

Climate box assembly

REMOVAL : Following sequence to be followed to replace the Climate Box assembly in the cabin.


Discharge the refrigerant through Recovery Unit.




Disconect the Expansion Valve inlet & outlet pipes from the engine compartment side (close the Expansion Valve & the pipe openings with a tape)




Remove the hoses at the heater inlet & outlet end, in the engine compartment.




Plug the heater inlet & outlet end with tape, so that while removing the climate box from inside of the cabin, coolant will not drain on the carpet.




Remove 2 screws from bottom of facia & disconnect PCB wiring.




Slowly remove the front plate without breaking of latches.




Remove 1 screw at top side of base plate and one at the bottom.




Remove the central cluster switch connection from the wiring harness.




Keeping the Mode knob at Face position, remove the Mode Bowden cable (control cable) plastic clip from the Base - plate assembly.




Rotate the Mode Knob towards defrost position in anti clockwise direction to remove the Mode Bowden cable (control cable) eyelet from the bevel gear.




Keeping the Temperature control knob on Max Cold position, remove the temperature control Bowden cable ( control cable ) plastic clip and the eyelet from the bevel gear form the Base – plate assembly.




Disconnect the electrical connectors for Blower Switch, PCB Assly and lamp assembly.




Remove the base plate assembly.




Remove cross member & vertical support.




Disconnect the electrical supply to the Climate box wiring harness by removing the connectors.




Disconnect the earth terminal while removing the climate box. Remove the hex nuts from the mounting points of the climate box on the fire wall and then remove the climate box with drain hose.

INDEX

Fig. 10 Climate Box FITMENT :


Fit the climate box with drain hose at it’s position on the firewall and tighten the seven hex nuts at its position for mounting the climate box.




Check & ensure that the wire harness connections are properly made. Climate box main connector to vehicle cabin wiring harness. Earth terminal to the stud.




Fit the vertical support for dashboard, route the Mode Bowden cable (control cable) & Temperature control Bowden cable (control cable) from outside of the vertical support member cross member and fit the dashboard at their position.




Fit the Base Plate Assembly on dashboard & tighten the 2 screws. Make sure that all the electrical connections are made properly with blower switch & illumination lamp.




Rotate the Temperature control knob at Max cold position & fit the plastic clip of Temperature control bowden cable (control cable) on Baseplate Assembly, ensuring proper routing of the cable through the slot on the bevel gear and check for free rotation of temperature control knob.




Keep the Mode knob at Defrost position & put the eyelet of the Mode Bowden cable (control cable) on the bevel gear.




Rotate the Mode knob at Foot – Defrost position 8 fit the plastic clip of Bowden cable (control cable) on Baseplate Assembly, ensuring proper routing of the cable through the slot on the bevel gear.




Check for free rotation of the Mode knob.

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11

AIR CONDITIONING

AIR CONDITIONING





Fit the center cluster connect electrical connection to PCB and front plate, without breaking the latches. Fit 2 screws of the front plate. Ensure that the hazard warning switch connector is connected properly. Connect the refrigerant pipes to Expansion valve ends. Make sure that o-rings are properly smeared with lubricant oil before connecting.




Remove the tape from the heater inlet & outlet ends.




Connect the hoses to the heater inlet & outlet end.




Check the system for leakage and charge the system.

2.

Blower Complete :




Remove the climate box as explained above.




Remove the connector for blower motor, resistor & anti freeze switch.




Remove the screws between the blower housing and evaporator housing.




Remove the screws on top side of the blower assembly.




Replace the Blower assembly with a new one & fit the screws.




Put the climate box at it’s position.




Tighten the nuts at mounting points & the earth terminal to the firewall.




Put the connector to the blower motor, resistor & antifreeze switch.




Fit the dashboard (Refer Climate Box section for details)

3.

Resistor :

The resistor is meant for regulating the speed of the blower as per the user’ s requirement. The speed is in 4 steps. It has 3 coils in series for regulating the speed of the blower, as per the user’ s requirement. The speed is in 4 steps. It also has a temperature safety fuse. This fuse blows off when the resistor temperature in creases beyond the permissible limit.

base-plate. In case it is not convenient in some cases, the dashboard should be removed.


Remove the wiring harness connector from the resistor.




Connect the wiring harness connector to the resistor.




Fit the dashboard ensuring the routing of both the bowden cables (control cable) from outside the vertical support for dashboard.




Fit back the control panel on the dash - board.

4.

Housing Evaporator Assly :

Evaporator housing holds the complete evaporator (cooling coil) assembly. When it is required to replace the evaporator, it is better to replace along with the housing assembly. Replacement procedure :


Remove the climate box from the cabin.




Separate the evaporator housing assly from the blower housing assly & distribution housing assly by removing the screws between the housing assemblies




Replace the Evaporator Housing Assembly with new one. And assemble with blower housing & distribution housing assly, with self tapping screws.




Fit back the climate box assembly in the cabin.

5.

Anti Freeze Switch :

The function of antifreeze switch is to protect the refrigerant system from the damage. It switches off the compressor when the water is condensed and forms to ice on the fins of evaporator. Suction pipe becomes extra cool and sometimes iced up, liquid refrigerant remains after expansion valve due to insufficient heat transfer across the evaporator surface and eventually the compressor will get damaged due to liquid refrigerant inflow. NOTE : Please do not tamper the set screw of anti freeze switch as it is factory set. Replacement procedure :


Remove the wiring harness connector from the anti freeze switch.

Replacement procedure :


Remove the Control panel base plate (Refer Climate Box removal for details).




Remove the mounting screws from mounting bracket on the housing evaporator assembly.




Resistor becomes accessible through the opening in the dash – board after removing the control panel




Remove the probe carefully from the Evaporator core.

12

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AIR CONDITIONING NOTE : The feeler is a capillary tube and must not be bent or twisted sharply as it may damage the unit.


The feeler of the new switch must be inserted to the same depth that is 100 mm and the remaining bend to be made so as to keep the feeler as close as possible to the housing.

6.

Housing Distribution Assembly :




Remove the climate box .




Separate the distribution housing from the entire assembly by removing the screws between the Housing Evaporator assembly and the Housing Distribution assembly.

Fit the Base-plate Assembly & Front-plate as.

9.

Rotary Knob for Mode :




Remove the Base-plate Assembly.




Pull out the knob by slightly flexible the snap-fits & replace it with a new one.




Fit the Base-plate Assembly Front-plate.

10. Rotary Knob for Blower switch :




Replace the Housing distribution assembly.




Fit the new Housing Distribution Assembly to the Housing Evaporator assembly with the help of screws.

7.




Kinematic Assembly :




Remove the front-plate by removing the 2 screws from the bottom.




Gently pull the knob of blower switch & replace it with new one.




Put the front-plate in it’s position 8 tighten the 2 screws.

11. Lamp Assembly :


Remove the Base-plate Assembly.




Disconnect the connector of lamp assly and pull out the three lamp holders from the Base - plate, replace with new lamp assly and connect the connector. Wires of the lamp assly should be snap-fitted into the wire clips.




Fit the Base - plate Assembly & Front-plate.

Kinematic assembly controls the flap movement and distributes the air as required at different outlets. Replacement procedure :





Remove the Bowden cable (control cable) holding clip on the kinematic base plate with a nose plier and remove the eyelet of Bowden cable (control cable) from gear partly. Remove the mounting screws from the kinematic base plate that is fitted on the Distribution Housing.




Replace the Kinematic Assembly with a new one.




Keep the Mode knob at Defrost position & put the eyelet of the cable on gear partly.




Now fit the Bowden cable (control cable) on the Kinematic baseplate with the clip.

8.

Control Panel Assembly :




In each switching position 1 to 4, It should show continuity between the respective terminal and the ground.




Remove the Base-plate Assembly (Refer Climate Box removal ).




Pull out the blower knob.




Remove the electrical connector from the blower switch and pull out the blower switch by flexing the snap-fits and fix the new switch.

INDEX

12. Lamp (Bulb) :


Remove the front-plate by removing the 2 screws from the bottom.




Gently pull out the bulb and fix the new bulb with blue caps.




Put the front-plate in it’s position & tighten the 2 screws.

Re - Installing the original Compressor : Oil should be changed at the time of re-installing the original compressor. Drain and measure the refrigerant oil contained in the compressor. Charge oil through the discharge port of the compressor with the same amount of new refrigerant oil. NOTE : In case for some reasons the flushing is not possible, ensure that the complete system contains 120 ml oil.

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13

AIR CONDITIONING

AIR CONDITIONING Installing a New Compressor : Drain and measure the compressor oil from the original compressor. Drain the oil quantity equal to Tolal oil – Drained oil from the new compressor (New compressor comes with 120 ml of oil).

TROUBLE SHOOTING TIPS The most basic and important element of effective trouble shooting is safety. The basic steps are: 1. Switch off the engine before you open the bonnet while looking for fault identification.

Eg : Drained oil from the old compressor Total oil in the new compressor

:

40 ml 120 ml

Oil to be drained from the new compressor = 120 ml – 40 ml = 80 ml. NOTE : Please ensures that the ports are covered with a tape to avoid entry of dirt, foreign particles, coolant, etc. and change the O Rings if damaged. Condenser or Evaporator : Drain as much of the original oil as possible from the evaporator or condenser. Add the same amount of new refrigerant oil, either to the original or new condenser or evaporator.

2. Use gloves and safety glasses when handling refrigerants used compressor oil. 3. Keep our environment safe by practicing proper recovery, evacuation and charging procedures. Do not release refrigerant to atmosphere. 4. Never use oxygen for pressure testing a system. It may explode in presence of oil. Instead use Nitrogen from a cylinder equipped with proper pressure regulator. The problems fall in two categories 1. Electrical problems

If replacing condenser, add approximately 20 ml oil.

2. Mechanical refrigeration system / component problems

If replacing evaporator, add approximately 20 ml oil. Receiver Drier : If replacing the RD, add approximately 20 ml oil.

Many times the problems overlap. For example, a malfunctioning of relay or contact may make compressor cycle on / off too frequently and damage compressor.

The RD must be replaced whenever the system has been opened to the atmosphere for repair.

Although the problem is electrical, it results into mechanical failure.

New RD must never be left open as it will absorb moisture from the air and become unserviceable.

Similarly, a system not evacuated properly may have moisture present leading to acid formation and destroying electrical contacts. This is a refrigerant side problem disguised as an electrical issue.

Blown or Ruptured Pipe / Hose : When replacement is required, add approximately 10 ml oil per pipe. Note: In case of sudden refrigerant leakage on any of the A. C. component, it is recommended to flush the system completely and then ensure that the complete A. C. system contains 120 ml compressor oil.

Before attempting any troubleshooting procedure, learn the Operating sequence of the unit. Most refrigerant - side problems, if permitted to continue result in compressor failure. For example, an overcharged system would lead to eventual premature compressor failure. Unless the root cause is determined the next compressor is also doomed to fail, Many problems produce similar symptoms. If cooling is not sufficient, the possible causes, could be :

14

INDEX

1.

Condenser dirty

2.

Fan direction reverse

3.

System over / under charged

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AIR CONDITIONING 4.

Evaporator / Blower damage

Procedure

5.

Expansion valve malfunctioning

6.

Filter - Drier choked

STEP 1 - Collect as much information from customer as possible. It could give vital clues.

7.

Non condensibles

8.

Leakage of refrigerant

9.

Compressor clutch worn out

STEP 2 - Conduct preliminary checks - engine off Sr. No. Problem

10. Belts snapped or slipping and many more other causes. It is always therefore essential to go to the root cause and not jump to conclusions or quick fix solutions based on symptoms.

a.

Dirty condenser /Radiator coil

Clean

b.

Dirty or loose fins

Clean

c.

Loose belts

Adjust belt tension

d.

Damaged-loose interconnecting piping

Repair

e.

Disturbed alignment

Rectify

f.

Idler pulley loose

Align / tighten

g.

Oil / Dirt patches at joints - indicating oil Refrigerant leak

Locate & rectify

Proceed in a logical manner to rectify the defect. Ensure following minimum equipment are available at service point 1. Safety equipment ( Gloves, Glasses ) 2.

Manifold gauges

3.

Vacuum pump

4.

Contact thermometer digital

5.

Leak detection equipment

6.

Weighing scale

7. Refrigerant recovery unit 8.

Recovery cylinder

9.

Sealed lubricant container

10. Container for recovered lubricant

h.

Indications burn out Piping / Wiring touching hot parts of engine, clutch burn out due to dirt dust or any other reason.

i.

Cables loose Condenser / Radiator / EBA /Clutch / Pressure Switch

Refix

Control Cables Loose / stuck

Repair

k.

All AC fuses

Check & replace

l.

Air Mix door operation

Check - It may be stuck

m.

Fresh / Recirculation Door operation

Check - it may be stuck

j.

11. Replacement Refrigerant (R134a) in sufficient quantity & of proper quality 12. Replacement filter / drier 13. Multimeter

1.

Solution

Repair

If step 1 & 2 do not reveal cause of malfunction, then only go to step 3.

STEP 3 - Inspection - Engine - on

AIR CONDITIONING

Before going in for diagnostic techniques & handling refrigerant circuit, it is essential to learn a. Refrigerant handling precautions b. Discharge system - Refrigerant Recovery c. System evacuation & charging d. System flushing

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15

AIR CONDITIONING Connect gauge manifold in the system before AC system is made operational through quick couplers. This will enable you to record suction & discharge pressures. Based on gauge pressure observations & with the help of chart given in this manual try to locate the problem.

PRECAUTIONS IN HANDLING REFRIGERANT Refrigerant (R134a) (Tetra flouroethane, CF3-CH2F) Specifications : Oil

:

HFC 134a CH2 F CF3 Mineral oil ND - 8

Care should be taken when discharging the air conditioning system to ensure the refrigerant is not released to the atmosphere but captured for recycling. Environment & friendly refrigerant R134a is not an ozone depleting substance but its release would add to the green house warming effect. Refrigerant R134a is transparent and colourless in both the gaseous and liquid states. At all normal temperatures and pressures it will be a vapour. The vapour is heavier than air and is non - flammable, non-explosive, nonpoisonous and non-corrosive (except when in contact with moisture). The following precautions in handling R134a should be observed at all times : NOTE : R134a and R 12 are not compatible and must never be mixed. l.

Always use safety glasses and gloves when handling or servicing air conditioning systems. If R 134a does enter the eye, freezing of the eye can occur and could result in blindness. The procedure outlined below is suggested if R 134a enters the eye. a.

Keep calm.

b.

Do not rub eyes.

c.

Splash large quantities of cool water into the eyes to increase the temperature

d.

Tape a sterile eye patch in place to prevent dirt from entering the eye

e.

Go immediately to a doctor or hospital for professional care

16

INDEX

DO NOT ATTEMPT TO TREAT YOURSELF 2. Always use proper workshop practices, do not bypass agreed practices 3. Always work in a well ventilated area 4.

Avoid skin contact, as R134a will cause frost bite on contact with bare skin

5.

Do not abuse the refrigerant cylinder, or any other tools you may need to use

6.

Do not weld or steam clean on or near any air conditioning components when pressurized.This may cause a dangerous pressure build up in the system.

7.

Do not discharge refrigerant into an enclosed area.

8.

When purging a system, discharge the refrigerant slowly.

9.

If it is necessary to transport or carry a cylinder of refrigerant in a car, keep it in a luggage compartment.

10. Refrigerant cylinders should always be protected from the radiant heat of the sun & keep in a cool place. 11. When filling a refrigerant cylinder, never completely fill it. Always leave space for expansion. If the cylinder was completely filled and the temperatures increased, hydraulic pressure with its tremendous force would result, leading to cylinder bursting accidents. 12. Never discharge a system or do brazing / welding / operation when the main engine is on. 13. Do not drop, dent or abuse refrigerant gas cylinders. 14. Always chain or strap cylinders in place to prevent them from tripping over or damage, from moving around. 15. Always keep the cylinders capped. 16. Never heat a cylinder with open flame or place electric heater in direct contact. 17. Always double check that you have proper refrigerant container. The refrigerant cylinders are colour coded to avoid confusion. R 134a is BLUE. 18. Use proper size spanners, wrenches to avoid damages to valve & threads.

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AIR CONDITIONING

1

3

4

5 2

1. 2. 3. 4. 5.

REFRIGERANT RECOVERY UNIT (RRU) REFRIGERANT RECOVERY CYLINDER MANIFOLD/GAUGE SET LOW SIDE CHARGING ADAPTOR HIGH SIDE CHARGING ADAPTOR

Fig 11

DISCHARGING THE SYSTEM REFRIGERANT RECOVERY Various Refrigerant Recovery Units ( RRU ) are now available. The following procedure is typical for the use of these units when recovering refrigerant from a car air conditioning system. 1.

Connect the RRU outlet to an R 134a recovery cylinder with a refrigerant hose and open the valve on the cylinder. Ensure that the cylinder has sufficient capacity to hold the refrigerant in the system to be serviced. This can be confirmed by weighing the cylinder or by referring to the volume gauge if fitted.

2.

Connect a gauge manifold set to the car air conditioner. Connect to both the suction and discharge sides of the system. Connect the centre hose of the gauge set to the inlet of the recovery unit. Connect the RRU to electrical supply.

3.

4.

The automatic recovery unit will operate until the air conditioning system has been emptied of refrigerant down to atmosphere pressure. The cylinder can now be closed.

5.

Measure the amount of PAG (Poly Alkaline Glycol) oil removed from the A/C system. This oil is normally separated from the incoming refrigerant into the RRU. New clean PAG oil must be added into the system before recharging with refrigerant.

AIR CONDITIONING

Open the gauge set and quickly connect stop taps to allow refrigerant to enter the RRU via the centre hose. At this point, depending on which unit is being used, the RRU will switch on. If the RRU is-not the automated type, switch the unit on.

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17

AIR CONDITIONING SYSTEM CHARGING AND EVACUATION

Charging the system includes the following steps :-

The following equipment is required for system charging and evacuation procedures.

1. Filling charging cylinder

1.

The refrigerant calibration charging cylinder or weighing device.

3. Charging system

2.

Pressure gauges and hoses.

3.

Vacuum pump

FILLING A DIAL-A-CHARGE- CYLINDER

4.

Refrigerant Recovery Unit (including compressor oil collector )

5.

Electronic leak detector

1. Open valve on bottom of charging cylinder, allowing refrigerant to enter cylinder from storage cylinder.

CAUTION : The wearing of safety goggles and gloves is mandatory during system charging or discharging. NOTE : All hoses at point of connection to the system must have isolation valves fitted.

2. Evacuation and leak test

4. Performance test

2. Bleed cylinder via valve on top (behind pressure gauge) as required to allow refrigerant to enter. This valve should be connected via a hose to a Refrigerant Recovery Unit ( RRU ) and recovery cylinder. When refrigerant reaches the desired level, close valve at bottom of cylinder and be certain that bleed valve is securely closed.

1 7

6

8 2 5

4 3

1. 2. 3. 4.

REFRIGERANT RECOVERY UNIT (RRU) REFRIGERANT RECOVERY CYLINDER ‘DIAL-A-CHARGE’ CHARGING CYLINDER R 134A SUPPLY CYLINDER

5. 6. 7. 8.

VACUUM PUMP MANIFOLD GAUGE SET LOW SIDE CHARGING ADAPTOR HIGH SIDE CHARGING ADAPTOR

Fig 12 18

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AIR CONDITIONING EVACUATION & LEAK TEST 1. Check that both manifold hand valves of gauge are closed and turn RRU off. 2. Connect the charging hoses onto the suction (low) and discharge (high) service valves in the system. NOTE : Do not use spanners. 3.

Connect the centre manifold charging hose to the vacuum pump inlet.

4.

Start vacuum pump and slowly open LOW SIDE manifold hand valve. Low side gauge reading should decrease to -1 kg / cm2 and high side gauge should read slightly below the zero index of gauge. If high side reading does not register, check system for blockage or leak.

NOTE : When high side gauge is slightly below the zero index of gauge, open high side manifold hand valve. 5.

After evacuating the system for 15 minutes, to a vacuum of - 1 kg / cm2 close both the low and high side hand valves, then stop the vacuum pump. The system must hold the vacuum of - 1 kg / cm2 for a minimum of 15 minutes. If vacuum is held then the system has no leaks and may continue to be evacuated for a further 15 minutes.

6.

Wear safety goggles.

7. Connect the centre charging hose to the charging cylinder hand valve on the bottom of the cylinder. Open the bottom charging cylinder hand valve. Do not open the low or high side valves on the manifold gauge at this time. 8.

LOW PRESSURE

CHARGING STATION

HIGH PRESSURE

100KPa = 1 kg / cm2

Fig 13 using the RRU and repair the faulty component or connection. Repeat steps 4 to 10 after repair of leak. NOTE : Various types and makes of leak detectors are currently in use. Whichever leak detector is used, it is important to follow the manufacturer’s instructions in regard to adjustment and setting of the instrument prior to conducting the test. Inspect for leaks by slowly moving the probe of the detector around all hose connections and points of possible leakages. Refrigerant R134a is heavier than air and will be more apparent at the bottom of a fitting.

Loosen the centre charging hose nut connected to the centre fitting of the manifold gauge set until a hiss sound can be heard. Allow the air to escape for a few seconds then retighten the nut.

NOTE : Do not start the engine 9.

Partially charge the system with 200g of R134a by slowly opening the high side manifold hand valve; low side gauge should register a pressure, if not check for blockage. Close the high side manifold hand valve as soon as 200g of R134a has entered the system.

AIR CONDITIONING

10. Check system for leaks with an electronic detector. If a leak is detected, remove refrigerant from system

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19

AIR CONDITIONING CHARGING THE SYSTEM

CHECKING THE SYSTEM OIL CHARGE

After leak check has proven the system to be leak free, charge the proper amount of refrigerant into system as follows :1. Open HIGH SIDE manifold hand valve slowly. Fill the system with as much of the specified charge as possible, then close the high side manifold hand valve. 2. Rotate the compressor by hand for 12 revolutions to ensure no liquid refrigerant is trapped in the suction side of the compressor. Failure to comply with this step, may result in irreversible damage to the compressor. 3. Start the engine and engage compressor clutch and evaporator fan on high speed. 4. Set engine speed to 1500 - 1700 rpm. 5. If the system has been charged with the specified amount ( 660 ± 20 gms ), go to step 7. 6. To complete the charging of the system, slowly open the LOW side of the manifold hand valve until the 660 ± 20 gms has been charged into the system. 7. Perform Cooling System Pressure Test. If unit operates satisfactorily, stop engine, shut stop valves at hose connections to system and disconnect hoses taking extreme caution, as the discharge hose can have upto 20.5 kg / cm2 stored in it. Install service valve caps as required. WARNING : Never run compressor without refrigerant in system as compressor lubricant relies on refrigerant flow. No sight glass is fitted to the system due to PAG oil’s foaming properties, which may be confused with a low gas charge. Topping up the system is not recommended. Accurate system refrigerant charge may only be determined by charging the correct amount of R134a i.e. 660 ± 20 gms Pressure gauge readings together with face air outlet temperatures are the only method of checking and diagnosing the system cooling capacity (comparing results with the appropriate graph) If in doubt as to gas charge, e.g:

The compressor is charged at the factory with specified 120ml refrigerant oil which circulates within the entire A.C. system. Only the recommend oil must be used when adding or changing oil as specified by A.C. system suppliers. These oils are not compatible with any other PAG oil. Mixing of oils of different manufacturers and different types can result in glue like substance, failure of lubrication and seizure of compressor. Although it is not necessary to regularly check the oil level within the system, all the A.C. system components will hold a system of the oil circulated. Therefore whenever an A.C. system component is replaced, a quantity of new refrigerant ( PAG ) oil must be added to the system. Where a major loss of system oil has occurred, due to: •

A broken hose or severe leak

•

Collision damage to refrigerant system components, or

•

If excess oil is suspected to be in the system, then

1.

Recover refrigerant from the system, then remove the compressor

2.

Carefully drain the refrigerant oil

3.

Flush remaining oil from the rest of the system using R134a refrigerant.

CAUTION : A Refrigerant Recovery Unit (RRU) should be used to flush the system, ensuring that the R134a is not vented to the atmosphere. The R134a must be reclaimed via the RRU into a separate bottle. 4.

Add recommended quantity of new refrigerant oil to the compressor.

5.

Install the compressor, If ‘O’ ring is damaged then replace the suction and discharge O-rings. Ensure Orings are not twisted and that the seals and O-rings are clean.

Suction pressure low

6. Evacuate, then recharge the system.

Discharge pressure low

7. PAG OIL PRECAUTIONS: DO NOT allow PAG oil to contact either bare skin or car paint work. IF CONTACT OCCURS, WASH OFF PAG OIL IMMEDIATELY.

Air outlet temperature ( face ) above graph range. Recover refrigerant from the system using R134a specific equipment. Evacuate system. Charge with 660 g of R134a. Carry out cooling system pressure test and suction (low side) pressure readings comparisons.

20

INDEX

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AIR CONDITIONING EVACUATION

CHARGING (R 134a 660 ± 20 gms)

SAFETY PRECAUTIONS

OPEN HIGH SIDE VALVES & ALLOW AS MUCH AS REFRIGERANT AS POSSIBLE TO ENTER SYSTEM, BUT NOT MORE THAN SPECIFIED

EVACUATIONCONNECT CHARGING STATION CONNECT GAUGE MANIFOLD START VACUUM PUMP -HIGH PRESSURE & LOW PRESSURE GAUGE READINGS (HP BELOW ZERO) (LP BELOW ZERO)

EVACUATE / DEHYDRATE TO -1 kg / cm2

CLOSE VALVES & ROTATE COMPRESSOR FRONT PLATE MANUALLY TO ENSURE NO LIQUID IS TRAPPED IN THE COMPRESSOR

START ENGINE SET TO FAST IDLE. (1500 - 1700 rpm) ACTIVATE A/C SWITCH. SET CONTROL TO MAXIMISE COOLING & HIGH FAN SPEED

OPEN LOW SIDE VALVE & COMPLETE THE CHARGING PROCESS (IF REQUIRED)

CONTINUE FOR 15 MINUTES

CAUTION: DO NOT ALLOW MORE THAN 2 kg / cm2 TO REGISTER ON THE LOW SIDE GAUGE DURING CHARGING

STOP PUMP OBSERVE THAT PRESSURE DOES NOT RISE ABOVE -0.9 kg / cm2 WITHIN 15 MINUTES

CLOSE ALL VALVES & TAPS. REMOVE HIGH & LOW FILLING HOSES. CONNECT HIGH SIDE FILLING HOSE TO RECOVERY UNIT INLET SIDE. SWITCH ON RECOVERY MACHINE & REMOVE ALL REFRIGERANT IN FILLING HOSES

IF PRESSURE STABILISES AT HIGHER LEVEL RE-EVACUATE

IF PRESSURE CONTINUOUSLY RISES-LEAK TEST RE-EVACUATE AFTER RECTIFICATION.

INDEX

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AIR CONDITIONING

21

AIR CONDITIONING

INVERTED DECANTING CYLINDER (LIQUID)

FLUSH GUN FLUSH, THEN REVERSE FLUSH

RECOVERY DEVICE

SELF MADE FITTING CONDENSER

Fig 14

FLUSHING THE A/C SYSTEM FOR CONTAMINATION OF LUBRICATING OIL REMOVAL Some oil is lost whenever air conditioning system components are replaced. Where the system has been ruptured, contaminated, or a compressor has to be removed and reinstalled or replaced, the system should be checked for contamination and, if so, the entire system must be flushed. Currently the only method recommended when flushing is with refrigerant R134a. CAUTION : A Refrigerant Recovery Unit (RRU) should be used to capture the R134a used for flushing. The R134a, must be reclaimed via the RRU into a separate bottle. Use only a dedicated R134a RRU.

IMPORTANT : The complete air conditioning system must contain 120 ± 10 cc of factory installed refrigerant oil. NOTE : A new compressor will contain 120 cc of factory installed lubricating oil. 1.

Flush individual components.

2.

Self made flushing will be required as A/C system component fittings all differ in size, shape and thread size.

3.

Invert decanting cylinder to use refrigerant in liquid form.

4.

Reverse flush components.

5. Do not flush through a compressor otherwise possible internal damage could occur 6.

22

INDEX

Recover / recycle flushing refrigerant, the recovery device will remove contaminants through a filtration system.

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AIR CONDITIONING FAULTY COMPRESSOR

E.G. 100 cc INSTALLED

NEW COMPRESSOR

DRAIN PLUG

E.G. 100 cc REMOVED

NEW COMPRSSOR

Fig 15 A.C. compressor

COMPRESSOR

Evaporator or Condenser

Reinstalling the original Compressor

Drain as much of the original oil as possible from the evaporator or condenser. Add the same amount of new refrigerant oil, either to the original or new evaporator or condenser.

1.

Drain and measure the refrigerant oil contained in the compressor.

2.

Charge oil through the discharge port of the compressor with the same amount of new refrigerant oil.

If replacing condenser - add approximately 20 cc oil. If replacing evaporator - add approximately 20 cc oil.

NOTE :

Filter - Drier Receiver ( FDR )

If the amount of oil in the original compressor was not checked, then approximately 120 cc of new oil should be added to the compressor being installed. (This is assuming the compressor being installed has first been drained).

If replacing the FDR - add approximately 20 cc oil

Installing a New Compressor 1.

Drain and measure refrigerant oil from the original compressor drain plug.

2.

Drain factory installed refrigerant oil from new compressor drain plug (total lubricant quantity 265 cc).

3.

Measure the same amount of new refrigerant oil that was drained from the original compressor. Install this amount of oil into the new compressor through the suction / discharge port whilst turning the compressor clutch pulley front face.

INDEX

The FDR must be replaced whenever the system has been opened to the atmosphere for repair. Blown or Ruptured Pipe / Hose When replacement is required add approximately 10 cc oil each. If slow leak through any joint.

GROUP INDEX

AIR CONDITIONING

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23

AIR CONDITIONING A.C. PERFORMANCE TESTING TESTING CONDITIONS - CHECK SHEET Car Location

Indoors or in the shade ( well ventilated area ) Ambient temperature not exceeding 400C (1040 F)

No Drivers / Passengers in car Doors / Windows

Open

Connect HIGH / LOW pressure Gauges

Connected

Engine Hood

Closed

Temperature switch Position

Max cooling

Mode switch position

Fresh Face Full Mode

Fan speed

Maximum

Engine speed

1500 RPM

Test duration

Minimum - 10 minutes.

High Pressure Gauge Reading

Should be 25 Kg / cm2

Low pressure gauge rating

3 Kg / cm2

Ambient temperature

0

MAXIMUM

MAXIMUM

c

Grill Temperature 1

Average grill temperature - (1+2+3+4)/4 =

____0

2

3

4

C*

* Performance is satisfactory if temperature measurement is within range as shown in graph 1

24

INDEX

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AIR CONDITIONING PROCEDURE : NOTE : Initially, conduct open door test and then close door test.
Insert temperature probe into dash vents as shown in Fig. 16. The probe MUST NOT exceed 50 mm.
Keep all dash vents open & facing straight ahead position. STEP 1 Park vehicle in shade, with bonnet hood closed. STEP 2 a. Open all the doors for open door test. b. Close the all doors & windows for close door test. STEP 3 Check the ambient temperature Place a thermometer in the centre dash vents. STEP 4 Connect both high & low pressure gauges to system. STEP 5 Start the engine and switch ON the A. C. STEP 6 Select the following : Mode Knob : Full Face Position Blower Switch Knob : On 4th speed. Fresh/Recirculation Switch : Fresh air mode for open door test Recirculation mode for closed door test. Temperature Control Knob : Full coldest position. STEP 7 Increase the engine speed to approx. 1500 rpm STEP 8 Record readings on high & low gauges (only whilst compressor running) Compare high pressure (Pd) & low pressure (Ps) with dotted area in graph 2. If the point falls outside dotted area, refer Trouble Shooting chart. STEP 9 Check centre grill temp. ofter 10 min. as shown in figure : A. If it is open door test : The drop in average grill temperature with reference to ambient temperature should be 15 0C minimum within 10 minutes (Fresh Air Mode), i. e. the point should fall in dotted area as shown in Graph 1. If it is not refer trouble shooting chart for further investigation. B. If it is close door test : Average grill temperature should be less than 10 0C within 10 minutes.

INDEX

Fig 16

Variation of Centre Grill Temp. for Open Door Test.

Graph 1

AIR CONDITIONING

Ps - Refrigerant suction pressure / Low pressure Pd - Refrigerant Discharge pressure / High pressure

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25

AIR CONDITIONING

Graph 2 26

INDEX

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AIR CONDITIONING DO’S AND DON’TS FOR AC SYSTEM S. No.

DO’s

REASON

1

Clean condenser During Regular Service of the Vehicle

Dirty & Clogged Condenser Results in AC tripping and less cooling

2.

Maintain proper Refrigerant level

Less Refrigerant Results in less cooling. Excessive Refrigerant Results in AC tripping and less cooling

3.

Add Recommended oil & Quantity in the compressor during refrigerant charging.

Adequate Quantity of Compressor oil prevents poor pumping and premature wearing of internal components.

4.

Clean evaporator periodically to remove dust and foreign particles.

Clogged evaporator results in less air flow and reduced cooling.

5.

Educate Customer on proper usage of AC controls (Refer owners manual)

Proper usage of AC control will give optimum cooling

6.

Adjust proper engine rpm.

Less rpm will result in stalling of engine and less cooling.

7.

Check coolant level and ensure proper engine tuning

This will prevent overheating of engine.

8.

Check proper belt tension.

Loose belt will slip and over tight belt will result in noise and premature failure of magnetic clutch of the compressor.

S. No.

DON’TS

REASON

1

Do not operate AC without refrigerant in the system

This will result in premature failure of compressor.

2.

Do not leak check the AC system with more than 20 kg / cm2 pressure.

Higher pressure may result in damage To AC components.

3.

Do not Leave AC joints open.

Moisture tends to enter the AC system if the joints remain open for long time.

4.

Do not charge refrigerant in the AC system without carrying out proper vacuum.

Improper or No vacuuming of the AC system results in less cooling conditions.

INDEX

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AIR CONDITIONING

27

AIR CONDITIONING Safety Tips


Never handle refrigerant without eye protection goggles. Don’t take chances.




Never discharge vapour from the system into an area where there is flame.




Never close the compressor discharge valve whilst the compressor is operating.




Discharge the air conditioning system slowly.




Never weld or steam clean on or near the system. Doing so can result in dangerous pressure build up in a closed system and a possible rupture may occur.




Be careful when working near exposed evaporator or condenser fins. Painful cuts can be inflicted by these fins.




Keep your hands clear of the engine and belts while the engine is running.

Installing Hoses and Fittings 1.

Always use Refrigerant Oil not Motor Oil to lubricate ID and OD of hoses and fittings before installation

Use only refrigerant hose and fittings. When installing new hose on old fittings, use same type of hose to ensure proper mating of hose and fittings. FUNCTION AND INSPECTION OF A. C. COMPONENTS :

SR. NO.

2.

COMPONENT

FUNCTION

INSPECTION

1

Fresh / Recirculation actuator motor

Actuates the fresh / recirculation flap as per the choice.

Remove the extreme left hand side grill cover & by pressing the fresh / recirculation switch, see the closing / opening of the flap. If it is not working, no current should flow between the terminals when the flap is at either of the ends.

2

Blower Resistor

It operates the blower at various speeds.

If the blower is not working at speed no 1, 2, & 3, & if it is working only at speed no 4, resistor has to be replaced with a new one.

3

Anti Freeze switch

It protects the A. C. system from freezing.

There should always be continuity, at both the terminals. If there is no continuity, switch has to be replaced.

4

Trinary Pressure switch

Protects the A. C. system from any consequential damage.

Check the continuity. The ohm meter should indicate zero reading. If, any resistance / open circuit is observed, replace the switch with new one.

5

VSV (vacuum solenoid valve)

Device for opening 1. Remove vacuum hoses & electrical or closing the vacuum connector from vsv path to idle up actuator. 2. Check VSV for proper vacuum circuit continuity. The V.S.V. opens or 3. Check VSV for short circuit - multimeter should closes according to the show open circuit between each terminal & signal from A/C circuit VSV body engine speed rises a little higher than normal idle speed

6

Magnetic clutch

Device for running the compressor with engine, when the air conditioner operation is needed it is controlled by A/C relay & compressor relay

28

INDEX

1. Disconnect electrical connector 2. Pulley should rotate freely with supply disconnected 3. Pulley should operate compressor with supply connected. 4. Check for noise.

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AIR CONDITIONING INDICA HVAC TROUBLE SHOOTING PROBLEM / SYMPTOMS

POSSIBLE CAUSES

REMEDY

1. LOW SIDE - High HIGH SIDE - High PS > 3 kg / cm2 Pd > 25 kg / cm2 Discharge air warm.

Evaporator Flooding due to Block valve Stuck Open Dirt in Block Valve. Moisture in the refrigerant circuit.

1. 2. 3. 4. 5.

2. LOW SIDE - High HIGH SIDE - High PS > 3 kg / cm2 Pd > 25 kg / cm2 Suction side piping is too hot to touch.

Non condensables (excessive air) 1. Large amount of air caused by insufficient evacuation after repair or servicing system. 2. Leak in the system, allowing air and moisture to enter.

1. Remove refrigerant 2. Evacuate / dehydrate 3. Change filter drier 4. Charge correct amount of oil & refrigerant 5. Check performance

3. LOW SIDE - High HIGH SIDE - High PS > 3 kg / cm2 Pd > 25 kg / cm2 Frosting on the Suction side piping.

Expansion valve stuck open.

Change expansion valve

4. LOW SIDE - High HIGH SIDE - High PS > 3 kg / cm2 Pd > 25 kg / cm2 DISCHARGE AIR - Warm HIGH SIDE TUBES - Very Hot COMPRESSOR CLUTCH - Could continually cycle on the high pressure switch Pressure does not come to normal when condenser cooled by water.

Excessive refrigerant Poor condenser cooling Engine or condenser fan not operating Fan direction reverse Condenser fins clogged with debris Radiator overheating

1. Check refrigerant quantity. 2. Check the pressure switch and condenser fan 3. Clean Condenser 4. Check pressure cap clearance between condenser / radiator. 5. Check coolant and any other radiator problem.

5. LOW SIDE GAUGE - Low or Vacuum HIGH SIDE - High PS < 3 kg / cm2 to Vacuum Pd > 25 kg / cm2 DISCHARGE AIR - slightly cool

Expansion valve stuck closed / or / insufficient refrigerant flow to suction side of compressor. Foreign material or moisture entry causing rust formation.

1. Remove refrigerant 2. Evacuate / dehydrate 3. Change filter drier 4. Charge correct amount of oil & refrigerant 5. Check performance

Remove refrigerant Evacuate / dehydrate Change expansion valve Change filter drier. Charge correct amount of oil & refrigerant. 6. Check performance.

AIR CONDITIONING

6. LOW SIDE - Low or Vacuum HIGH SIDE - Low PS < 1.8 kg / cm2 to Vacuum Pd < 25 kg / cm2 DISCHARGE AIR - slightly cool

INDEX

Clogging on HIGH SIDE. Clogging between compressor outlet and evaporator inlet (High side) Very little or no refrigerant flow

GROUP INDEX

1. 2. 3. 4.

Remove refrigerant Clean and flush system. Change filter drier Charge correct quantity of oil & refrigerant

NEXT

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29

AIR CONDITIONING PROBLEM / SYMPTOMS

POSSIBLE CAUSES

HIGH SIDE TUBES - Cool and showing to suction (low) side of signs of sweating or moisture build up compressor. at the position after the point of restriction. Temperature difference found on the both the sides of the clogged component.

REMEDY 5. Check performance

7. LOW SIDE GAUGE - Normal to Vacuum (Gradual reduction) HIGH SIDE GAUGE - Normal PS 3 kg / cm2 to Vacuum Pd 14 to 16 kg / cm2 DISCHARGE AIR- Becomes warmer as low side cycles to a Vacuum.

Excessive moisture in the system. Moisture can freeze within the expansion valve and cause blockages through rust formation.

1. Remove refrigerant 2. Evacuate / dehydrate 3. Change expansion valve (check) 4. Change filter drier 5. Charge correct amount of oil & refrigerant 6. Check performance

8. LOW SIDE - High HIGH SIDE - Low PS > 3 kg / cm2 to Vacuum Pd < 25 kg / cm2 COMPRESSOR - Noisy DISCHARGE AIR - Warm DISCHARGE HOSE - Cool

Compressor Malfunctioning Compressor faulty, internal failure Blockage in Suction Hose after low side filling port.

Replace Compressor. Remove refrigerant Evacuate / Dehydrate Change filter drier change correct amount of oil and refrigerant check performance.

9. ABNORMAL NOISE

1. Belt slippage/damage

1. Check belt tension for correct operation. Change belt 2. Replace Bearing pulley 3. Check Bracket mounting / bolts/engine mounting bolts 4. Replace Compressor

2. Idler pulley mis alignments 3. Compressor clutch pulley faulty 4. Compressor internal damage 5. Loose A/C plumbing touching body work 10.HIGH / LOW PRESSURE Equalise after Compressor stopping Compressor is not hot to touch.

Faulty Compressor discharge or inlet valve Faulty compressor seal.

Replace Compressor

11.Compressor pressure drop rapidly after switching off & does not stabilize to saturation pressure as per ambient temperature .

Non condensibles in the system

Recover refrigerant/ Check for leak and repair.

12.Line to condenser is excessively hot

Restricted flow of refrigerant in system

Remove, restriction evacuate & replace RD & charge through charging unit.

13.OUTLET GRILL Temperature Low; no air flow

1. Loose connection. 2. Capillary loose -sensing 3. Evaporator frosted

Attend

30

INDEX

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AIR CONDITIONING PROBLEM/SYMPTOMS

POSSIBLE CAUSES

REMEDY

14.Insufficient / no air flow

1. Blower rotation direction wrong 2 Sealing disconnected insulation piece blocking air passage 3. Mode cable not adjusted properly. 4. Voltage insufficient <12 V, at blower connection 5. Improper earthing 6. Open circuit, wiring harness 7. Fuse blown

Attend

15.Compressor Clutch engagement not satisfactory

1. Open circuit 2. Weak battery 3. Faulty clutch relay 4. No refrigerant. 5. Shorted clutch coil 6. Oil / dirt on clutch plate

Attend

16.Check Condenser / Radiator Fan-Direction of rotation

Condenser fan pusher type Radiator fan puller If fan not operating a. Loose connection b. Loose wiring harness c. Motor burnout

Attend

Note : All Ps, Pd values mentioned in trouble shooting chart are for ambient temp. 350C, for other ambients, refer graph 2 .

AIR CONDITIONING

INDEX

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31

AIR CONDITIONING ASSY HVAC CONTROLS COMPLETE

1

ASSY HVAC CONTROLS COMPLT-BEHR

6

ASSY FACIA HVAC CONTROLS (BEHR)

2

ASSY BASEPLATE HVAC CONTROLS COMPLETE BEHR

7

ASSY PCB FOR HVAC CONTROL PANEL

3

ASSY BLOWER SWITCH M/S BEHR

8

AC ON/OFF PUSH BUTTON (BEHR)

4

KNOB (BLOWER CONTROL) BEHR

9

FRESH AIR/RECIRC PUSH BUTTON (BEHR)

5

KNOB (MODE & F/R & TEMP) -BEHR

10 FACIA HVAC CONTROLS (BEHR)

32

INDEX

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AIR CONDITIONING ASSY HVAC UNIT COMPLETE

1

ASSY HVAC UNIT COMPLETE RHD BEHR

11 O’RING (ID 14.0 x 1.78 THK)-BEHR

2

ASSY.BLOWER COMPLT (BEHR)

12 ASSY THERMOSTAT -BEHR

3

FRESH/RECIRC SERVO MOTOR DLX M/S BEHR

14 ASSY KINEMATIC LINKAGES

4

PLASTIC CONNECTING ROD FOR MICRO MOTOR BEHR

6

ASSY EVAPORATOR UNIT RHD BEHR

15 ASSY CABLE (MODES CONTROL) BEHR

7

ASSY BLOWER RESISTOR (4-SPEED) M/S BEHR

16 CLIP BOWDEN CABLE SINGLE END (BEHR)

9

ASSY BLOCK VALVE 2T FINAL (324335)-BEHR

17 ASSY CABLE (TEMPERATURE CONTROL) BEHR

10 O’RING (ID 11.10 x 1.78 THK)-BEHR

INDEX

(DISTRIBUTION CONTROL)

AIR CONDITIONING

18 ASSY W/H CABIN COOLING DLX M/S BEHR

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33

AIR CONDITIONING A C PIPING

1

ASSY HOSE SUCTION COMPLT. PL (110CC)-(BEHR)

8

O’RING (ID 10.77 x 2.62 THK)-BEHR

2

ASSY HOSE SUCTION 110CC PL BEHR

9

O’RING (ID 140 x 178 THK)-BEHR

3

ASSY CLAMP HOSE SUCTION BEHR

10 CLAMP -HOSE DISCHARGE (CONDENSER END)

4

O’RING (ID 17.17 x 1.78 THK)-BEHR

11 ASSY TUBE LIQUID WITH CLAMP BEHR

5

O’RING (ID 13.94 x 2.62 THK)-BEHR

12 ASSY TUBE LIQUID (BEHR)

6

ASSY HOSE DISCHARGE WITH CLAMP 110CC

13 O’RING (ID 765x178THK)- BEHR

7

ASSY HOSE DISCHARGE 110CC

14 CLAMP (TUBE LIQUID)-BEHR

34

INDEX

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AIR CONDITIONING ASSY MF CONDENSER COMPLETE

1

ASSY MF CONDENSER COMPLT BEHR

7

O’RING (ID 7.65 x 1.78 THK)-BEHR

2

ASSY MF CONDENSER + FAN + R/D (BEHR)

8

ASSY RECEIVER DRIER BOTTLE (BEHR)

3

ASSY MF CONDENSER + FAN BEHR

9

ASSY TUBE LIQUID R/D OUTLET (BEHR)

4

CONDENSER SIDE SEALING RH BEHR

10 TRINARY PRESSURE SWITCH (SEDAN) M/S BEHR

5

CONDENSER SIDE SEALING LH BEHR

11 ASSY R/D MTG BKT BEHR

6

ASSY TUBE LIQUID R/D INLET (BEHR)

INDEX

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AIR CONDITIONING

35

AIR CONDITIONING ASSY MF CONDENSER + FAN

1

ASSY MF CONDENSER + FAN BEHR

5

ASSY COND FAN SHROUD (WITHOUT FAN)-BEHR

2

ASSY MF CONDENSER CORE (BEHR)

6

ASSY CONDENSER FAN MOTOR (IFB) M/S BEHR

3

ASSY CONDENSER FAN 110W - BEHR

7

HEX FL NUT AM6 TS17430-8-SS8451-8C

4

CONDENSER FAN BLADE 110W - BEHR

8

HEX NUT M6LH IS 13164-P3-8-SS8451-8C

36

INDEX

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ELECTRICAL

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ELECTRICAL

INTRODUCTION :

The electrical system of Indica MPFI incorporates the details and repair instructions for a number of electrical aggregates and special accessories apart from the standard ones. These include a variety of telltale lamps and audio warning signals operated by various electronic control units. Most of the electrical loads are supplied through relays. Details of wiring harnesses with their routing and schematic electrical circuits of different systems are included. These are only for guidance during troubleshooting. However, due to continuous improvements on the product, the actual wiring layout, locations of components and connectors, the wire colour codes etc. are likely to be different on the car; which would be informed to you from time to time.

ELECTRICAL

INDEX

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i

ELECTRICAL CONTENTS Sr. No.

Description

Page No.

1.

Circuit diagram Symbols

1

2.

Wire colour coding

2

3.

List of bulbs used in the car

2

4.

Location of fuses & relays

3

5.

Alternator

6.

7.

8.

a)

Checks on the car

4

b)

Removal & installation from the car

5

Instrument cluster indicator gauges a)

Removal & installation of instrument cluster

6

b)

Speedo unit, odo unit, trip meter, rpm meter

7

Lighting & signaling a)

Head lamps, Front parking lamps, Front turn signal lamps

9

b)

Head lamp beam adjustment

10

c)

Rear parking lamps, Stop lamps, Rear turn signal lamps

12

d)

Side repeater lamps

12

e)

Registration plate lamps

13

f)

Roof lamp

13

g)

Engine lamp (if fitted)

14

Wiper system a)

Front wiper system

15

b)

Rear wiper system

16

c)

Wiper care

17

d)

Wind screen wash system

18

e)

Heated rear window controller

19

9.

Horn

20

10.

Buzzer unit

21

11.

Antitheft cum keyless entry system a)

Preliminary checks

22

b)

Removal and Installation of Master cum follower / follower unit

23

INDEX

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ELECTRICAL

iii

ELECTRICAL Sr. No.

Description

Page No.

12.

Interior light delay unit

24

13.

Brake indicator check

25

14.

Chime unit

26

15.

Steering lock cum ignition switch

27

16.

Combi - switch

28

17.

Facia switches

30

18.

Window winding system

31

19.

Power socket

32

20.

Digital clock

33

21.

Flasher unit and Hazard Warning switch

34

22.

Fuel gauge & Fuel level meter

35

23.

Trouble shooting guide

36

24.

Service details for Front Wiper Motor

53

25.

Service details for Rear Wiper Motor

68

26.

Service details for Alternator

81

27.

Service details for Starter Motor

102

28.

Layout for Wiring Harnesses (RHD)

117

29.

Schematic Circuit Diagrams (RHD)

125

iv

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ELECTRICAL 1.

CIRCUIT DIAGRAM SYMBOLS SYMBOL

DESCRIPTION

SYMBOL

GROUND OR EARTH

DESCRIPTION

SYMBOL

DESCRIPTION

MAGNETIC CLUTCH

DIODE

BATTERY

CABLE JOINT

TEMP. SENSOR

0

t

SINGLE WAY SWITCH

CROSSOVER WITH JOINT

DIGITAL CLOCK

TWO WAY SWITCH

CROSSOVER WITHOUT JOINT

HORN

LAMP / BULB

FUSE

STEERING LOCK CUM IGN. SWITCH

RESISTOR

M

MOTOR

LED

LOCK ACC. IG.

M

VARIABLE RESISTOR

(B)

(A)

WIPER MOTOR

START

RELAY

M

THERMISTOR 0

t CIGARETTE LIGHTER HEATER DEFROSTER

SOLENOID VALVE

(A) (D) (B)

(J)

ELECTRONIC CONTROLLER

3

G

M

W/S WASHER MOTOR

ALTERNATOR

BLOWER MOTOR

COUPLER

FAN

(C)(D)

(E)

J

B G

A

D C

H E F

ELECTRONIC CONTROLLER / RELAY BASE

VIEW FROM CABLE ENTRY

BUZZER

THERMOSTAT SW.

ELECTRICAL

(C) (E)

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1

ELECTRICAL 2. WIRE COLOUR CODING Code

Colour Name

NOTE :

G

Green

Lg

Light Green

SL

Sky Blue

Wire insulator has one colour or one main colour with another tracer colour stripe. (e.g. ‘L’ indicates blue colour. ‘L / W’ indicates blue main colour with white tracer colour stripe).

P

Pink

V

Violet

O

Orange

W

White

L

Blue

Br

Brown

Gr

Gray

Y

Yellow

B

Black

R

Red

3. LIST OF BULBS USED IN THE CAR Sr.No.

Description

Rating

Type

Remark

1.

Head lamp (Halogen H4)

12V, 60/55 W

P43t38 CAP

2 Nos.

2.

Front & Rear Turn Signal (Amber colour bulb)

12V, 21 W

BAU 15S CAP

4 Nos.

Position Lamp Front

12V, 5 W

W5W, W2, 1X9.5D

2 Nos.

3.

CAP LESS

4.

Engine lamp (If Provided)

12V, 5 W

W5W, W2, 1X9.5D

1 Nos.

CAP LESS

5. 6.

Side Repeater Lamp (Amber colour)

12V, 5 W

Reading Lamp (Spot Lamp)

12V, 5 W

W5W, W2, 1X9.5D

2 Nos.

CAP LESS

W5W, W2, 1X9.5D

2 Nos.

CAP LESS

7.

Rear Registration plate lamp

12V, 5 W

W5W, W2, 1X9.5D

2 Nos.

CAP LESS

8.

Position Lamp Rear

12V, 5 W (of 21/5W Bulb)

BAY 15D CAP

2 Nos.

9.

Stop Signal Lamp

12V, 21W (of 21/5W Bulb)

BAY 15D CAP

2 Nos.

10.

Reverse Signal Lamp

12V, 21W

BA 15S CAP

2 Nos.

11.

Rear Fog Lamp

12V, 21W

BA 15S CAP

2 Nos.

12.

Roof Lamp

12V, 10 W

Festoon Bulb

1 No.

13.

Front Fog Lamp

12V, 55 W

H3 - (55W)

2 No.

2

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ELECTRICAL 4. LOCATION OF FUSES & RELAYS A. LOCATION OF RELAYS / CONTROLLERS / FUSES IN ENGINE COMPARTMENT FUSE BOX MPFI PETROL

Fig. 1

B. LOCATION OF RELAYS / CONTROLLERS / FUSES IN CABIN COMPARTMENT FUSE BOX MPFI PETROL

C

B A

Fig. 2 C. LOCATION OF RELAYS / CONTROLLERS / FUSES BELOW CO-DRIVER SEAT IN CABIN COMPARTMENT MPFI PETROL

ELECTRICAL

Fig. 3

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3

ELECTRICAL 5. ALTERNATOR

ENGINE WITH ALTERNATOR

Checks on the car : CRANKSHAFT PULLEY

Start the Engine : a.

Battery charge indicator does not glow : Check if lamp is faulty. Check fuse continuity. Replace if necessary.

10-11mm

Connect an ammeter of suitable range in series with the positive terminal of the battery. Raise the engine speed to nearabout 2000 rpm and switch ‘ON’ the Headlamp, Parking lamp, Heater, Tail lamp and other electrical loads.

ALTERNATOR

Rated current output should be reached without voltage dropping to 13 volts. If not remove Alternator for thorough checks. ENGINE WITH A.C. ALTERNATOR AND POWER STEERING

Reduce the engine speed to nearabout 1500 rpm, and ensure that the ammeter reading falls around 3 to 5 Amps. Check the voltmeter reading. It should read between 13.8 to 14.2 volts. If not, remove the alternator and check the regulator. b.

CRANK SHAFT PULLEY

ALTERNATOR

Warning indicator continues to glow : Check the belt tension. If found slack, adjust the belt deflection to the specified value. Repeat test. Fig.4

8-9 mm

A. C. COMPRESSOR

8-9 mm

TENSIONER POWER STEERING PUMP

Fig. 4 Schematic

4

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ELECTRICAL Removal of alternator from the car 1)

Remove all the electrical connections from alternator.

2)

Loosen both the screws of slider mounting on alternator bracket.

3)

Loosen the belt tensioner and remove the belt.

4)

Then unscrew the alternator top mounting bolt and the bottom mounting nut. Fig. 5.

Installation 1)

Hold the alternator in position and fit the top mounting bolt and the lower mounting nut of the alternator.

2)

Keep the tensioner at higher most position & install the belt.

3)

Slide the tensioner by rotating the bottom slider screw till correct belt tension is set & then tighten both the screws of slider mounting on alternator bracket. Ref. Fig. 6

4)

Ensure that the belt tension is as per the specified value. [8 - 9 mm ( for Engine with A/C, Alternator & Power steering) and 10- 11 mm ( for Engine with Alternator)] Ref. Fig. 4

5)

Connect the electrical connections to the alternator.

NOTE : FOR DETAILED DESCRIPTION ON REMOVAL, FITMENT & TROUBLE SHOOTING, REFER ALTERNATOR SECTION.

Fig. 5

Fig. 6

ELECTRICAL

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5

ELECTRICAL 6. INSTRUMENTS CLUSTER INDICATOR GAUGES : Remove steering wheel as per procedure given in ‘BODY’ section. Refer to safety precautions relating to Airbags.

UPPER NACELLE

Removal of Instrument Cluster 1)

Remove the upper steering nacelle and then the lower steering nacelle. Fig.7 by removing 3 screws (The upper and lower nacelle can be removed without removing the steering wheel also)

2)

Unscrew the two screw on the front bezel and remove the rear bezel. Then remove the front bezel by removing two front screws. Fig.8

3)

Remove the mounting screws on the Instrument cluster. Fig.9

4)

Disconnect the connectors from behind the cluster.

5)

Take out the Instrument cluster.

LOWER NACELLE

Fig. 7

Installation of the instrument cluster Follow the steps given above in the reverse order. Note :Cluster is supplied as a single unit. Please do not attempt to dismantle.

Fig. 8

Fig. 9 6

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ELECTRICAL SPEEDOMETER, MAIN ODOMETER AND TRIPMETER (ON LCD) : The speedometer indicates the car speed in km/hr. The odometer records the total distance the car has been driven.The tripmeter can be used to measure the distance travelled on each trip or between fuel fillings. Odometer, Tripmeter and Illumination intensity control on instrument panel (LCD) : The instrument panel has an LCD to display the following : Main Odometer - Counts upto 999999 kms (Non- resettable) Tripmeter A (Resettable) - Counts upto 1999.9 kms Tripmeter B (Resettable) - Counts upto 1999.9 kms Intensity level of instrument panel illumination - selection among preset levels. LCD has two line display. The first line displays the Odometer count. The second line displays either of Tripmeter A, Tripmeter B, Intensity level of panel illumination. The 'MODE' knob is used to select one of Tripmeter A, Tripmeter B or Intensity level of panel illumination. Switching among the above three functions can be done by pressing the knob. The selection and control of functions are done through 'MODE' and 'SET' push buttons (knobs) provided on either side of the LCD. The 'SET' knob is used to control the chosen function. Pressing the knob for a few seconds resets the chosen tripmeter and varies the intensity level of instrument panel illumination.

Odometer

Display for Trip - A

Set Knob

Tripmeter or Intensity level of panel illumination

Display for Trip - B

Mode Selector Knob

The panel illumination intensity varies among preset levels as follows: = ====

Min Max

This display returns to Tripmeter A after a few seconds of intensity level selection, if left in this mode. NOTE Main odometer and tripmeter A indication will remain on display even if the ignition key is removed. Reduced contrast in display may occur at low and high temperatures. RPM meter :

Intensity Level Indicator

The meter indicates engine speed in revolutions per minute (rpm) Change gears at appropriate engine rpm and car speed to get optimum fuel economy. The permitted engine rpm upper limit is the start of Red Zone on the dial.

INDEX

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7

8

INDEX

GROUP INDEX LCD

Mode Selector Knob

Fuel Gauge

Engine RPM Meter

* All indicators and Chrome ring may not be provided on some clusters.

Temperature Gauge

Set Knob

Speedometer

Indicators*

Petrol

ELECTRICAL

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ELECTRICAL 7.

LIGHTING AND SIGNALING : Head Lamps, Front Parking Lamps and Front Turn Signal Lamps

HEAD LAMP MOUNTING LUG HEAD LAMP TOP SIDE OF HEAD MOUNTING LAMP LUG

Removal of Head Lamp Assembly & Head Lamp Bulb 1.

Remove the front bumper as per procedure given in Body Section Fig.11

2.

Remove the connectors for head lamp, parking lamp and front turn signal lamp

3.

Remove the two flange screws on top of the head lamp and the nut behind it Fig.10

4.

Take out the head lamp assembly.

5.

Remove the rubber cap & take out the retaining clip. Then take out the bulb.

BULB FOR HEAD LAMP HEAD LAMP BULB RETAINER CLIP

DIREC- DIRECTION LAMP TION LAMP HOLDER

Fig. 10

Installation of head lamp Follow the steps given above in the reverse order. Inspection of head lamp 1.

Check the connectors for any loose terminals or wires broken at the term. ends.

2.

See if any of the filaments in the bulbs is blown. Replace faulty bulbs

3.

Check if the lens or reflectors is damaged. Replace head lamp if it is so.

For connections refer the schematic circuit for Head lamps, Parking lamps, Fog lamps.

Fig. 11

ELECTRICAL

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9

ELECTRICAL Head lamp beam adjustment : 0

Before adjusting the headlamp beam, 1.

The tyre pressure should be as specified and the car should be on level ground.

2.

The car should be loaded as specified (ECIE condition)

3.

The car should be rolled for a few meters after loading to allow the springs to settle.

4.

1

2 3

The head lamp levelling switch should be in “zero” position.

Procedure : Dimension, Arrows and Dimension line should not appear on the screen. Screen colour should be light and non-reflecting and marking lines should be dark and of 5 mm thick with sharp features.

Switch position

Loading condition

0

Unladen

The headlamps should be set one at a time.

0

Driver

The setting is to be checked on the car against the board and adjust the focussing (Horizontal movement) and levelling (Vertical movement) only if required using the headlamp adjusting screws. Fig. 13

0

Driver+ Co-driver

1

All seats occupied

2

All seats occupied +50kg in boot

The board details are shown for RHD version. The headlamp settings on LHD version are mirror opposite. Fig. 14

3

Driver + 290 kg in boot

Fig. 12 HEADLAMP ADJUSTING SCREWS

VIEW WITHOUT LEVELLING MOTOR

Fig. 13 10

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ELECTRICAL

HEADLAMP SETTING SCREEN (FOR RHD VEHICLE AT 10M FROM HEADLAMP)

ELECTRICAL

Fig. 14

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11

ELECTRICAL Rear Parking Lamps, Stop Lamps and Rear Turn Signal Lamps : Removal of the Rear Cluster Lamp 1)

Open the tailgate

2)

Remove the two flange screws holding the rear cluster lamp onto the D Pillar outer panel. Fig.15

3)

Reach out from inside the rear wheel arch and remove the wing nut.

4)

Pull the rear cluster lamp out, till the catch is released.

5)

Disconnect the 6 pole connector and take out the rear cluster lamp. Fig.16

Fig. 15

Installation of Rear Cluster Lamp Follow the steps given above in the reverse order.

TAIL LAMP AIR BREATHER TUBE

Inspection of rear cluster lamp 1) 2)

TAIL LAMP BULB

Check if the connectors for any loose terminals or wires broken at the ter. ends.

PIGTAIL WITH HOLDER

See if any of the bulbs are blown. Replace blown bulbs.

Also refer to Wiring Diagram section.

6 POLE CONNECTOR

Side Repeater Lamps Removal of side repeater lamp Use a small screw driver to push in and release the catch and take out the lamp. Fig.17 Pull out the 2 pole connector and take out the lamp.

Fig. 16

Installation of side repeater lamp Connect the 2 pole connector and insert the lamp into the cut out and press till the catches hold.

SCREW DRIVER

NOTE : Screws are to be tightened gently on plastic flanges.

SIDE REPEATER LAMP

Fig. 17 12

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ELECTRICAL Registration Plate Lamps

ROOF LAMP

Removal Remove the 4 screws which hold the 2 lamps on to the rear bumper and take out. Remove the electrical connection from the lamp. Fig. 18 Installation Hold the lamp in position under the rear bumper and tighten the two screws.

Roof Lamp Fig. 19 Removal Pull the roof lamp from the roof lamp mounting bracket till the catches are released.

Fig. 19

Remove the electrical connections from the lamp and take it out.

+ 12V +

Installation

(12V 5W 2 NOS.)

Insert the lamp into the cut-out in the roof molding and press till the catches are engaged. A schematic circuit diagram showing the Roof lamp is given in Fig. 20 & 20a

(12V 10W)

OFF

The connectors for the roof lamp are as shown in Fig. 20a

OFF

ON

DOOR E

Fig. 20 TERMINALS

ELECTRICAL

Fig. 20a

Fig. 18

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13

ELECTRICAL Engine lamp (if fitted) Removal Remove the two screws (1) & (2) which hold the engine lamp bracket onto front windscreen bottom panel (Fig. 21)

Push-Pull Switch

Remove the electrical connector to the engine lamp. Inspection Ensure that the mounting holes are not broken. Ensure that the bulb is not broken. Installation Follow the removal procedure in a reserve order.

14

INDEX

Fig. 21

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ELECTRICAL 8. WIPER SYSTEM : Front wiper system : Front wiper controller : Function : It generates the variable time delay during the Intermittent wipe operation of the wipers on the vehicles. Location Near steering column ( Refer Fig.1) In cabin fuse box. Connection details Fig. 22 & 23

Terminal Active Level Name

Terminal

Description

Fig. 22

Condition Type

J

Input

Combi switch - wash

VCC

Switch operated

D

Input

Combi switch - intermittent

VCC

Switch operated

C

Input

Wiper motor park Sw. Com.

VCC/GND

Wiper moving/Wiper park

B

Supply

—

VCC

I/G position

E

Ground

—

GND

Permanent

A

Output

Park to combi switch

VCC

—

Also refer wiring diagram section.

Performance check : •

When the intermittent input (Ter. D) goes high, Ter. A should get connected to Ter.B for one wipe cycle (The unit assumes the wipe cycle is completed when Ter.C goes to GND from VCC level). Then for time ‘t’ seconds (the time should vary from 2 to 15 second with the resister R varying from 0 to 64 K). (Varied by knob provided on combi switch on RHS ).Ter. A and B should be disconnected. Again Ter.A and B get connected for one wipe cycle. This cycle continues as long as Ter.D is high.

ELECTRICAL

Fig. 23

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15

ELECTRICAL •

When wash input (J) becomes active, output Ter. A should get connected to terminal B after 0.7 sec. (Delay provided for water to reach from the nozzle to glass) and when Ter. J goes low Ter. A gets disconnected from Ter. B after 2 sec. The wash should have higher priority than the intermittent signal.

WIPER ARM MOUNTING NUTS

WIPER ARM

Alternately use the test rig for Front wiper control unit (Part No. 2699 5420 9928) and check the proper functioning. Removal of front wiper system 1.

Disconnect the battery negative terminal

2.

Remove both the front wiper arms and blades by removing the wiper arm mounting nuts. Fig. 24.

3.

Remove the six hex screws holding the wiper motor mounting bracket beneath the leafscreen bottom panel. Fig.24

4.

WIPER MOTOR MOUNTING BRACKET

LEAF SCREEN

WIPER MOTOR

WIPER MOTOR MOUNTING SCREWS

Fig. 24 WIPER ARM REAR WASHER NOZZLE

Take out the bracket along with the motor and the links.

Installation Follow the steps given above in the reverse order.

WIPER ARM MOUNTING NUTS

NOTE : FOR DETAILED DESCRIPTION REFER CONTROLLER DIAGRAM.

Rear Wiper System Fig. 25 Performance check : •

•

TAIL GATE

When the intermittent input (Ter. D) goes high, Ter. A should get connected to Ter.B for one wipe cycle (The unit assumes the wipe cycle is completed when Ter.C goes to GND from VCC level). Then for time of 6 seconds Ter. A and B should be disconnected. Again Ter.A and B get connected for one wipe cycle. This cycle continues as long as Ter.D is high. When wash input (J) becomes active output Ter. A should get connected to terminal B after 0.7 sec. (Delay provided for water to reach from the nozzle to glass) and when Ter. J goes low Ter. A get disconnect from Ter. B after 2 sec. The wash should have higher priority than the intermittent signal. Alternately use the test rig for Front wiper control unit (Part No. 2699 5420 9928) and check the proper functioning.

Fig. 25 Removal 1.

Disconnect the battery negative cable.

2.

Remove the arm and blade of the rear wiper by removing the mounting nut.

3.

Remove the rear wiper cover.

4.

Remove the rear wiper bracket and take out the motor. .

Installation Follow the steps given above in the reverse order. Detailed connections in the circuit for Rear wiper are as given in wiring diagram section. NOTE : FOR DETAILED DESCRIPTION REFER WIPER SECTION.

16

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ELECTRICAL Wiper Care : Wiper blade attack angle on windshield glass should be 900 i. e. perpendicular. Remove wiper and set wiper arm on windshield glass in the centre position, check the gap between arm strip and glass. Adjust by twisting wiper arm strip as shown in the figure. Fig. 26

NOT OK

OK

WINDSHIELD GLASS

WINDSHIELD GLASS

OK

NOT OK WINDSHIELD GLASS

TO OL WINDSHIELD GLASS

Fig. 26 Straighten the secondary lever & yoke, if found twisted. Slide the flexer inside the rubber, if found protruding out and crimp the claw to avoid it from coming out again as shown in Fig. 27

SECONDARY LEVER

FLEXER

CLAW CRIMPING

Fig. 27 Lubricate hinge joint area with oil, once a month to achieve proper arm pressure. Fig. 28

CHECK FREE MOVEMENT OF ARM & BLADE JOINT

LUBRICATION AREA (ONE DROP EACH)

ELECTRICAL

Fig. 28

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17

ELECTRICAL Windscreen Wash Removal 1)

Disconnect the battery negative cable

2)

Remove the front bumper

3)

Disconnect the windscreen washer tube from the bottle.

WASHER BOTTLE

Disconnect the connector to front windscreen washer pump and take out the front wash pump from the wash bottle. 4)

Unscrew the bolts holding the washer bottle bracket and take out the bottle along with the bracket. Fig. 29

Installation

Fig. 29

Follow the above steps in the reverse sequence. Inspection Connect the battery positive and negative terminals to washer motor positive and negative terminals and check if it is working properly. Check the bottle for cracks and leakages if any. For circuit diagram of the Windscreen washer refer wiring diagram section. NOTE : Where there are 2 motors mounted on the Washer bottle, one is for front and the other is for rear washer. The rear washer tube is enclosed in the floor wiring harness.

18

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ELECTRICAL Heated rear window controller : (If fitted). Function When ‘Heated Rear Window switch on facia is switched ‘ON’, heating element on tailgate glass gets supply for 15 minutes. Supply to tailgate glass heating element gets cut off if, during activation time ignition supply is cut off. Location In cabin fuse box Connection details Fig. 30 Terminal Name

Description

Type

Active Condition Level

C

Input

Heated Rear VCC Window Switch

Switch on

B

Supply Ignition Switch ON

VCC

I/G Position

E

Ground Ground to

GND

Permanent

Fig. 30

Unit A

Output Output to Rear VCC Window Heating element

For circuit refer wiring diagram section. Performance check

•

When ‘Heated Rear Window Switch (TER C)’ becomes active for 0.5 sec. (TYP) then ‘Output (TER A)’ becomes active for 15 min.

•

Output (TER A) becomes inactive every time ‘Supply (TER B Ignition SW) becomes inactive or ‘Heated Rear Window Switch (TER C)’ becomes active during active period of output (TER A).

ELECTRICAL

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19

ELECTRICAL 9. HORN : Fig. 31, 32, 33 Removal Horn is located on the right hand side of the car, behind the front bumper, on frame radiator support. To remove the horn, first remove the front bumper and unscrew the M8 flange nut holding the horn onto the horn mounting bracket. Disconnect the 2 wires from the horn. Inspection of the horn Connect the positive ter. of the horn to battery (+) and negative ter. to battery (-). If a clean and sharp sound is heard, the horn is OK. If no sound is heard, check continuity of the horn coil using a multimeter.If the coil is OK, check the settings of the setting screw. Adjust the setting screw till a clean and sharp sound is given out.

FRAME RADIATOR SUPPORT

HORN MOUNTING BRACKET

HORN

WELD NUT

Fig. 32

HEX PL SCREW ASSY. BRACKET

HEX SCREW

HEX FL NUT

Fig. 31

Fig. 33 20

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ELECTRICAL 10. BUZZER UNIT Function Its function is to generate the warning sound to alert the driver about any abnormal condition of the car. It receives the input from the chime unit.

_

A

+

C

Location In cabin fuse box Connection details Fig. 34 Ter.

Description

Name Type C A

Active

Level

Input

Chime Unit output

Ground Ground to Unit

VCC GND

Fig. 34

Performance check Sound

:

Buzzer type :

Sound output should not show a cracking sound. Tone should be good for entire voltage range. Beep at the rate of 1 beep/second.

ELECTRICAL

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21

ELECTRICAL 11. ANTI THEFT CUM KEYLESS ENTRY SYSTEM : Fig. 35 This vehicle is fitted with an integrated unit for antitheft alarm and keyless entry.The same system also performs the central door locking function. The system consists of a control unit fitted under the driver’s seat, four motorised actuators - one master cum follower at driver’s door and one follower each at the three other door’s and a user remote on the driver’s keyring. An antenna placed on the ‘C’ pillar (right side) near the rear seat latch serves to receive the wireless signal from the user remote. Switches are placed at each of the front doors, to sense whether these are properly closed. A status LED on the instrument cluster indicates system status.

Fig. 35

Preliminary checks Control Unit

Carry out the following preliminary checks as per given order before starting the repairs.

•

Check fuse in cabin fuse box (30A) Replace blown fuse, if any.

•

Check all related electrical connections including earth connection for cleanliness and proper gripping. Check specially the control module earth connection located. Rectify as required.

•

Operate driver’s side door lock from inside and outside and check functioning of central locking system. Locate the faulty unit and carry out repairs as given in subsequent paras.

•

•

Operate LOCK & UNLOCK buttons on the user remote and check functioning of the system. During locking, the system responds with two flashes of the direction indicators, if the operation is succesfull. During unlocking, the system responds with one flash. Incase a LOCK command is unsuccesfull the system will give only one flash. If so, check for proper fitment and operation of master actuator on drivers door. If the keyless entry or central locking functions are found inoperative, check if the LED on the user remote is blinking when the LOCK/UNLOCK buttons are pressed. If so, replace the battery in the user remote. If user remote is O.K. check for proper fitment of connectors and relays at the control unit. If these are O.K. replace relays first, followed by control module.

22

INDEX

Coded Plug

Fig. 35a Check the mechanical link between the master unit and door lock for proper functioning. The link should operate the master unit on rotation of the key. Removal of Master cum follower unit/Follower unit. a)

Take the driver’s side door window glass to upper most position.

b)

Remove door inner trim. (Refer Body group in this manual). Open out required portion of plastic membrane.

c)

Disconnect electrical connectors of master cum follower.

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ELECTRICAL d)

Remove the 2 mounting screws of the master cum follower unit.

e)

Disconnect the link connecting pivot and the master cum follower unit. Fig. 36

f)

PIVOT

Follow the above procedure (‘a’ to ‘e’) for removal of follower unit from co-driver side door, rear LH door and rear RH door. Note the type of follower unit.

LINK FROM PIVOT TO MASTER CUM FOLLOWER UNIT

(Link connecting master cum follower unit and the pivot) Inspection

•

Check proper operation of door handle, inner handle and door lock. Rectify any defect.

•

Check the proper functioning of the replaced master cum follower unit/follower unit on the rig. Hold the output lever lightly to check that unit is exerting force. If not, replace with a working unit.

Fig. 36 MASTER

For any of the ter. connection details for master and follower unit refer Fig. 37 Installation of Master cum follower unit / follower unit : a)

Fit master cum follower unit on the door.

b)

Tighten the 2 mounting screws.

c)

Assemble the solenoid link from master cum follower to link connector.

CONNECTOR

WIRING DIAGRAM

RED/ BLACK TER.1 TER.4

C NC

NO

TER.5 TER.2 3

2

5

4

1

BROWN/YELLOW

NOTE :

TER.3

BROWN/ BLUE

While fitment ensure that knob and master cum follower lever is in same mode i.e. both are in unlock position or in lock position. Lock the connecting link in position by plastic clip. d)

Assemble the front door to door latch.

e)

Connect electrical connectors of the master cum follower to wiring harness connector.

f)

Follow the above procedure (‘a’ to ‘e’) for installation of follower units on the co-driver side door, rear RH door and rear LH door.

BRACKET

FOLLOWER WIRING DIAGRAM GREEN/RED TER.1

NOTE :

A

Do not disturb the adjustment of door handle link and door lock link. If disturbed readjust and ensure proper functioning of door handle and door lock. Check and ensure proper functioning of the central locking system g)

SCREW

M

A’ TER.2 YELLOW/RED

2

1

ELECTRICAL

Fix plastic membrane, door inner trim. (For procedure refer Body group from this manual).

Fig. 37

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23

ELECTRICAL Inspection of the master/ follower Give positive supply to yellow-red wire of the master unit and negative to green-red wire. The plunger should move out. Reverse the polarities and the plunger should move in. The circuit diagram for the system is given in wiring diagram section.

12. INTERIOR LIGHT DELAY UNIT Function It delays switching off the Roof lamp within the passenger area of the car, once the doors are closed allowing some light for inserting the ignition key. Location In cabin fuse box. Performance check Fig. 38 When any of the door inputs (Ter. H, or J) is active while ignition input (Ter. C) is inactive, output (Ter. A) is made active remains so for a time duration of 6.5 ± 2 sec. after all inputs (Ter. H & J) becomes inactive. If during this period ignition input (Ter. C) becomes active, output. (Ter. A) becomes inactive within 1 sec. For circuit of Interior light delay unit refer wiring diagram section.

H

Fig. 38

Connection details : Ter. Name

Ter. Type

Description

Active Level

Condition

H

Input

Driver door switch

GND

Door open

J

Input

Front passenger door switch

GND

Door open

Co-driver A

Output

Output to lamps

GND

—

B

Supply

Supply to unit

VCC

Permanent

E

Ground

Ground to unit

GND

Permanent

C

Input

Ignition switch on

VCC

I/G Position

24

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ELECTRICAL 13. BRAKE INDICATOR CHECK Function The indicator for brake fail lamp/ parking lamp is checked, every time when ignition key is switched ‘ON’, by turning it ‘ON’, until the engine is started and alternator voltage is developed. Connection details Fig. 39 S1, L1 FLUID LEVEL SW/LAMP FOR BRAKE FLUID LEVEL INDICATION / PARKING BRAKE INDICATION L2 / LAMP FOR BATTERY CHARGE INDICATION S3

IGNITION SW/ (IGNITION POSITION)

-

+

ALTERNATOR

L2 L1

S3 ! S1

P

+ve

•

•

Vcc

EARTH

Fig. 39

ELECTRICAL

INDEX

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25

ELECTRICAL 14. CHIME UNIT Function It generates an output signal in some faulty condition / usage and passes it to the Buzzer Unit for various abnormal conditions as mentioned below, ●

Seat belt open and key in ignition position

●

Lamps ‘ON’ with key out and door open.

●

Key in and door open

Location In cabin fuse box Connection details Fig. 40

Fig. 40

Ter. Name

Pin Type

Description

Active Level

Condition

H

Input

Driver door switch

GND

Door Open

J

Input

Parking Lamp Switch

VCC

Lamps ON

D

Input

Seat Belt Switch

GND

Seat belt not attached

C

Input

Mainline Switch

VCC

“Key in” Position

A

Output

Output from unit

VCC

See Perf. Check table

B

Input

Mainline Switch

VCC

“Key in” Position

E

Ground

Ground to unit

GND

Permanent

Performance check INPUT

OUTPUT

KEY IGN

KEY IN

DRVER

PARKING LAMP SEAT BELT

POSITION

POSITION

DOOR SW.

SWITCH

SWITCH

-

ACTIVE

ACTIVE

-

-

ACTIVE

-

INACTIVE

ACTIVE

ACTIVE

-

ACTIVE

ACTIVE

ACTIVE

-

-

ACTIVE

ACTIVE

OUTPUT IS INACTIVE IN CASE OF : 1) AFTER 6.5 ± 2 SEC START OF CHIMING 2) CHANGE IN OUTPUT CONDITION MAKING OUTPUT ACTIVE

26

INDEX

For the circuit of chime unit, refer Circuit diagram section

GROUP INDEX

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ELECTRICAL 15. STEERING LOCK CUM IGNITION SWITCH Fig. 42 Function To lock the steering. To start & stop the engine. LOCK

To switch on accessories and other electrical system. ST

IGN

250

50

900

400

For removal of steering lock cum ignition switch, refer Mechanical steering group of this manual.For circuit connections, refer Fig. 42 and wiring diagram section.

15 P

Steering Column

30 15aK A

Location

OFF FOR TERMINAL DETAILS, REFER THE TABLE GIVEN BELOW

Fig. 42

Connection details :

NO DETENT AND SPRING RETURN

CONTACT WAY OF SWITCH - 158 O +5O

OFF

LOCK

START

IGNITION 123O @

+30

155O-144 137O @

15 - 30 50 - 30

15a- 30 P

- 30

KA - 30

KA - 30 0O

60O

30O

90O

120O

ELECTRICAL CONNECTION CAN EXIST.

THIS REQUIREMENT MUST BE MET WHEN KEY IS ROTATED FROM LOCK TOWARD OFF POSITION.

@ CONTACT BETWEEN 30-15a AND 30-50 WILL NOT OCCUR SIMULTANEOUSLY AT ANY POSITION OF KEY TRAVEL.

THIS REQUIREMENT MUST BE MET WHEN KEY IS ROTATED TOWARD LOCK

ELECTRICAL CONNECTION MUST EXIST.

150O

ELECTRICAL

POSITION.

Fig. 43

INDEX

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27

ELECTRICAL POSITION Key in

Key out LOCK

LOCK

ACC.

Steering Locked Steering Free

Steering Free Steering Free

IGN

CRANK

TERMINALS

Key in sensor Battery Accessories Ignition Crank Key rotation forward Key rotation backward

Steering Locked Steering Locked

Steering Free Steering Free

Steering Free Steering Free

Fig. 44

16. COMBI - SWITCH Fig. 52

Location It is mounted on steering column.

Function

Removal :

It’s left side lever operates turn signals, head lamps, parking lamps and number plate lamps. It’s right side lever operates the windshield wiper and washer.

28

INDEX

For removal and installation of combi-switch refer Steering group from this Manual. Connection details : Fig. 53

GROUP INDEX

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PREVIOUS

ELECTRICAL

ELECTRICAL

Fig. 45

INDEX

GROUP INDEX

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29

ELECTRICAL 17. FACIA SWITCHES Fig. 46

‘ON’ STATE INDICATION

Function

LEGEND ILLUMINATION

1

Functions of different facia switches are given in the following table.

2

Location Facia switches are located on the dashboard on right side of steering column. The circuit various Ter. connections can be known from Fig. 48 4

3

5

Fig. 47

TER. 5

TER. 4 FREE TER. 3 1 ✬

2

TER. 1 TER. 2

4 ✬

3

STICKER LOCATION

Fig. 48

Fig. 46 Sr. No.

Description

Colour of illumination for ON state

1

Switch rear window heater

2

Switch rear fog lamp

3 4

Switch front fog lamp Switch rear wiper

30

INDEX

Type

Colour of Sticker

Amber

Not latched. ON only when Pressed in

Red

Amber

Not latched. ON only when pressed in.

Yellow

Amber Green

Legend

Not latched. ON only when pressed in Latched in ON position

GROUP INDEX

White No sticker

NEXT

PREVIOUS

ELECTRICAL 18. WINDOW WINDING SYSTEM : Fig. 49 The automatic window winding facility is provided on some models.The window winding operation is electrically operated. The driver alone can control the closing and opening of all the window glasses in addition to individual occupant. Window winding switches are provided on Central console for driver as well as co-driver. One switch each is fitted on rear RH / LH doors. The switch will function when ignition key is turned to ‘ON’ position. For taking window glass ‘UP’, press , and and hold the switch towards position marked . for down, press towards position marked

WINDOW WINDING SWITCH ON CENTRAL CONSOLE

Do not press switch further when window glass is at its extreme position. Do not operate window glass frequently, otherwise Window winding motor may get over heated and stop working till it cools down.

WINDOW WINDING SWITCH ON REAR DOOR

Inspection For non functioning of the Window winding mechanism,

•

Check fuses (located in fuse box placed below Driver’s seat). If blown then replace them.

•

Check all related electrical connections at connectors.

•

If found OK, then check operating switch for proper functioning. Replace them if required. Switch ON the ignition key and check for electrical supply at different stages like different connectors, and operating switches with the help of test lamp.

•

• •

Check Window winding motor for free rotation by connecting electrical supply. If found defective then replace the motor.

TERMINALS

Fig. 49

BAT. SUPPLY B

SW1

ACC. SUPPLY R1R2

A

720 K1

(UP) J

E

NC

M

C D

J A

E H

C

720 K1 6900 6900

B

D

NC

Check drive square of the drive unit, if found worn out then replace drive unit. Check for the free movement of the Window winding mechanism. If found hard and defective, then replace the assembly.

NC K1

SW2 H

(DOWN)

Dual Relay 12 V-30A is used for window winding. The terminals & connection details (circuit) are as shown in Fig. 50 The circuit for the power windows is given in wiring diagram section.

INDEX

ELECTRICAL

Fig. 50

GROUP INDEX

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31

ELECTRICAL 19. POWER SOCKET : Fig. 51 A power socket is fitted on the center console and can be used to connect load upto 10A maximum. To use, remove the cap first

Power Socket

20. DIGITAL CLOCK : Fig. 52 Function It indicates time in hours and minutes. Location It is located on dash board. Connection details Fig. 53 Terminal No. 1. 2. 3. 4.

Connection

Function

Battery (B+) Ground

Supply connection Ground connection Display Intensity control Display ON/OFF control

Parking switch Ignition switch

Fig. 51

Setting procedure After connecting the BATTERY, GROUND AND IGNITIONThe display shows 1.00, display blinking (Clock Running) Display blinking stops when any of ‘H’ or ‘M’ is pressed and dot starts blinking once in one sec.

Fig. 52

By pressing and releasing ‘H’ switch, the hours count increments (1 to 12) By pressing and releasing ‘M’ switch, the minutes count increments (00 to 59) If ‘H’ switch is kept pressed, hours count will keep on incrementing at a rate of 1 count per second. If ‘M’ switch is kept pressed, minutes count will keep on incrementing at a rate of 1 count per second for first five counts and subsequently at a faster rate.

PART NO.

Terminals Ter.1

XXXX XXXX XX XX SR NO.

If ‘Z’ switch is pressed, the internal seconds count is reset to ‘0’.

Ter.2 Ter.3

When any of pressed switch is released, clock starts running from that time. (Dot blinking).

Ter.4

Fig. 53 32

INDEX

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ELECTRICAL Checking Digital Clock 1. Check display ON/OFF signal coming from ignition switch. 2. Reset the clock by removing & replacing fuse. 3. Repeat the setting procedure.

21. FLASHER UNIT : Function It provides blinking output to side indicators and hazard warning lamps.

B

L E

Location

Fig. 54

It is located in cabin fuse box. Connection details

FLASHER

L

Connection details are shown in Fig. 54 Checking flasher unit B

a)

Connect bulb to the flasher unit and battery as shown in Fig. 55. The bulb should blink at 90 ± 30 cpm.

b)

Disconnect one of 21 W bulbs. The remaining bulb should blink atleast 1.8 times of (a) or 140 cpm whichever is greater.

E

12 V 21 W x 2

10 A Fuse SWITCH +

-

Fig. 55

ELECTRICAL

INDEX

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33

ELECTRICAL Hazard Warning Switch Fig. 56 Removal 1)

Remove the facia central cluster.

2)

Remove the two screws 1 & 2 holding hazard warning switch on to the facia central cluster. Fig. 57

3)

Disconnect the connector and take out the switch.

Inspection : Ensure that the mounting lugs of the facia central cluster are not broken. Installation

Fig. 56

Follow the removal procedure in a reverse order for installing of the Hazard warning switch. For the circuit of hazard warning switch refer the wiring diagram sections.

Fig. 57

34

INDEX

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ELECTRICAL 23. FUEL GAUGE AND FUEL LEVEL METER Removal of fuel level sensor (tank unit) 1)

Fold the rear seats. Fig. 59

2)

Remove the plastic cover on the cut-out in the floor carpet. The tank unit will now be accessible.

3)

Remove the tubes connecting to the tank unit.

4)

Unscrew the six screws which hold the unit and take it out.

CUT-OUT IN THE FLOOR CARPET FOR FUEL TANK

Installation Follow the above given procedure in the reverse order. Inspecting the fuel gauge Use an ohmmeter to confirm that the resistance of the fuel level sensor changes with the level of float position Fig 71. The specified resistance values of the fuel gauge is given below :

Fig. 58

Tank Fuel Level in mm

Capacity in Litres

Position of float in Tank

Ressistance value in Ohm

Tolerence value in Ohm

9.5

1.1

Empty Low

120

+8/-0

44.5

7.5

Empty High

70

+5

64.5

9

1/4

50

+4

109.5

18

1/2

32.5

+3

164.5

29.5

3/4

17

+3

207.5

37

Full Tank

5

+1/-2

Also refer to fuel section. 2PIN CONNECTOR IGN

METER BROWN METER GAUGE

FULL

WIRE SEAL VIOLET

3/4

TERMINAL (Violet)

1/2

TENK UNIT

BRAZED SOLODERED

1/4

ELECTRICAL

TERMINAL (BROWN)

EMPTY HIGH EMPTY LOW

Fig. 60

INDEX

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35

ELECTRICAL 24. TROUBLE SHOOTING GUIDE : 1.

Charging and Battery : 1.1. Alternator. 1.2. Battery.

2.

Starting and Ignition : 2.1. Starter motor. 2.2. Ignition coil.

3.

Instruments, Gauges and Tell Tale Lamps : 3.1. Fuel gauge and Fuel level meter. 3.2. Temperature transducer / Gauge. 3.3. RPM Meter.

4.

Lighting and Signalling : 4.1. Head Lamps, Front Parking lamps and front turn signal lamps. 4.2. Rear parking lamps: stop lamps, Rear turn signal lamps and Rear Fog lamps 4.3. Side repeater lamps. 4.4. Registration plate lamps. 4.5. Roof Lamps. 4.6. Hazard warning.

5.

Wiper and Wash System : 5.1. Front Wiper. 5.2. Front Windscreen Wash 5.3. Rear Wiper 5.4. Rear Windscreen Wash

6.

Miscellaneous Accessories : 6.1. Horn 6.2. Heated Rear Window. 6.3. Immobiliser/Anti theft system. 6.4. Window Winder.

36

INDEX

NOTE : In addition to these guidelines also refer to the respective sections for additional troubleshooting of Alternator, Starter motor & Wiper motor.

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ELECTRICAL BATTERY & ALTERNATOR : Fault

• Battery getting discharged

Possible Causes

Remedial Action

1) Alternator belt loose

Tighten belt

2) Idle speed of engine too low

Adjust engine idle speed

3) Battery terminals loose

Tighten the terminals

4) Battery terminals corroded

Clean the terminals

5) Alternator voltage regulator setting wrong

Replace alternator voltage regulator

• Battery getting warm

1) Alternator voltage regulator faulty

Replace the regulator with a genuine spare.

• Battery indication in

1) Alternator terminals loose

Connect the terminals properly

instrument cluster remains

2) Alternator drive belt snapped

Replace alternator belt

ON after engine is started

3) Battery terminals loose

Tighten battery terminals

4) Battery terminals corroded

Clean the terminals

5) Starter motor connections loose

Tighten the connections

frequently

ELECTRICAL

INDEX

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37

ELECTRICAL STARTING AND IGNITION PETROL MPFI ENGINE - ELECTRICAL ITEMS Fault ●

●

Engine not cranking at all

Engine cranking, but not starting

Possible Causes

Remedial Action

1) Starter motor terminals loose

Tighten starter motor terminals

2) 4 pole connector from Cabin W/H to Front W/H loose

Fix the connector properly

3) Black-white wire terminal in 4 pole connector from Cabin W/H to Front W/H loose

Fix the connector properly

4) Ignition switch faulty

Replace ignition switch

1) Starter motor terminals loose

Tighten starter motor terminals

2) Battery discharged (Check alternator charging system)

Recharge battery. Replace battery if battery is dead

3) Starter motor solenoid not working properly

Replace starter motor

4) Starter motor faulty

Replace starter motor

FUEL GAUGE/FUEL METER :

●

Fault Fuel gauge not working

38

INDEX

Possible Causes 1) Connectors loose at the instrument cluster

Remedial Action Fix the connectors properly

2) 18 pole connector from Cabin W/H to Floor W/H loose

Fix the connectors properly

GROUP INDEX

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PREVIOUS

ELECTRICAL Fault

●

Fuel gauge needle flickers when vehicle is moving

Possible Causes

Remedial Action

3) 2 pole connector at the tank unit loose

Fix the connector properly

4) Fuel meter faulty

Replace fuel meter

5) Fuel tank unit faulty

Replace fuel tank unit

1) Damping inadequate

Replace gauge

TEMPERATURE TRANSDUCER/GAUGE Fault ●

Temperature gauge not working

Possible Causes

Remedial Action

1) Connectors loose at the instrument cluster

Fix the connectors properly

2) 20 pole connector from Cabin W/H to Front W/H loose or 10 pole connector from Front W/H to Engine W/H loose

Fix the connector properly

3) Two pole connector at Temperature transducer loose

Fix the connector properly

4) Temperature transducer faulty

Replace temperature transducer

5) Temperature gauge faulty

Replace temperature gauge

ELECTRICAL

INDEX

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39

ELECTRICAL RPM METER Fault ●

RPM meter not working

Possible Causes 1) Connectors on the cluster loose/20 pole connector from Front W/H to Cabin W/H loose / 3 pole connector on alternator loose

Remedial Action Fix the connectors properly

2) Alternator phase signal output is not available at terminal W on the alternator

Check the output with an RPM meter in working condition. If there is no output, replace alternator

3) RPM meter faulty

Replace RPM meter with the correct RPM meter with proper pulley ratio

HEAD LAMPS, FRONT PARKING LAMPS & FRONT TURN SIGNAL LAMPS Fault

Possible Causes

Remedial Action

Head Lamps ●

●

●

Single head lamp (RH or LH) not working

Single head lamp (RH or LH) not working in high/low beam

Both lamps not working in high / low beam

40

INDEX

1) Grounding point no. E5 (RH) or E4 (LH) loose

Tighten grounding properly

2) Head Lamp connector (3 pole) loose

Fix connector properly

3) Bulb blown

Replace bulb

1) High/Low beam filament in the bulb blown

Replace bulb

2) High/Low beam terminal (pink/blue wire) has come off the connector

Insert the terminal into the connector properly

1) Head lamp high / low beam fuse (15A) in cabin fuse box loose/blown

Fix the fuse in the base properly. If blown, check for short in the circuit and then replace the fuse

2) Head lamp high / low beam relay in cabin loose

Fix the relay properly

3) Head lamp high / low beam relay faulty

Replace relay

4) Connectors at combi-switch loose/10 pole connector from Front W/H to cabin W/H loose

Fix the connectors properly

GROUP INDEX

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PREVIOUS

ELECTRICAL Fault

●

High beam does not come on when flash switch is activated

Possible Causes

Remedial Action

5) High / Low beam switch in combi-switch faulty

Replace combi-switch

1) connector loose at combi switch

Fix the connector properly

2) Flash switch faulty

Replace combi-switch

1) Connector (2 pole) loose 2) Bulb loose/fused

Fix the connector properly Fix the bulb properly. Replace bulb if blown

3) Grounding point no E5 (RH) or E4 (LH) loose

Tighten the grounding properly

4) Parking lamp LH/RH fuse (5A) in cabin fuse box loose/blown

Fix the fuse properly in the base. If blown, check for short in the circuit and then replace the fuse

5) Battery supply not reaching parking lamp LH/RH fuse input

Check the continuity from battery to the lamps through the combi-switch, Front W/H and Floor W/H connectors and rectify the discontinuity in the circuit.

1) Combi-switch connectors loose/20 pole connector from Front W/H to Cabin W/H loose

Fix the connectors properly

2) Combi switch faulty

Replace combi-switch

1) Grounding point in engine compartment i. e. point no. 31/3 near LH head lamp loose

Tighten the grounding properly

2) Connector at the lamp (2 pole) loose

Fix the connector properly

3) Bulb loose/fused

Fix the bulb properly. Replace bulb if blown

Front Parking Lamps ●

●

Single front parking lamp not working

Both parking lamps not working

Front turn signal lamps ●

Front right / left signal lamps not working

ELECTRICAL

INDEX

GROUP INDEX

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PREVIOUS

41

ELECTRICAL REAR PARKING/ STOP/ REAR TURN SIGNAL/ REAR FOG LAMPS. Fault

Possible Causes

Remedial Action

Reverse lamps ●

●

Single reverse lamp not working

Both reverse lamps not working

1) Grounding point no. E13 loose

Tighten grounding properly

2) Bulb loose/fused

Fix the bulb properly. Replace bulb if blown

3) 6 pole connector from W/H to Rear Cluster Lamp loose.

Floor Fix the connector properly

1) Reverse lamp fuse (20A) in cabin fuse box loose / blown

Fix the fuse in the base firmly. If blown, check for short in the circuit and then replace the fuse

2) Reverse lamp switch faulty

Replace reverse lamp switch

1) Grounding point no. E13 loose

Tighten grounding properly

2) Parking lamp LH/RH fuse (5A) in cabin fuse box loose /blown

Fix the fuse properly in the base, if blown, check for short in the circuit and then replace the fuse

3) 6 pole connector from floor W/H to Rear cluster lamp loose

Fix the terminal properly

4) Bulb loose / fused

Fix the bulb properly. Replace bulb if blown

5) Battery supply not reaching parking lamp LH/RH fuse input

Check the continuity from battery to the lamps through the combi-switch, Front W/H and Floor W/H connectors and rectify the discontinuity in the circuit.

1) Combi switch connectors loose/20 pole connector from Front W/H to Cabin W/H loose

Fix the connectors properly

2) Combi switch faulty

Replace combi -switch

1) Grounding point no. E13 loose

Tighten grounding properly

Parking Lamps ●

●

Single parking lamp rear not working

Both parking lamps not working at all

Stop Lamp ●

Single stop lamp not working

42

INDEX

GROUP INDEX

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ELECTRICAL Fault

●

Both stop lamps not working

Possible Causes

Remedial Action

2) 6 pole connector from floor W/H to Rear cluster lamp loose

Fix the connector properly

3) Bulb loose/fused

Fix the bulb properly. Replace bulb if blown

1) Stop lamp fuse (10A) in cabin fuse box loose/blown

Fix fuse firmly in the base. Replace if blown

2) Connector (18 pole) from Cabin W/H to Floor W/H loose

Fix the connector properly

3) Adjustment of stop lamp switch not proper

Adjust the switch to correct setting

4) Brake lamp switch faulty

Replace switch

1) Grounding point no. E13 loose

Tighten grounding properly

2) Bulb loose / fused

Fix the bulb properly. Replace bulb

1) Flasher fuse (10A) in cabin fuse box loose/blown

Fix fuse properly in the base. Replace fuse if blown

2) Flasher in cabin fuse box faulty

Replace Flasher

3) Connector at Hazard Warning Switch loose

Fix the connector properly

1) Grounding point no. E13 loose

Tighten grounding properly

2) 6 pole connector from Floor W/H To Rear cluster lamp loose

Connect the terminal properly

3) Bulb loose / fused

Fix bulb properly in holder. Replace bulb if blown

1) Rear fog lamp fuse (20A) in cabin fuse box loose/blown

Fix the fuse properly. If blown, check for short in the circuit and then replace the fuse

2) Rear fog lamp relay in cabin fuse box loose

Fix relay properly

3) Rear fog lamp relay located (near steering column) faulty

Replace relay

Rear turn signal lamps ●

●

Rear right / left turn signal lamps not working

No indicator lamp is working

Rear Fog Lamp ●

●

Single lamp not working

Both lamps not working

INDEX

GROUP INDEX

NEXT

PREVIOUS

ELECTRICAL

43

ELECTRICAL Fault

Possible Causes

Remedial Action

4) Both bulbs blown

Replace bulbs

5) Rear fog lamp switch faulty

Replace switch

6) Connections loose at fuse

Fix the connectors properly

box base / rear fog lamp switch ●

Rear fog lamp switch symbol not lighting

1) Bulb loose/fused

Fix bulb properly. Replace if blown

●

Rear fog lamp switch onstate indication not lighting

1) Bulb loose/fused

Fix bulb properly. Replace if blown

●

Both legend and on-state indication not lighting for rear fog lamp switch

1) Bulb loose/fused

Fix bulb properly. Replace if blown Tighten the grounding properly

2) Grounding near side repeater lamp RH is loose

SIDE REPEATER LAMPS : Fault ●

Side repeater lamps not working

Possible Causes

Remedial Action

1) Connectors (2 pole) at the lamps loose

Connect the connectors properly

2) Bulb loose/ blown

Fix the bulb properly. Replace bulb if blown

3) Grounding point no. E15 (RH) or E16 (LH) loose

Tighten grounding properly

REGISTRATION PLATE LAMPS : Fault ●

Single registration plate lamp not working

Possible Causes

Remedial Action

1) Grounding point no. E13 loose

Tighten grounding properly

2) Lamp connector loose

Fix connector properly

3) Bulb blown Replace bulb

●

Both lamps not working

44

INDEX

4) Parking lamp fuse (5A) in cabin fuse box loose/blown

Fix the fuse in the base properly. If blown, check for short in the the circuit and then replace the fuse

1) Combi-switch faulty light stalk

Replace combi-switch light stalk

GROUP INDEX

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PREVIOUS

ELECTRICAL ROOF LAMPS : Fault ●

●

Spot lamps not working

Cabin lamp not working in ‘ON’ position

Possible Causes

Remedial Action

1) Bulbs loose / blown

Fix the bulbs properly. Replace bulbs if blown

2) Switch erratic

Replace roof lamp

1) Bulb loose/fused

Fix the bulb properly. Replace bulb if blown

2) Switch operation erratic

Replace Roof lamp

HAZARD WARNING : Fault ●

Indicator lamps are not working when hazard warning switch is operated

Possible Causes

Remedial Action

1) Connector at the switch loose 2) Hazard warning switch faulty

Fix the connector terminal properly Replace switch

3) Flasher fuse (10A) in cabin fuse box loose/blown

Fix fuse properly in the base. Replace fuse if blown

4) Flasher in cabin fuse box faulty

Replace Flasher

ELECTRICAL

INDEX

GROUP INDEX

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PREVIOUS

45

ELECTRICAL FRONT WIPER : Fault ●

Front wiper system not working at all

Possible Causes

Remedial Action

1) Grounding point no. E3 loose

Tighten grounding properly

2) Connector (6 pole) loose at the front wiper motor

Fix the connectors properly

3) Wash wiper fuse (25A) in cabin fuse box loose/ blown

Fix the fuse firmly in the base. If blown, check for short in the circuit and then replace the fuse

4) Front wiper controller in Fix the controller in the base cabin loose in the base properly

●

Front wiper system does not work in all speeds

5) Front wiper controller faulty

Replace controller

6) Front wiper motor faulty

Replace front wiper motor

1) Terminals in the front wiper motor connector loose / Terminals in front wiper controller base loose

Connect the terminals properly

2) Front wiper controller erratic

Replace front wiper controller

FRONT WINDSCREEN WASH : Fault ●

Front Windscreen washer not working

46

INDEX

Possible Causes

Remedial Action

1) Water tank empty

Fill tank with Windscreen washer fluid

2) Washer tube joints are open

Connect the joints properly

3) Grounding point no. E5 loose

Tighten grounding properly

4) Connection loose at front windscreen washer pump. connection from Cabin W/H to Front W/H loose

Fix the connectors properly

5) Wash wiper fuse (25 A) in cabin fuse box loose/blown

Fix the fuse in the base properly. Replace if blown

6) Front windscreen washer pump faulty

Replace pump

7) Front windscreen washer switch in combi-switch stalk faulty

Replace switch

GROUP INDEX

NEXT

PREVIOUS

ELECTRICAL REAR WIPER : Fault ●

Rear wiper system not working at all

Possible Causes

Remedial Action

1) Grounding point no. E14 loose

Tighten grounding properly

2) Connector (4 pole) loose at the rear wiper motor

Fix the connector properly

3) Wash wiper fuse (25A) in cabin fuse box loose/blown

Fix the fuse firmly in the base. If blown, check for short in the circuit and then replace the fuse

4) Rear wiper controller / relay in cabin loose in the base

Fix the controller / relay in the base properly

5) Rear wiper controller / relay faulty

Replace the faulty part

6) Rear wiper switch in facia pack faulty

Replace switch

7) Rear wiper motor faulty

Replace rear wiper motor

●

Rear wiper switch symbol not lighting

1) Bulb loose / fused

Fix the bulb properly. Replace if blown

●

Rear wiper switch on-state indication not lighting

1) Bulb loose/fused

Fix the bulb properly. Replace if blown

●

Both legend and on-state indication on Rear wiper switch not lighting

1) Grounding near side repeater lamp RH i. e. grounding point no. E15 is loose 2) Bulb loose / fused

Tighten the grounding properly

Fix the bulb properly. Replace if blown.

REAR WASH : Fault ●

Rear Windscreen washer not working

INDEX

Possible Causes

Remedial Action

1) Water tank empty

Fill tank with Windscreen washer fluid

2) Washer tube joints are open

Connect the joints properly

3) Grounding point no.E5 loose

Tighten grounding properly

4) Connection loose at rear windscreen washer pump / connection from Cabin W/H to Front W/H loose.

Fix the connectors properly

5) Wash wiper fuse (25A) in cabin fuse box loose/blown

Fix the fuse in the base properly. Replace if blown.

6) Rear windscreen washer pump faulty

Replace pump

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ELECTRICAL

47

ELECTRICAL Fault

Possible Causes

Remedial Action

7) Rear windscreen washer switch in pack of Facia switches faulty

Replace switch

●

Rear windscreen washer switch symbol not lighting

1) Bulb loose/fused

Fix the bulb properly. Replace if blown

●

Rear windscreen washer switch on-state indication not lighting

1) Bulb loose/fused

Fix the bulb properly. Replace if blown

●

Rear windscreen washer switch illumination not working at all

1) Grounding near side repeater lamp RH is loose 2) Bulb loose/fused

Tighten the grounding properly Fix the bulb properly. Replace if blown

HORN : ●

●

Fault Horn not working

Horn sound distorted

48

INDEX

Possible Causes 1) Grounding point no.E4 loose

Remedial Action Tighten grounding properly

2) Ring terminals at horn loose

Connect the terminal properly

3) Horn fuse (15A) in Engine compartment fuse box in Cabin fuse box loose/blown

Fix the fuse firmly in the base. Replace if blown

4) Horn relay in cabin loose

Fix the relay properly

5) Horn relay coil fuse (5A) in cabin fuse box loose/blown

Fix fuse firmly. If fuse d\blown, check for short in the circuit and then replace the fuse

6) 20 pole connector from Cabin W/H to Front W.H loose

Fix the connector properly

7) Horn switch terminal / horn switch contact in steering pad improper

Replace control switch plunger topping/Adjust horn switch contact in steering pad properly

1) Horn terminals loose

Connect the terminals properly

2) Horn setting screw disturbed

Adjust the setting screw till a clean and sharp sound is obtained

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ELECTRICAL HEATED REAR WINDOW Fault ●

Heated Rear Window not working

Possible Causes

Remedial Action

1) Grounding point no. E14 loose

Tighten grounding properly

2) Connection loose at Heater/ Connection from Cabin W/H to Floor W/H loose or Floor W/H to Tail gate W/H loose

Fix the connectors properly

3) Heated Rear Window fuse (20A) in cabin fuse box blown, loose/blown

Fix fuse firmly in the base. If check for short in the circuit and then replace the fuse

4) Heated Rear Window timer loose

Fix the timer firmly in the base

5) Terminals loose at Heated Rear Window fuse base/ Heated Rear Window timer base

Connect the terminals properly

6) Heated Rear Window timer in cabin fuse box faulty

Replace timer

7) Heated Rear Window switch faulty

Replace switch

8) Heater coil open

Check for continuity in the heater coil. Replace rear windscreen glass if coil is open.

•

Heated Rear Window switch symbol not lit

1) Bulb loose /fused

Fix the bulb properly. Replace if blown

•

Heated Rear Window switch ON-state indication not lit

1) Bulb loose/fused

Fix the bulb properly. Replace if blown

•

Both the legend and ONstate indication on Heated Rear Window switch not lighting

1) Grounding near side repeater lamp RH is loose 2) Bulb loose/ fused

Tighten the grounding properly Fix the bulb property. Replace if blown

ELECTRICAL

INDEX

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PREVIOUS

49

ELECTRICAL IMMOBILISER / ANTI THEFT SYSTEM : Fault •

•

One or more of the doors (but not all doors) not locking / unlocking properly

Immobiliser ECU System not working at all

Possible Causes 1) Grounding point no. E12 loose

Tighten grounding properly

2) ECU connector (34 pole) loose Ground point for Immobiliser ECU = E1

Fix the connector properly

3) Connection from door W/H to Floor W/H (8 pole for Front door RH, 4 pole for Front door LH, 6 pole for rear doors) loose

Fix the connector properly

4) Central Locking Unit controller connection loose

Fix the connector properly.

5) Link between CLU actuator and latch has come off or is broken

Fit the link properly. Replace link if broken

6) CLU actuator faulty

Replace actuator

1) Grounding point no. E1 loose 2) Battery discharged

Tighten grounding properly

Vehicle not starting (starter not working)

50

INDEX

Recharge/ Replace battery

3) ECU connector (34 pole) loose

Fix the connector properly.

4) Immobiliser fuse (30 A) in cabin fuse box loose/blown blown,

Fix fuse firmly in the base. If check for short in the circuit and then replace the fuse Fit the link properly. Replace link if broken

5) Link between master actuator and latch on Driver door has come off or is broken 6) CLU Master actuator not working/ micro-switch faulty •

Remedial Action

Replace master actuator

1) Air connection or supply not present.

Check the 12V between, Key-in & ground, Ignition & ground, Starter & ground.

2) Inertia switch in operated condition.

Release the inertia switch, check if vehicle is starting.

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ELECTRICAL Fault

Possible Causes

Remedial Action

3) Low battery voltage

Replace/recharge vehicle battery.

•

Lock or unlock function is not working with remote.

1) Discharged battery on remote

Check LED on the remote, when any one button is pressed(lock/unlock) i.e. remote battery is OK. If that LED is flickering or not glowing, then battery is dead.Change the battery.

•

Vehicle is continuously going into panic mode, when vehicle is locked by remote

1) Door open or door switch faulty

The unit is sensing door open signal One of the door switch is faulty. Check all the door switches including Dickey & bonnet.

•

Vehicle is not going into panic mode, when vehicle is locked by remote & door is opened by mechanical key.

1) Door switch faulty.

When vehicle is locked by remote then open individual door & check if vehicle goes into panic mode. If not then that particular door switch is faulty. Rectify.

•

Central door locking not working 1) Fuse/relays faulty.

Check the fuse of the CDL 30A. Check the relays of CDL which are mounted on immobilser bracket. Replace.

•

In CDL function, front doors are locking & rear doors are not locking.

Interchange the two pole connector wires from patch harness which are going to the Actuators.

•

Vehicle does not go into lock 1) Key present in ignition. mode when operated by remote

Remove key out of vehicle, close the door & lock using remote.

•

Vehicle automatically gets unlocked after few kms/miles.

Rectify.

1) Wrong connection.

1) Master lock actuator connector is not latched properly.

ELECTRICAL

INDEX

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51

ELECTRICAL WINDOW WINDER : Fault • One or more of the window winders not working

●

•All Window winders moving slowly/not working at all

Possible Causes 1) Fuse (30A) for the respective door loose/ blown under driver seat 2) Grounding point no.E12 loose. 3) Relay in relay box under driver seat not fixed firmly 4) Motor connections are loose

INDEX

Fix fuse firmly in the base. If blown, check for short in the circuit and then replace the fuse Tighten grounding properly. Push the relay firmly till clicking sound is felt. Remove the door trim and fix the connector properly.

5) Relay faulty Replace the relay 6) Door W/H connector not mating with Floor W/H

Fix the connectors firmly.

1) Battery discharged

Replace/charge the battery

2) Grounding point no. E12 loose 3) Cabin W/H to Floor W/H connector (4 pole) loose 4) Relay coil fuse (5A) under driver seat loose/blown

Tighten grounding properly

5) Accessory supply not coming upto Coil fuse (5A) and 6) Glass not moving smoothly in the rubber beading 7) Cabin W/H to Floor W/H connector (4 pole) loose

52

Remedial Action

GROUP INDEX

Fix the connector properly Fix the fuse properly. If blown, check for short in the circuit and then replace the fuse Connect the Floor W/H harness Cabin W/H properly Align glass and rubber beading properly Fix the connectors properly

NEXT

PREVIOUS

ELECTRICAL 25. SERVICE DETAILS FOR FRONT WIPER MOTOR : 1)

GENERAL DESCRIPTION :

Wind Shield Wiper Motor Model 5SW60B series are of units designed to operate a link type Wiper system to be used on Cars / Utility vehicles. The Wiper Motor is a self switching two pole design having permanent magnet field system and provided with a gear box, housing a final gear. The power developed by the motor is transmitted by worm teeth, provided on the Armature shaft, through the final gear system to the rotary link. The rotary motion of the rotary link is converted to reciprocating linear motion (to and fro motion) of the connecting rods which in turn operates the wiping blades. The contacts in the cover plate ensure regenerative breaking to the Armature on completion of the wiping cycle when the switch turned ‘OFF’ and ensures consistent parking position of the Wiper arms and blades. The arms resting position is pre-set to suit the installation requirements.

TYPICAL PERFORMANCE CURVE :

ELECTRICAL

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53

ELECTRICAL 2)

PRECAUTIONS :

1)

Circuit cable resistance drop does not exceed 1.0 volt with motor current of 5.0 Amps.

2)

Observe correct polarity while connecting motor.

3)

Ensure recommended Arm / Blade sizes are used.

ROUTINE MAINTENANCE : 1)

Check for light run current, speed, direction of rotation and parking position of wiper motor to ensure correct assembly.

2)

Bring the motor to parking position electrically and then assemble the rotary link in line with the noted marking on the gear box casting to ensure correct parking position.

3)

Ensure that the fasteners are tightened to the recommended tightening torque values.

WIPING SYSTEM CHECK : The wind screen wiper has a link type transmission, check spindle assembly for any signs of seizure or rusting. Ensure that there is no looseness on the spindles and between the bearings and the links. The linkages must operate freely. If the bearings are worn out replace with new linkages.

WIPER MOTOR ASSEMBLY CHECK : Motor terminal voltage.

13.5 Volts

Typical light

1.8 Amps (Normal Speed)

Running current

2.8 Amps (High Speed)

54

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ELECTRICAL 3)

SPECIFICATION : 1.

TYPE

5SW60

2.

RATED VOLTAGE

12V

3.

TEST VOLTAGE

13.5 ± 0.2V

4.

STARTING VOLTAGE

8V MAX

5.

OPERATING VOLTAGE

10 ~ 15V

RANGE 25 ± 5OC

6.

TEST TEMPERATURE

7.

OPERATING TEMPERATURE

8.

RANGE

- 20OC — +90OC

INSULATION RESISTANCE

1M.ohm MIN

2 Nm LOAD

45 ± 5 RPM

9. SPEED 10.

14 Nm LOAD

11.

LOCK TORQUE (AT 0 RPM)

> 25 NM

12.

LOCK CURRENT

20 Amps.

13.

NOISE - LOW SPEED /

50 dB (A) MAX /

HIGH SPEED

> 20 RPM

60 dB (A) MAX

WIRING DIAGRAM :

ELECTRICAL

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55

EXPLODED VIEW

ELECTRICAL

56

INDEX

GROUP INDEX

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SPARE PARTS LIST

ELECTRICAL

ELECTRICAL

INDEX

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57

ELECTRICAL 6)

SYSTEM DISMANTLING

1)

Wiper Motor with wiping system. Ref. Fig.1

Fig.1

2)

Remove the circlip form the rotary link. Ref. Fig.2

Fig.2

3)

Remove the motor fixing screws 3 nos from the system.Ref. Fig.3

Fig.3

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ELECTRICAL

4)

Remove the rotary link nut from the system.Ref. Fig.4

Fig.4

5)

Remove the spindle assembly fixing screws 2 nos from bracket. Ref. Fig.5

Fig.5

6)

SYSTEM DISMANTLING :

When dismantling the unit, carefully note down the positions in which the various components are fitted in order to ensure their correct replacement on re-assembly.

ELECTRICAL

Fig.6

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59

ELECTRICAL

1)

Remove the rubber grommet. Ref. Fig.7

Fig.7

2)

Unscrew the cover plate fixing screws (3 Nos). Ref. Fig.8

Fig.8

3)

Remove the cover from the cover plate body casting. Ref. Fig.9

Fig.9

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ELECTRICAL

4)

Remove the cover seal from the gear box assembly. Ref. Fig.10

Fig.10

5)

Remove the gear wheel. Ref. Fig.11

Fig.11

6) Remove the belliveli washer from the gear wheel shaft. Ref. Fig.12

ELECTRICAL

Fig.12

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61

ELECTRICAL

7)

YOKE FIXING SCREW

Unscrew the yoke fixing screws (2 Nos). Ref. Fig.13

Fig.13

8)

Hold the armature shaft and remove the yoke assembly to avoid brush damage. Ref. Fig.14

Fig.14

9)

Please hold the 3 brushes by hand and remove the armature. Ref. Fig.15

Fig.15

62

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ELECTRICAL 10) Unscrew 2 nos brush plate fixing screw and separate the brush plate assembly. Ref. Fig.16

8)

BENCH INSPECTION :

1)

Moulded gear check : Inspect the moulded gear teeth for any damage or excess wear. If so replace the gear assembly.

2)

Commutator check : Ensure that the commutator surface is clean and smooth. If not, clean with a smooth emery paper and wipe of the dust with petrol.

3)

Fig.16

Armature Electrical Check : Use 110 Volts AC mains 15W bulb with two probes. Connect as shown in figure. The bulb should not glow if the bulb glows replace the armature. Ref. Fig.17 Fig.17

4)

Armature winding ground test : Check the Armature on a growler tester for short circuit and continuity of windings. Ref. Fig.18

ELECTRICAL

Fig.18

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63

ELECTRICAL 5)

Ensure proper positioning of the rotary links after every re-assembly. Align the rotary link position in line with the noted mark on the gear box casting.

9)

REASSEMBLY :

It is reverse order of dismantling procedure. Note the following precautions.

1)

Ensure that the ball at the armature shaft end replaced in its groove with grease.

Fig.19

Smear “Turbo 41’ oil over armature shaft and final gear output shaft before assembly. Prior to yoke fixing, ensure contact of brushes with the commutator. Ref. Fig.19 If not in position, motor will have excessive frictional losses. If the ball gets in between the magnets and the armature it will result in motor locking condition while energising, leading armature burning.

2)

LOW TEMPERATURE GREASE KRYOTEX EP2 Fig.20

Smear low temperature grease KRYOTEX EP2 over the armature shaft splines. Ref. Fig.20

3)

Assemble armature on to the gear box followed by brush carrier assembly, Ensure that the contact of brushes on to the commutator, before fixing yoke assembly on to the gear box. Ref. Fig.21 Fig.21

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ELECTRICAL

4)

Ensure that the gaskets are replaced properly in its positions at the appropriate stage of re-assembly. Ref. Fig.22

Fig.22

5)

BELLIVELI WASHER

Belliveli washer in position. Ensure that the Belliveli Washer is replaced in proper position on to the gear spindle as shown in Ref. Fig.23 If it is assembled vice-versa, motor will have frictional losses.

Fig.23

6)

Adjust the armature end float with the thrust screw gap 0 to 0.05 mm. Ref. Fig.24

ELECTRICAL

Fig.24

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65

ELECTRICAL

7)

While assembling the yoke on to the gear box match the notch on the yoke and gear box for proper magnetic polarity. Ref. Fig.25

Fig.25

8)

✘

Do not mallet the yoke assembly. It might result in magnet breakage. Ref. Fig.26

Fig.26

10) TIGHTENING TORQUE : description

value

Thrust screw nut

2.0

— 2.6 Nm

Yoke fixing screw

2.0

— 2.6 Nm

Brush Plate fixing screw

0.8

— 0.9 Nm

Cover plate fixing screw

2.0

— 2.5 Nm

Rotary link nut

12 to 14 Nm

66

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ELECTRICAL 11) TROUBLESHOOTING : BEFORE STARTING ENSURE THE BATTERY CONDITION diagnostic procedures The following procedures assume that the service technician has checked. 1)

The continuity of circuit harness wiring.

2)

That the wiper-motor assembly-to-dash mounting hardware is tight.

3)

Circuit fuses, and

4)

That the washer holes are clear, not kinked, disconnected or broken.

DEFECT

REMEDY

a)

Motor not working when switched ‘ON’

1) 2)

b)

Motor does not park after switching ‘OFF’

1) Cover plate defective --change cover plate.

c)

Jerky movement of the motor while running.

1) 2)

d)

Intermittant function

Check fuse. Check connections of both socket and plug.

Look for proper seating of brushes on commutator. Ensure Armature is free for defects.

1) Ensure the Wiper Motor Switch contacts are OK.

ELECTRICAL

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67

ELECTRICAL 26. SERVICE DETAILS FOR REAR WIPER : 1)

GENERAL DESCRIPTION :

Rear Screen Wipermotor Model RW43 series is a single spindle, single speed unit designed to operate a single Arm and Blade to wipe the Rear Wind Screen of Vehicles. The Motor is a self switching two pole design having permanent magnet field system, and provided with Gear Box housing and final Gear. The power developed by the motor is transmitted by worm teeth on an extension of the Armature Shaft through the final gear system. The rotary motion of the finalgear is converted to oscilatery motion through a transmission mechanism housed in the Gear Box, which operate the wiper Arm and Blade. The contacts in the Switch moulding provided on the Gear Box ensure a re-generative breaking on completion of the wiping cycle when the switch is turned “OFF”, and ensures consistant parking position of the Wiper Arm and Blade. The Arm resting position is preset to suit the installation requirements. The wiper motor incorporates radio interference capacitor.

PRECAUTIONS : 1)

Circuit cable resistance drop does not exceed 1.0 volt with motor current of 5.0 Amps.

2)

Observe correct polarity while connecting motor.

3)

Ensure recommended Arm / Blade sizes are used.

68

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ELECTRICAL 2)

ROUTINE CHECKS :

1)

Remove oil, tarspots or similar deposits from the wind screen with methylated spirits (denatured alcohol).

2)

Do not use silicone or wax polishes on wind screen.

3)

Ensure all electrical connections are in good condition.

4)

Keep wiping blades in good condition.

5)

Worn or perished blades should be replaced.

WIPER MOTOR CHECK : Unsatisfactory operation may be due to Electrical or Mechanical faults. Before dismantling the unit consideration should be given to the nature of fault.

WIRING DIAGRAM :

ELECTRICAL

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69

ELECTRICAL 3)

SPECIFICATION : 1.

TYPE

RW43

2.

RATED VOLTAGE

12V

3.

TEST VOLTAGE

13.5 ± 0.2V

4.

STARTING VOLTAGE

8V MAX

5.

OPERATING VOLTAGE

10 ~ 15V

RANGE 25 ± 5OC

6.

TEST TEMPERATURE

7.

OPERATING TEMPERATURE

8.

RANGE

- 40OC — +80OC

INSULATION RESISTANCE

1M.ohm MIN

9.

0.6 Nm LOAD

38 ± 5 RPM

10.

2 Nm LOAD

> 25 RPM

11.

LOCK TORQUE (AT 0 RPM)

> 7 NM

12.

LOCK CURRENT

14 A MAX

13.

NOISE

50 dB (A) MAX

THERMAL CUTOUT

SETTING TEMP : 135O — 145O OPEN

SPECIFICATION

110O — 85O RESET

SPEED

BREAK CURRENT - 14 AMPS TIME:2 - 8 SEC. AT NORMAL AMBIENT OF 30O

70

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EXPLODED VIEW

ELECTRICAL

ELECTRICAL

INDEX

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71

ELECTRICAL

72

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ELECTRICAL 6)

LIGHT RUN TEST :

Use a 12 Volts battery with two probes with an ammeter connected as shown in Fig.1 and ensure the speed of 45 wipes/minute and current of 1.5 - 2.0 Amps. If the values are not in line with the above specification (Normal speed) dismantle and rectify suitably. If the Wiper Motor does not start after the Wiper Switch is turned ‘ON’. a)

Inspect the lead connections and plug connection.

b)

Inspect Wiper Switch

c)

Inspect the fuse

d)

Inspect the brush contacts with the commutator

e)

Inspect for dirt or heavy Carbon Content on the Commutator Dia.

REDUCTION IN WIPING SPEED This may be due to excessive friction between wiper blades and screen.

Fig.1

WIPER MOTOR DOES NOT STOP RUNNING Defective Switch. Replace with a new one.

LOW WIPING SPEED This may be due to poor motor performance. This may be due to excessive mechanical loading in wiping system. Dismantle wiper motor and check thoroughly.

INDEX

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73

ELECTRICAL 7)

DISMANTLING :

When dismantling the unit, carefully note down the positions in which the various components are fitted in order to ensure the correct replacement on reassembly. Unscrew the arm fitting nut. Ref. Fig.2

Fig.2

1)

Remove the spring and associated plastic parts provided from gear box for proper seating on to the vehicle panel. Ref. Fig.3

2)

Dismantle flexible water supplying tube from the washer jet.

Fig.3

3)

Unscrew the cover fixing screws 4 nos. from the gear box. Ref. Fig.4

Fig.4

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ELECTRICAL 4)

Lift off the transmission mechanism assembly from the gear box after removing jumpring. Ref. Fig.5

Fig.5

5)

Lift-off the moulded gear assembly from the gear box after removing jumpring. Ref. Fig.6

Fig.6

6)

Unscrew the yoke fixing screws from the gear box. Ref. Fig.7

ELECTRICAL

Fig.7

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75

ELECTRICAL 7)

Pull off the armature assembly from the yoke (ensure that the ball at the end of the shaft is intact). Ref. Fig.8

8)

Unscrew the brush box fixing screws from the gear box. Ref. Fig.9 Lift-off the brush carrier assembly using a lock pin.

8)

Fig.8

BENCH INSPECTION :

Brush replacement : If the brush length is below the minimum required length, replace the complete brush carrier assembly. Minimum required length : 4.5 mm New brush length : 6.5 mm Brush spring pressure check : This design permits for easy removal of the brush springs. Test as shown in Ref. Fig.10 Required spring pressure : 140 - 200 Gm.f. If not so replace the brush in ‘SETS’ and not individually.

Fig.9 Fig. 9

Moulded gear check : Inspect the moulded gear teeth for any damage or excess wear. If so replace the Gear assembly. Commutator check : Ensure that the commutator surface is clean and smooth. If not, clean with a smooth emery paper, and wipe of the dust with petrol...

Fig.10

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ELECTRICAL

1)

Armature Electrical check : Use 110 Volts AC mains 15W bulb with two probes. Connect as shown in figure. The bulb should not glow. If the bulb glows replace the Armature. Ref. Fig.11

Fig.11

2)

Armature winding ground test : Check the Armature on a growler tester for short circuit and continuity of windings. Ref. Fig.12

Fig.12

9)

REASSEMBLY :

It is reverse order of dismantling procedure. Note the following precautions. Ensure that the ball at the armature shaft end is placed in its groove with grease. Ref. Fig.13

ELECTRICAL

Fig.13

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77

ELECTRICAL If not in position Motor will have excessive frictional losses. If the Ball gets in between the magnets and the Armature, it will result in motor locking condition while energising, leading to Armature burning. Smear ‘KRYOTEX EP2’ grease over the armature shaft splines. Smear ‘Turbo 41’ oil over armature shaft and final gear output shaft before assembly. Ref. Fig.14 Prior to yoke fixing, ensure contact of brushes with the commutator.

Fig.14

Assemble Armature on to the Gear box after fixing Brush carrier assembly on to Gear box. Ensure that the contact of brushes on to the commutator, before fixing yoke assembly on to the Gear box. While assembling the yoke onto the gear box match the notch on the yoke and gear box for proper magnetic polarity. Ensure that the grease should touch Limit Switch contacts. Belliveli Washer. Ensure that the Belliveli Washer is replaced in proper

Fig.15

position on to the gear spindle and lever assy as shown in Ref. Fig.15 If it is assembled vice-versa, motor will have frictional losses.

a)

Adjust the armature end float with the thrust screw gap 0 to 0.05 mm Ref. Fig.16 Fig.16

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ELECTRICAL

b)

Do not mallet the yoke assembly. It might result in magnet breakage.

✘

Ref. Fig.17

Fig.17 Check for Light run current, speed, direction of rotation and parking position of wiper motor to ensure correct assembly. Ensure that the fasteners are tightened to the mentioned tightening torque values.

10) TIGHTENING TORQUE : description

value

Thrust screw nut

2.0

— 2.6 Nm

Yoke fixing screw

2.0

— 2.5 Nm

Brush Plate fixing screw

0.8

— 0.9 Nm

Cover plate fixing screw

2.0

— 2.5 Nm

ELECTRICAL

INDEX

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79

ELECTRICAL 11) TROUBLESHOOTING :

BEFORE STARTING ENSURE THE BATTERY CONDITION DIAGNOSTIC PROCEDURES The following procedures assume that the service technician has checked. 1)

The continuity of circuit harness wiring.

2)

That the wiper-motor assembly-to-dash mounting hardware is tight.

3)

Circuit fuses, and

4)

That the washer holes are clear, not kinked, disconnected or broken.

DEFECT

REMEDY

a)

Motor not working when switched ‘ON’

1) 2)

b)

Motor does not park after switching ‘OFF’

1) Cover plate defective --change cover plate.

c)

Jerky movement of the motor while running.

1) 2)

d)

Intermittant function

80

INDEX

Check fuse. Check connections of both socket and plug.

Look for proper seating of brushes on commutator. Ensure Armature is free for defects.

1) Ensure the Wiper Motor Switch contacts are OK.

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ELECTRICAL 27. SERVICE DETAILS FOR ALTERNATOR : 1)

GENERAL DESCRIPTION :

The A 128 Alternator with internal cooling fans and with inbuilt Regulator is designed as a battery charging machine for Passenger Cars. The Alternator is designed and matched to form part of an integrated battery charging system for Automotive applications. This is a 3 phase machine of revolving field and stationary armature type, self limiting in current output. It is ventilated and cooled by means of two internal fans welded on to either side of the rotor.

TYPICAL PERFORMANCE CURVE :

ELECTRICAL

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81

ELECTRICAL PRECAUTIONS : DO’s :

DONT’s :

•

Do ensure that all electrical connections are clean and secure.

•

Do not flash the Alternator output leads to check the working of the Alternator.

•

Do ensure that no electrical connection in the circuit including the battery is open. Do observe correct polarity while connecting battery to altenator ie. connect negative to negative and positive to positive. Otherwise, Alternator will be damaged.

•

Do not run the Alternator with the battery disconnected.

•

Do not disconnect any lead of Alternator / Regulator with the engine in running condition.

•

Do not disconnect battery cables while the engine is running.

•

Disconnect all Alternator terminals, while carrying out welding jobs on the vehicle.

•

Disconnect the battery earth cable before removing the Alternator.

2)

ROUTINE CHECKS :

•

Ensure correct battery electrolyte level.

•

Check the general condition of the battery.

•

Apply petroleum jelly to battery terminals.

•

Ensure that the ventilation slots are clear.

•

Keep the Alternator clean.

•

Ensure that the electrical connection and tight & secure.

•

Check and ensure that mounting bolts are tightened properly.

•

Ensure that the belt on the Alternator is in good condition.

•

Check the belt tension and ensure that it is neither too slack nor too tight.

•

Adjust the belt deflection to 10-15 mm when pressed at midway of the longest point between pulleys. (Refer Page 5)

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ELECTRICAL 3)

SPECIFICATION : 1.

TYPE

A128

2.

RATING

CONTINUOUS

3.

NOMINAL OUTPUT

12V-90A

4.

WEIGHT

5.2 KG APPROX. (WITH PULLEY)

5.

RATED MAXIMUM

6000 R.P.M.

OUTPUT SPEED 6.

MAXIMUM PERMISSIBLE SPEED

18.000 R.P.M.

7.

POLARITY

NEGATIVE EARTH

8.

REGULATOR SYSTEM

BUILT-IN REGULATOR WITH LRC

(LOAD RESPONSE CONTROL) 9. 10.

REG. SET VOLTAGE

14.0 ~ 14.8 V

LRC - TIME DELAY (NO LOAD TO 100% LOAD)

2 ~ 6 SEC.

11.

DIRECTION OF ROTATION

CLOCK (VIEWED FROM PULLEY SIDE)

12.

OPERATING TEMPERATURE

-30O TO 100OC

WIRING DIAGRAM :

ELECTRICAL

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83

ELECTRICAL 4)

SALIENT FEATURES :

•

Starconnected 3 phase output winding wound on a laminated stator.

•

12 pole wound field rotor, carried on ball-race bearings in aluminium end brackets and belt driven from engine.

•

Rectifier with large fins converts the generated A.C. into D.C.

•

Built in hybrid regulator provides voltage control and diagnosis. It also provides load signal to ECU to achieve idle speed staties.

•

Less weight and compact in size.

•

The Alternator is cooled by means of two internal fans one each assembled on either side of rotor assembly.

CHECKING AFTER REASSEMBLY :

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ELECTRICAL 5)

ALTERNATOR CHARGING SYSTEM CHECKS ON VEHICLES : before starting ensure the battery condition SWITCH ON THE IGNITION

NO DOES WARNING LAMP GLOW ?

CHECK WARNING LAMP FOR ANY DEFECT. CHECK "WL" TERMINAL IN ALTERNATOR FOR PROPER CONNECTION.

YES RUN THE ENGINE AT IDLE SPEED

NO

DOES WARNING LAMP GO OFF ?

CHECK THE BELT TENSION. IF FOUND SLACK ADJUST THE BELT DEFLECTION AS PER PROCEDURE ON Pg4 AND CHECK FOR CHARGING. IF THE UNIT IS STILL NOT CHARGING REMOVE THE ALTERNATOR AND CHECK.

YES RAISE THE ENGINE SPEED TO AROUND 2000 ± 200 RPM. ENSURE THAT THE AMMETER READING IS LESS THAN 20A. INCASE THE BATTERY IS DISCHARGED ALLOW CHARGING OF BATTERY TILL THE AMMETER READING COMES TO LESS THAN 20A. CONNECT THE VOLTMETER ACROSS THE ALTERNATOR MAIN TERMINALS. CHECK THE VOLT METER READING DOES THE VOLTMETER READ BETWEEN 14.0 TO 14.8 VOLTS ?

N

YES

O

SWITCH "ON" THE HEADLAMP PARKING LAMP, TAIL LAMP AND OTHER ELECTRICAL LOADS EXCEPT HEATER.

IS RATED CURRENT OUTPUT REACHED WITHOUT VOLTAGE DROPPING BELOW 13.0 VOLTS ?

REMOVE THE ALTERNATOR AND CHECK REGULATOR

NO NO

REMOVE THE ALTERNATOR AND CHECK

ELECTRICAL

YES ALTERNATOR FOUND ACCEPTABLE

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85

EXPLODED VIEW

ELECTRICAL

86

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ELECTRICAL

ELECTRICAL

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87

ELECTRICAL 6)

DISMANTLING

Before dismantling the parts, note down the position of various parts, in order to ensure their proper replacement on reassembly. Follow the step by step procedure mentioned below :1)

Remove the 4 No’s through bolt securing the front bracket and rear bracket. Ref. Fig.1

Fig.1

★

Blow hot air over the rear bracket bearing housing for few seconds till to temperature of the bearing housing 15OC over the ambient temperature. Ref. Fig.2

a i s

Fig.2

★

Separate the front end bracket assembly from the rear end bracket plus stator assembly using a wooden mallet. Ref. Fig.3

Fig.3

88

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Fig. 3

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ELECTRICAL 2)

Clamp the rotor assembly in a soft jaw and remove the pulley nut.

(Take care of rotor claws from gettingdamaged). Ref. Fig.4

Fig.4

3)

Remove the pulley from front bracket assembly. Ref. Fig.5

Fig.5

4)

Separate the rotor from the front bracket assembly. Ref. Fig.6

ELECTRICAL

Fig.6

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89

ELECTRICAL

5)

Remove the spacer from rotor assembly. Ref. Fig.7

Fig.7

6)

To remove rear bearing, clamp the rotor assembly in a soft jaw. Place the puller in the bearing rear and remove it. (Take care of rotor claws from damage) Ref. Fig.8

Fig.8

7)

Unscrew the 4 nos front end bearing retaining plate fixing screws. Ref. Fig.9

Fig.9

90

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ELECTRICAL

8)

Remove the retainer plate. Ref. Fig.10

Fig.10

9)

Remove the front end bearing by using a soft pusher rod. Ref. Fig.11

Fig.11

10) De-solder the stator leads from the rectifier and remove the stator assembly. Ref. Fig.12

ELECTRICAL

Fig.12

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91

ELECTRICAL

11) Unscrew 4 Nos screws from rectifier and regulator. Ref. Fig.13

Fig.13

12) Remove the rectifier and regulator from the rear bracket. Ref. Fig.14

Fig.14

13) De-solder the joint (2 places) between rectifier and regulator. Ref. Fig.15

Fig.15

92

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ELECTRICAL 7) BENCH INSPECTION : On dismantling the unit conduct the following checks:

Brush check •

Minimum required Brush lenghth : 7.5mm Ref. Fig.16

7.5 mm minimum

If the brushes are below the minimum required length renew the brushes in sets not individually. De’ solder the brush lead assy. INSERT New brush assembly and solder. Make sure that the brushes move freely inside the brush box.

Fig.16

Slip ring check •

SLIP RING

Clean slip ring surface with a fine piece of cloth and ensure that the surface is smooth and clean.

Ref. Fig.17 If the surface is very rough and cannot be polished, replace the rotor assembly. There should not be any trace of oil or grease on the slip ring surface.

SRE BEARING Fig.17

Bearing check (SRE & DE) •

Bearing should rotate freely without any excessive play. If play is observed, the bearings should be replaced.

OHM METER

Rotor assembly check Resistance Check : Use ohm meter 0-10 ohm range and connect as shown in fig. Connect the probes of the meter to the slip ring. The value should be 2.68 ± 0.13 ohms. If value is outside this limit, change the rotor assembly. Ref. Fig.18

ELECTRICAL

Fig.18

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93

ELECTRICAL 8)

ROTOR GROUND TEST :

•

Using 230 volt AC main supply, con nect a 15W bulb as shown in figure 18. Connect one of the probes to the slip ring and the other to the shaft. The lamp should not glow. If the lamp glows it indicates earthing. Replace the rotor assembly.

15W BULB

110V AC SUPPLY Fig.19

Stator insulation test •

Using 230 volt AC main supply, con nect a 15W bulb. Connect one of the probes to any of the three leads and the other probe to the body. The lamp should not glow. If the lamp glows it indicates poor insulation. Replace the stator assembly. Ref. Fig.20 110V

Fig.20

Stator winding resistance check •

Use Ohm meter with two probes con nect thicker wire and lead 1. The Value should read around 0.086 Ohms at 20 OC. Repeat it between star connection and lead 2 and 3. Ref. Fig.21

Fig.21

94

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ELECTRICAL 9)

RECTIFIER ASSEMBLY CHECK :

•

Remove the rectifier assembly from the unit and check as follows:

a) Testing of positive heat sink diodes i) Continuity check Connect as shown in figure 22. Use multimeter with two probes. Connect the positive probe of the multimeter to positive terminal and negative probe to phase connecting points one by one on the rectifier assembly. It should not indicate open circuit. Replace the rectifier assembly if it is open circuit.

Fig.22

ii) No Continuity check Connect as shown in figure 23. Use multimeter with two probes. Connect negative probe of multimeter to positive terminal and positive probe to phase connector points one by one on the rectifier assembly. All diodes should indicate no continuity. If there is continuity it indicates short circuit. Replace the rectifier assembly.

b) Testing of negative heat sink diodes i)

Fig.23

Continuity check

Connect as shown in figure 24. Use the multimeter with two probes. Connect the positive probe of multimeter to phase connecting points and negative probe to rectifier body. All diodes should indicate continuity. If not, it indicates open circuit. Replace the rectifier assembly.

ELECTRICAL

Fig.24

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95

ELECTRICAL ii) No Continuity check Connect as shown in figure 25. Use the multimeter with two probes. Connect negative probe of multimeter to phase connecting points and positive probe to rectifier body. Now all diodes should indicate no continuity. If not, it indicates short circuit. Replace rectifier assembly.

Fig.25

Fig. 25

10) regulator check •

Use LTVS authorised test equipment for checking Regulators and test as per instructions given in the test equipment manual. Connect the negative to the equipment as per the markings on the Regulator. Ref. Fig.26

Fig. 26

96

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ELECTRICAL 11) REASSEMBLY : It is reverse order of dismantling procedure. Note the following precautions.

Note : While re-assembly special tool to be used to push the brushes inside the brush slots and the pin to be inserted to hold the brushes up while dropping front end bracket assembly into rear end bracket assembly.

1)

Using the brush lifting tool, push the brushes inside the brush box assembly. Ref. Fig.27

Fig.27

2) From the rear side, insert the pin for positive locking of the brushes and remove the brush lifting tool. Ref. Fig.28

ELECTRICAL

Fig.28

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97

ELECTRICAL

Note : Use a hot air blower which delivers air suitable to raise the bracket temperature near the bearing housing to 50 o~60 oC. Focus the nozzle of hot air blower to SRE bearing housing and take care that to hot air is not directed towards the plastic mouldings. Fig.29

3)

Insert the rotor assembly in the rear bracket assembly.After re-assembly remove the pin. Ref. Fig.30

PIN Fig.30

4)

Place the rotor assembly inside the tool and ensure positive locking of the rotor claw. Ref. Fig.31

Fig.31

98

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ELECTRICAL

5)

Tighten the pulley nut. Ref. Fig.32

Fig.32

ELECTRICAL

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99

ELECTRICAL 12) TIGHTENING TORQUE : description

value

Pully Hexacon Nut

99 - 13.7 N-m.

Insul Bush Nut

12.8 - 18.6 N-m.

Rectifier & Regulator Bearing

2.0 - 5.3 N-m.

Hexacon Through Bolt

3.5 - 5.3 N-m.

TESTING AFTER REASSEMBLY : Test the Alternator in a test bench as per diagram shown in page (5) and read the values as per the specification (Ref. Page 4).

100

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ELECTRICAL 13) TROUBLESHOOTING : BEFORE STARTING ENSURE THE BATTERY CONDITION DEFECT 1. Warning light does not appear when Ignition switch is on.

CAUSE (a) If the bulb does not light, ground WL terminal of the alternator. (b) If the bulb now lights the caused are : (ii) Jammed brushes or brush lead adrift. (iii) Dirty slip ring (iv) Rotor open circuit. (v) Yellow lead connecting rectifier to regulator open.

If the bulb does not light even after grounding WL Terminal, the causes are : (vi) Fused warning lamp bulb. the wiring harness. After rectifying the short replace bulb.

REMEDY

Free brushed, Replace , if necessary. Clean the slip ring. Check that the ends of the rotor winding are soldered properly to slip ring terminals. Resolder the windings, if open, or replace the rotor.

(c)

2. Warning lamp glows dim

3. Warning lamp 'on'. Ammeter shows no charge while engine is running.

Check for short circuit, if any, in

(vii) Short circuited warning lamp holder. (d) If still WL does not appear when Ignition switch is on, the cause is faulty Regulator.

Replace Holder.

(i)

High resistance in warning lamp (ii) Regulator defective. (iii) Rotor defective.

Check and correct.

(i)

Loose belt.

(ii)

Aux. diode lead 'A' open.

Tighten the belt to the limits as indicated in routine maintenance. Check diode connection and trace short. Rectify if possible or

Replace regulator.

Replace Regulator. Replace Rotor.

replace rectifier assembly. (iii) Shorted rotor (iv) Stator open/shorted

Replace rotor. Replace stator assembly.

4. Warning lamp 'on' or dim but ammeter shows charges (low output)

(i)

Faulty bridge.

Replace defective heat sink assy.

5. Warning lamp goes off. Ammeter shows low output

(i)

Faulty rectifier bridge.

Replace defective heat sink assy.

(ii)

Stator winding short.

Rectify or replace stator assembly

(i)

High resistance in the Negative line. Slip ring dirty.

Check connections and ensure use of recommended wire. Clean the slip ring and recheck.

Faulty regulator. Rotor shorted to earth on negative side.

Replace regulator. Rectify or replace rotor assembly

6. Warning lamp (Ammeter) flickers considerably.

(ii) 7. Overcharging (battery gases)

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(i) (ii)

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101

ELECTRICAL 28. SERVICE DETAILS FOR STARTER MOTOR : 1)

GENERAL DESCRIPTION :

The SM82 pre-engaged Starter is a 4-pole, 4-brush, series and parallel wound field, direct - drive machine of 82 mm frame size. This light-weight Starter is designed for use on petrol engines upto 1800 C.C. (4 cylinder) and has a solenoid actuated roller clutch drive. On closing the Starter switch on the panel, the solenoid gets energised, thereby, pulling the plunger towards the core. An actuating plastic lever has one of its ends connected to the plunger and the other to the drive assembly. The pinion is thus thrown into mesh with the flywheel ring gear when the solenoid plunger moves in. The plunger, at the end of its travel, closes a pair of contacts which connect the Starter directly to the battery. As soon as the engine fires, the plunger is brought back to its original position by the plunger return spring placed over it. This disengages the drive from the ring gear.

TYPICAL PERFORMANCE CURVE :

102

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ELECTRICAL 2)

PRECAUTIONS :

The following points must be adhered to when starting the engine :•

Ensure that all electrical connections to the Starter are in a good condition.

•

Turn the Starter switch and release as soon as engine fires.

•

If the engine does not fire, allow it to rest before operating the switch again.

•

If the engine does not start, ascertain the cause and do not drain the battery by keeping on cranking the engine.

•

Do not operate the Starter when the engine is running, otherwise serious damage could occur both to the Starter pinion and the flywheel ring gear teeth.

•

Do not operate the Starter with a low charged battery.

SOLENOID CHECK : To check the solenoid switch connect a bulb in series with the main terminal contact, energise the winding if the bulb glows solenoid switch is OK.

ROUTINE MAINTENANCE : •

Ensure that the starter motor mounting bolts (to the engine) are securely fastened.

•

Check that the electrical connections are clean and tight.

•

Cables should be examined for fractures, particularly where the strands enter the teminal lugs.

•

Inspect fixing brackets for any cracks.

ELECTRICAL

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103

ELECTRICAL 3)

SPECIFICATION :

NOMINAL OUTPUT

0.8 K.W MIN.

ENGAGING SYSTEM

PRE-ENGAGED DRIVE CONDITION

PERFOMANCE SPECI- NO LOAD FICATION AT + 25O C LOAD LOCKED

VOLTAGE CURRENT TORQUE (VOLTS) (AMPS) (Nm) 11

SPEED (R.P.M)

50 MAX

--------

6000 MIN

9.7 ± 0.2 230 MAX

4.5 MIN

2300 MIN

13.0 MIN

------------

7.0

± 0.2

550 MAX

OPERATION OF SOLENOID SWITCH

1) PULL IN VOLTAGE 8V MAX. WHEN PINION TRAVEL RESTRICTED AT 2 MM 2) DROP OFF VOLTAGE 4V MAX.

WEIGHT

4.1 Kg (APPROX)

CONNECTION DIAGRAM :

12

104

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ELECTRICAL

ELECTRICAL

INDEX

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105

ELECTRICAL

106

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ELECTRICAL 6)

DISMANTLING :

1) Remove the two fly leads from solenoid switch. Ref. Fig.1

Fig.1

Fig. 1 SOLENOID FIXING NUT

2) Unscrew solenoid fixing NUTS and withdraw the complete solenoid unit from the fixing bracket. Ref. Fig.2

Fig.2

PLUNGER

3) Withdraw the plunger from the operating lever. Ref. Fig.3

ELECTRICAL

Fig.3

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107

ELECTRICAL

4)

Remove the BG. screws (2 Nos.) from the outer face of the commutator end cover. BG SCREW

Ref. Fig.4

Fig.4

5) Remove the through bolts. Ref. Fig.5

THROUGH BOLT Fig.5

6)

Fig. 5

The commutator end bracket assembly can be removed leaving the brush gear in its position on the commutator, using a nylon mallet. Ref. Fig.6

Fig.6

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ELECTRICAL

7)

Disassemble the insul brushes from the brush plate assembly. Ref. Fig.7

Fig.7

8)

Fig. 7

Slide out the brush plate assembly. Ref. Fig.8

Fig.8

9)

Withdraw the yoke assembly from the armature and fixing bracket using a nylon mallet. Ref. Fig.9

ELECTRICAL

Fig.9

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109

ELECTRICAL

10) Remove the plastic engaging lever assembly and Armature assembly simultaneously. Ref. Fig.10

Fig.10

11) Remove the jump ring collar using a mild steel tube of suitable bore. Remove the jump ring from its groove. Remove the thrust collar, thrust washer and shim. Ref. Fig.11

Fig. 10

Jump ring

Thrust collar

Fig.11

12) Remove the drive assembly. Ref. Fig.12

SHIM THRUST WASHER JUMP RING

DRIVE ASSEMBLY THRUST COLLAR Fig.12

110

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ELECTRICAL

13) Removal of pole screw from the yoke. Ref. Fig.13

Fig.13

7)

BENCH INSPECTION :

Brush wear : Check / Renew

Brushes A. New length

- 16 mm.

B. Minimum length

- 10 mm.

}

Fig.14

Fig.14

Brush Spring •

Check Spring pressure in conjunction with new brushes.

•

Fit brush on the commutator with brushes in working condition.

•

Spring pressure reading at the moment of lift should be 1.8 / 2.5 kg (New) 1.25 / 2.0 kg (Washout pushable) Ref. Fig.15

ELECTRICAL

Fig.15

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111

ELECTRICAL

8)

ARMATURE TEST :

•

If growler equipment is available, check for short circuited windings.

•

Insulation Test - If the lamp glows renew the armature.

A

MM N CO W O ENT O R R M

EG ON S

-

Ref. Fig.16 FT SHA

Fig.16

•

Armature winding ground test : Check the Armature on a growler tester for short circuit and continuity of windings. Ref. Fig.17

Fig.17

15W

Brush Plate Test •

Insulation test Before testing ensure B.G. plate is free from dust. Connect the test lamp to the brush box. If the lamp glows - renew the brush plate. Ref. Fig.18

Fig.18

112

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ELECTRICAL 9)

FIELD COIL TEST :

•

Closely inspect field coils insulation.

15W

WINDING

Check Joints (for continuity) and look for evidence of burning (insulation faults).

Insulation Test •

If lamp glows - Renew the field coils. Ref. Fig.19

Replacement of field coils BODY •

Tighten the screws by means of special fixture while pole pieces are held in position by suitable mandrel.

Fig.19

REASSEMBLY : It is reverse order of dismantling procedure. Note the following precautions. 1.

When assembling the C.E. bracket to the C.E. side of the yoke, the brush plate assembly should not tilt and to be adjusted to fixing holes.

2.

Slide the drive assembly onto the armature. Slide collar, and locate jump ring onto the groove. Lock the jump ring to the thrust collar, put back the thrust washer and shim before sliding the armature assembly into the D.E. bracket.

3.

Replace new rubber seals.

Lubrication : Apply grease (OKS 410) into C.E. and D.E. bearing bushes and OKS 475 for drive splines.

ELECTRICAL

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113

ELECTRICAL 10) Testing : After reassembly, Check for no load, lock torque and run torque as follows insert fig. VOLTAGE CURRENT TORQUE CONDITION (VOLTS) (AMPS) (Nm)

SPEED (R.P.M)

NO LOAD

11.0

50 MAX

--------

6000 MIN

RUN TORQUE

9.7 ± 0.2

230 MAX

4.5 MIN

2300 MIN

LOCK TORQUE

7.0 ± 0.2

550 MAX

13.0 MIN

------------

Fig.20

TIGHTENING TORQUE : description

value

Yoke fixing screws

15.7 - 17.2 N-m.

B.G. fixing screws

3.5 - 4.0 N-m.

Fixing bolt

5.7 - 6.2 N-m.

Starter terminal nut

5.1 - 5.7 N-m.

Solenoid mounting nut

5.1 - 5.7 N-m.

114

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ELECTRICAL 11) TROUBLESHOOTING :

BEFORE STARTING ENSURE THE BATTERY CONDITION DEFECT 1) Pinion fails to engage. tery:

CAUSE Discharged Battery.

REMEDY Substitute with a fully charged batif the starter now cranks the engine, then the battery must be attended to.

2) Armature fails to rotate or rotates slowly and the starter does not crank the engine though pinion has engaged with ring gear

Defective solenoid switch.

Remove starter for further inspection. Check solenoid, plunger and spring replace, if necessary.

Discharged / Defective battery.

Substitute with a fully charged battery. if the starter now cranks the engine, then the battery must be attended to.

Loose or oxidised battery terminals / Corroded or loose connections / Defective earth connections.

Clean the terminals and smear petro leum jelly. Tighten all connections.

Brushes wornout and not making proper contact with commutator.

Replace brushes, if found to be wornout.

Dirty, oily or badly burnt commutator.

Remove dirt or oil. If commutator is burnt, replace armature.

Starter terminal or brush box having earth fault. Defective Solenoid Switch. Defective Armature / Field Coils.

Remove the starter for further investigations and replace parts as found to be necessary.

Contd...

ELECTRICAL

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115

ELECTRICAL TROUBLE SHOOTING Contd... DEFECT

CAUSE

3) Armature rotates but pinion Pinion sticky on shaft. fails to engage. bricated

REMEDY Shaft splines and the pinion internal splines to be cleaned and lucheck solenoid switch.

Burrs on pinion or ring gear.

Deburr by filing.

4) Armature rotates, pinion engages with the ring gear but the engine is not cranked (A whining noise is heard).

Clutch slip.

Remove the starter from the vehicle and replace drive assy., test and refit starter.

5) Starter continues to run after the Ignition switch is released.

Sticky starter switch or Ignition switch

Disconnect starter cable immediately at starter battery terminal. Replace starter switch or Ignition switch as applicable.

Sticky solenoid switch contacts.

Remove the starter for solenoid inspection and replace solenoid, if required.

Pinion / Ring gear fouled or damaged.

Clean throughly, deburring pinion and ring gear by filing.Replace, if necessary.

First ensure that the battery cables and connections are in good conditions, clean and tight with the earth connection secure. Ideally check the battery condition using a battery tester.

If the battery has been removed from the vehicle it is essential that it is reconnected with the correct polarity. Reverse polarity connection will seriously damage the Alternator & associated parts.

6) Starting problem before investigating any starting problem, it is essential to ensure that the battery is in a satisfactory condition. A defective battery will result in cranking difficulties.

Identify your vehicle symptom, then follow in order the likely causes and checks.

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8 HEADLAMP LEVELLING MOTOR RH 9 ABS ECU HU 10 FRONT WHEEL SPEED SENSOR RH 11 AC COMPRESSOR CLUTCH

6 FRONT POSITION/PARKING LAMPS 7 FRONT BLINKERS RH

1 FR AND REAR WASH MOTORS 2 FRONT FOGLAMP RH 3 EARTH 4 HORN 5 HEADLAMP RH

23 EARTH - E11 24 TO ENGINE W / H 25 TO SENSOR W / H 26 BONNET SWITCH 27 FUSE AND RELAY BOX (ENGINE) 28 FRONT FOGLAMP LH 29 HOOTER 30 HEADLAMP LH 31 POSITION / PARKING LAMPS LH 32 FRONT BLINKERS LH 33 HEADLAMP LEVELLING MOTOR LH

12 BRAKE FLUID SWITCH 13 EARTH 14 TO FLOOR W / H 15 TO CABIN W / H 16 TO MAXIFUSE (ENGINE W / H) 17 FRONT WHEEL SPEED SENSOR LH 18 EARTH E13 19 FRONT WIPER MOTOR 20 TO CABIN W / H 21 TO FRONT WASHER 22 TO ENGINE COOLING W / H

LAYOUT OF FRONT WIRING HARNESS (RHD)

ELECTRICAL

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ELECTRICAL

117

118

INDEX

GROUP INDEX

9 SIDE INDICATOR RH 10 DRIVER DOOR SWITCH

6 FUSE AND RELAY BOX - CABIN 7 DASH SPEAKER RH 8 EARTH

4 FACIA SWITCHES 5 INST LIGHT DIMMER

1 TO FRONT W / H 2 TO FLOOR W / H 3 TO DRIVER DOOR W / H

19 RADIO / MUSIC SYSTEM 20 CIGARETTE LIGHTER

29 COMBINATION SWITCH (ON STEERING COLUMN) 30 INSTRUMENT CLUSTER

26 STOP LIGHT SWITCH 27 HEADLAMP LEVELLING SWITCH 28 STEERING LOCK / IGNITION SWITCH

23 TO FRONT W/H 24 TO ACCESSORY RELAY (12V 50A) 25 DIGITAL CLOCK

13 SIDE INDICATOR LH 14 FRONT DOOR SWITCH LH 15 EARTH 16 DASH SPEAKERS LH 17 TO CO-DRIVER DOOR LH 18 HAZARD WARNING SWITCH

21 TO CABIN HVAC W/H 22 TO SRS / AIRBAG W/H

11 TO ROOF LAMP 12 EARTH - ROOF

LAYOUT OF CABIN WIRING HARNESSES (RHD)

ELECTRICAL

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8 PRETENSIONER RH

6 INHIBIT SWITCH 7 PRETENSIONER LH

4 ECU SRS 5 GROUND

1 DRIVER AIRBAG 2 PASSENGER AIRBAG 3 CABIN W/H

LAYOUT OF AIRBAG WIRING HARNESSES (RHD)

ELECTRICAL

ELECTRICAL

119

120

INDEX

GROUP INDEX 6 TO FLOOR WIRING HARNESS 7 EARTH / GROUND FOR TAILGATE

4 TAILGATE SWITCH 5 HIGH MOUNTED STOP LAMP

1 REAR WIPER MOTOR 2 REAR GLASS HEATER 3 REAR GLASS WASH TUBE

LAYOUT OF TAILGATE WIRING HARNESSES (RHD)

ELECTRICAL

NEXT

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LAYOUT OF FLOOR WIRING HARNESSES (RHD)

ELECTRICAL

ELECTRICAL

INDEX

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121

ELECTRICAL

122

INDEX

GROUP INDEX

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PREVIOUS

ELECTRICAL

ELECTRICAL

INDEX

GROUP INDEX

NEXT

PREVIOUS

123

ELECTRICAL

124

INDEX

GROUP INDEX

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ELECTRICAL

31. Schematic Circuit Diagrams (RHD)

125

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ELECTRICAL INDEX AND SYMBOLS DESCRIPTION OF CIRCUIT SCHEMATIC INDEX AND SYMBOLS LAYOUT FUSE AND RELAY BOXES FUSE DISTRIBUTION DIAGRAM EARTH/GROUND POINT LOCATIONS EMS ECU NON AC AND COOLING EMS ECU STARTING CHARGING AND AC EMS CONNECTOR DETAILS INSTRUMENT CLUSTER HEADLAMP/PARKING LAMP, FOGLAMPS INTERIOR LIGHT CHIME UNIT & SWITCHES WIPERS AND WASH ANTITHEFT IMMOBILISER SYSTEM POWER WINDOW WINDING SYSTEM MUSIC SYSTEM, CLOCK, HORN, CIGARETTE LIGHTER HAZARD WARNING SIDE INDICATORS ANTILOCK BRAKING SYSTEM AIRBAG SYSTEM - DAB / PAB AIRBAG SYSTEM - DAB

126

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ELECTRICAL

CIRCUIT SCHEMATICS RELAY FUSE BOX FOR INDICA AND INDIGO SOUTH AFRICA MPFI PETROL E-II VERSION

127

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ELECTRICAL

CIRCUIT SCHEMATIC FUSES DISTRIBUTION

128

INDEX

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NEXT

ELECTRICAL

CIRCUIT SCHEMATIC - EARTH GROUND POINT LOCATIONS

129

INDEX

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NEXT

ELECTRICAL

CIRCUIT SCHEMATIC EMS ECU START/CHARGING HD INDICA/INDIGO MPFI EURO-II

130

INDEX

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ELECTRICAL

131

INDEX

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ELECTRICAL

CONNECTOR DETAILS FOR ECU EMS

132

INDEX

NEXT

ELECTRICAL

CIRCUIT SCHEMATIC INSTRUMENT CLUSTER

133

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC HEADLAMP/PARKING/FOGLAMPS

134

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC INTERIOR LIGHTS, CHIME UNIT AND SWITCHES

135

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC INTERIOR LIGHTS AND SWITCHES - INDICA/INDIGO

136

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC WIPERS AND WASH

137

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC ANTITHEFT IMMOBILISER SYSTEM

138

INDEX

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ELECTRICAL CIRCUIT SCHEMATIC

WINDOW WINDING SYSTEM

139

INDEX

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NEXT

ELECTRICAL

CIRCUIT SCHEMATIC-HORN/CLOCK MUSIC SYSTEM/CIG LIGHTER

140

INDEX

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NEXT

ELECTRICAL

CIRCUIT SCHEMATIC HAZARD WARNING AND SIDE INDICATOR

141

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC ANTILOCK BRAKING SYSTEM

142

INDEX

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ELECTRICAL

CIRCUIT SCHEMATIC - AIR BAG SYSTEM - DAB/PAB

143

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ELECTRICAL

CIRCUIT SCHEMATIC AIR BAG SYSTEM - DAB

144

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DIAGNOSTICS AIR BAG ABS EMS

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DIAGNOSTICS AIRBAG CONTENTS : 1) General A) Salient Features

2

2) Detailed Description A) Electrical

3

3) Specification A) Laptop/Desktop B) Vehicle Interface Unit

3

4) Installation and Operating Procedure A) Installation B) Operating Procedure

5

5) Maintenance A) Trouble shooting

11

6) Faultcode list and Repair Guidelines

12

DIAGNOSTICS

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1

DIAGNOSTICS AIRBAG 1. GENERAL : Air Bag ECU is used for controlling firing of air-bags for passenger safety on a vehicle in event of a crash. This air bag module has a provision for sensing the front impacts. The system includes the possibilities to handle front air bags (driver and passenger) and seat pretensioners for driver and passenger. The Micro-controller inside the ECU , evaluates continuously the signal from the all the sensor. Based on the analog signal the crash algorithm will decide whether to fire the air bag system . During the ignition (start up) of the vehicle ,the system will make number of self tests and the functionality will be indicated by the warning lamp which is placed in the instrument cluster as per the Air Bag manufacturer ’s requirements.

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)

Read Central ECU data Read Sensor Information Read Manufacturing / Repair Date Read ECU Status Read DTCs i.e. Error Codes Clear DTCs Read Vehicle Identification Write Vehicle Identification No Write Manufacturing / Repair Date Write Ignition Data Set Diagnostic mode

The ECU has a standard interface based on Key Word 2000 Protocol for Diagnostics The interface allows checking Electrical connections , resetting errors and reading the ECU data etc. TATA MOTORS has developed a diagnostic unit which handles these functions and provides a user friendly interface based on laptop PC. A. SALIENT FEATURES The Diagnostic tester for Airbag ECU module has a capability to communicate with the ECU on a serial K-line interface . The Tester comprises a vehicle interface unit and custom built GUI (graphical user interface) . The system software is a user friendly. The user can load it on laptop/Desktop. The vehicle interface unit is light weight and compact in size to facilitate easy portability. This works on vehicle battery supply. This tester will execute all the commands supported by ECU , which help in diagnostic of the Airbag system. This diagnostic unit is capable of performing the following functions. DIAGNOSTICS

2

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DIAGNOSTICS AIRBAG 2. DETAILED DESCRIPTION : A. Electrical Required power supply : Power supply for the Laptop/Desktop.The Vehicle Interface Unit does not require any external power supply . It works on vehicle battery, provided through the OBD cable .

PC/Laptop (with software)

Serial cable RS232 COM Port

Vehicle Interface Unit

To vehicle wiring Harness

Connect the RS232 cable to the Laptop/Desktop COM port The OBD cable is connected to the Diagnostic connector of the wiring harness.Fig. 2, 3 & Fig. 6.

OBD Cable

Fig 1.

3. SPECIFICATION : A. Laptop / PC (Fig. 4) Operating system : WIN 98/ WIN 2000 /WIN XP or later version CPU Speed : 933 Mhz or greater RAM : 128 MB Video Display : 800 x 600 resolution with 24 bit colour RS232 port : Minimum 1No. CD ROM Drive Printer Port (optional) The software works with the above features of a Desktop/ Laptop . Any other combination of speed and RAM less then specified will slow down the response of the software.

Fig 2.Diagnostic connector under co-driver seat

B. Vehicle Interface Unit (Fig. 5) Interface unit from M/s Silicon Engines, USA OBD cable RS232 cable

DIAGNOSTICS

Fig 3.Diagnostic connector cap removed

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3

DIAGNOSTICS AIRBAG Diagnostic Equipment Components :

Fig 4. Laptop

Fig 5. Interface Unit

DIAGNOSTICS

Fig 6. OBD cable connected to diagnostic connector 4

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DIAGNOSTICS AIRBAG 4. Installation and Operating Procedure A. Installation of Software The Installation CD of the software is supplied with the kit . Follow the following steps to install the software: Installation Procedure:1) Insert the CD in the CD Rom . 2) Set-up will start running automatically . 3) After this the program will guide you for further installation. 4) After successful installation , a short-cut to program will appear on desk-top. 5) This program will be loaded in following directory ‘C:/Program files/TATA MOTORS’ 6) When user clicks the short-cut, screen will appear as shown in Fig.7

Fig 7.

MID and Site code values in Fig.7 are for example . These values are machine dependent. These values will be different for every machine.The Application status will be ‘LOCKED’, for unlocking the program user has to send MID and Site code by E-mail on following E-mail ID [email protected] 7) After this we will send you Init code on mail. Please enter that code in Init code box. 8) Then Application status will change to ‘LICENSED’ .Click continue to start the application. 9) Now your application is unlocked. B. Operating Procedure i. Main Menu : This is the main form for the application All the functions catering to the Diagnostic of the ECU can be performed through the tester. To perform any function press the respective button.This also gives context sensitive help for the system. Just Press ‘F1’ on any button, the help for the particular button will be displayed . DIAGNOSTICS

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5

DIAGNOSTICS AIRBAG

STATUS DISPLAY

DATA DISPLAY AREA Fig 8.

To start the communication between the ECU and the Tester press the “START” button. This initialises the ECU communication and enables the other commands. The Following operations can be performed with the help of these commands a] READ ‘ CENTARL ECU DATA’ b] READ ‘SENSER INFO’ c] READ ‘DATE: MFG/REP’ d] READ ‘ECU STATUS’ e] READ DTCs f] CLEAR DTCs g] WRITE VIN h] READ VIN i] WRITE ‘DATE: MFG/REPAIR’

DIAGNOSTICS

6

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DIAGNOSTICS AIRBAG ii. DETAILS : a] CENTRAL ECU DATA :This service allows to know the Identification of the ECU. This information includes following : • Hardware No. • PCB major index / PCB minor index • Major/ Minor Version of software • Index No. • Version No. • Calibration No. from the pre-production units • ECU Squib version • Number of Asics lines • Safing Type : Integrated Safing or Software Safing Screen shown in Fig.9 will displayed on clicking this button.

Fig 9.

b] SENSOR INFO : Click this button to Retrieve the sensor information from the ECU . This provides a synthesis of the information received from the ‘Inhibit key Sensor’ . i.e this service gives whether Inhibition Key is Configured or Not Configured . The fault codes corresponding to the inhibit key sensor are accessible by ‘Read DTCs’ function. The Diagnostic tester displays the sensor ECU information:ISOFIX A SENSOR / INHIBITION KEY:- INHIBIT KEY CONFIGURED

On clicking of this , user has to select either ‘MFG. Date’ or ‘Repair Date’ of from popup menu. ‘MFG. Date’ displays date of manufacturing. ‘Repair Date’ displays date of repair. For e.g. the tester displays the ECU manufacturing date as -

c] READ DATE MFG/REP :

MANUFATURING DATE DATA : 26/02/2002

This services allow the user to know the following dates 1) The Date of manufacture of the vehicle 2) The Date of the last service i.e. Repair Date DIAGNOSTICS

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7

DIAGNOSTICS AIRBAG

Fig 10.

d] READ ECU STATUS: This service allows the user to read following ECU parameters 1) No. of recorded Faults in ECU RAM 2) No. of Intermittent Faults 3) Warning Lamp after Crash 4) ECU Lock status 5) ECU Configuration Status 6) ECU to be changed after crash 7) Configuration Of Satellites 8) No. of Recorded Crashes 9) Last Safing State 10) Instantaneous State of Warning Lamp 11) Instantaneous State of Inhibition Lamp 12) INHIBIT status function for Airbag

13) Instantaneous State for passenger Airbag inhibition 14) AIRBAG inhibition 15) Configuration of Squib lines 16) Squib Firing Status

DIAGNOSTICS

8

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DIAGNOSTICS AIRBAG e] READ DTCs :

g] WRITE VIN:

This allows to read error codes recorded in the error buffer in ECU. ACU-3 can record up to 16 error codes. Reading the 16 error codes requires to execute two commands. On clicking of ‘ READ DTCs ’, user has to first select ‘ First 8 DTCs ’ and then ‘Second 8 DTCs ‘ from the popup menu. After this Error codes will displayed in the list. If errors are not there then ‘ No Errors Present ‘ message will be displayed. If errors are present it will be displayed in the data display. Just double click on any one of the error codes , if remark or the action is there it will automatically pop-up . e.g. The Errors will be displayed as 0240:- ERR_WLAMP_LEAK_GND 1242:- ERR_BATTERY_VOLTAGE 0DCB:- ERR_CAP_NOT_CHARGED(1) 0DC1:- ERR_CHARGE_SEQUENCE

This service is used to write Vehicle Identification Number (VIN) . Enter the VIN number in the text window. This has to be entered as per the Car Manufacturer. The maximum length of VIN number is 19. If length of VIN number is less then 19 then number will be stored with succeeding zeros. After clicking the button a small screen will appear in the data display area , enter the VIN number and then Click ok .

MAT6042213PR12345

Fig 11. After the VIN number is entered the data display area displays:-

f] CLEAR DTCs : This service is used to clear faults from the error buffer in ACU-3. If the errors are physically cleared then the tester will give the following message in the status display:ERRORS ARE CLEARED FROM THE ECU AND THE ASSEMBLY But error codes will be recorded again if they are not physically cleared.

VIN No. ENTERED MAT6042213PR12345

IN

THE

ECU:-

Note : Do not enter special characters like “ # “, “,”,” * “ etc. If VIN No is “MAT6042213PR12345” Then stored number will be MAT6042213PR123450 h] READ VIN: This service is used to read the VIN number from the ECU. The ECU is capable to store 19 bytes of data in its memory. If length of VIN number is less then 19 then number will be stored with succeeding zeros. The command displays the following response in the data display area:VIN No. IN THE ECU:- MAT6042213PR123450 DIAGNOSTICS

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9

DIAGNOSTICS AIRBAG i] WRITE DATE DATA: This function allow the user to write the following dates : 1) The Date of manufacture of the vehicle 2) The Date of the last service i.e. Repair Date On clicking this , the user has to select either ‘MFG. Date’ or ‘Repair Date’ from the popup menu. MFG Date : Enters today’s date in the ECU as the manufacturing Date . REPAIR Date : Select the date from the date picker which appears at the bottom . Enter this date if required for future reference. e.g. The Data display area displays as MFGDATE DATA ENTERED IN THE ECU = 26/02/2002 j] IGNITION LOCK : This service is used to lock and unlock the ignition system. This command prohibits any possibility of ignition of the squibs which allows the secure handling of the module and vehicle without any risk of inadvertent airbag inflating. After clicking this , user has to select ‘LOCK IGN’ or ‘UNLOCK IGN’ from popup menu. LOCK IGN : Locks the ignition if required. This function may not be always useful. Since the ECU comes in Locked condition UNLOCK IGN : Unlocks the Ignition . This is mandatory , if the ECU comes in locked condition to the plant . e.g. If the ignition is unlocked the data display area displays following Firing of the squibs is UNLOCKED Note : The Airbag ECU comes in Locked condition from the manufacturer. This will prevent the squibs from firing during the assembly. This unit has to be unlocked after the assembly is complete. DIAGNOSTICS

10

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DIAGNOSTICS AIRBAG 5. Maintenance : A. Troubleshooting Problem ECU communication error

Software Not Working

Cause

Remedy

1) LEDs status On the Silicon Engines interface unit.

- Check the OBD cable connection with Diagnostic Connector of wiring harness. - Check the OBD cable connection with Multi protocol Interface module. - Check the ‘DSR’ and ‘DTR’ LEDs on Silicon Engines module. If both are red re-initialise the unit.

2) Com port connection

- Check the com settings. - Connect RS232 cable to COM Port.

Corrupt version of software

Reinstall the software.

For software support or assistance please visit the following website : http://ed.tatamotors.com

DIAGNOSTICS

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11

AIRBAG FAULTCODE & REPAIR GUIDELINE 6. FAULTCODE AND REPAIR GUIDELINES : DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN

ERR_LEAK_PLUS_ SQUIB (1)

Co-driver pre tensioner line shorted to +ve supply. Firing of pre-tensioner inhibited.

Co-driver Pretensioner line shorted supply line

Check the wiring harness for damage. Replace if necessary.

ERR_LEAK_PLUS_ SQUIB (2)

Driver Pretensioner line shorted Driver Pretensioner line to +ve supply. Firing of shorted supply line. Pretensioner inhibited.

Check the wiring harness for damage. Replace if necessary.

ERR_LEAK_PLUS_ SQUIB (3)

Driver airbag line shorted to +ve Driver airbag line shorted supply. Firing of airbag inhibited. supply line.

Check the wiring harness & Clockspring for damage. Replace if necessary.

ERR_LEAK_PLUS_ SQUIB (4)

Co-driver airbag line shorted to +ve supply. Firing of airbag inhibited.

Passenger airbag line shorted supply line.

Check the wiring harness for damage. Replace if necessary.

ERR_LEAK_PLUS_ SQUIB (9)

RH side airbag line shorted to +ve supply. Firing of airbag inhibited.

RH Side airbag line shorted Check the wiring supply line. harness for damage. Replace if necessary.

ERR_LEAK_PLUS_ SQUIB (12)

LH side airbag line shorted to +ve supply. Firing of airbag inhibited.

LH Side airbag line shorted supply line.

ERR_LEAK_GND_ SQUIB (1)

Co-driver pre tensioner line shorted to GND supply. Firing of pre-tensioner inhibited.

Co-driver pre-tensioner line Check the wiring shorted to Vehicle Ground. harness for damage. Replace if necessary.

ERR_LEAK_GND_ SQUIB (2)

Driver pre tensioner line shorted Driver pre-tensioner line to GND supply. Firing of shorted to Vehicle Ground. pre-tensioner inhibited.

ERR_LEAK_GND_ SQUIB (3)

Driver line shorted to GND. Firing of airbag inhibited.

Driver airbag line shorted to Check the wiring Vehicle Ground. harness & Clockspring for damage. Replace if necessary.

ERR_LEAK_GND_ SQUIB (4)

Co-driver line shorted to GND. Firing of airbag inhibited.

Passenger airbag line shorted to Vehicle Ground.

FAULT CODES

Check the wiring harness for damage. Replace if necessary.

Check the wiring harness for damage. Replace if necessary.

Check the wiring harness for damage. Replace if necessary.

DIAGNOSTICS

12

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AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN

ERR_LEAK_GND_ SQUIB (9)

RH side airbag line shorted to GND. Firing of airbag inhibited.

RH Side airbag line shorted Check the wiring to Vehicle Ground. harness for damage. Replace if necessary.

ERR_LEAK_PLUS_ SQUIB (12)

LH side airbag line shorted to GND. Firing of airbag inhibited.

LH Side airbag line shorted Check the wiring to Vehicle Ground. harness for damage. Replace if necessary.

ERR_HIGH_RES_ SQUIB (1)

The resistance in the Co-driver Pretensioner is higher than the specified limit.

Co-driver Pretensioner not Check connections connected or connection and wiring harness for loose or line open. damages. If problem persists try replacing wiring harness or Pretensioner.

ERR_HIGH_RES_ SQUIB (2)

The resistance in the Driver Pretensioner is higher than the specified limit.

Driver Pretensioner not connected or connection loose or line open.

ERR_HIGH_RES_ SQUIB (3)

The resistance in the Driver airbag line is higher than the specified limit.

Driver airbag not connected Check connections or connection loose or line and wiring harness for open. damages. If problem persists try replacing wiring harness or airbag.

Check connections and wiring harness for damages. If problem persists try replacing wiring harness or Pretensioner.

ERR_HIGH_RES_ SQUIB (4)

The resistance in the co-driver airbag line is higher than the specified limit.

Passenger airbag not connected or connection loose or line open.

Check connections and wiring harness for damages. If problem persists try replacing wiring harness or airbag.

ERR_HIGH_RES_ SQUIB (9)

The resistance in the RH side airbag line is higher than the specified limit.

RH side airbag not Check connections connected or side airbag and wiring harness for pigtail not connected to the damages. If problem airbag wiring harness or persists try replacing connection loose the airbag or wiring harness.

DIAGNOSTICS

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13

AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN

ERR_HIGH_RES_ SQUIB (12)

The resistance in the LH side airbag line is higher than the specified limit. LH side airbag not connected or side airbag pigtail not connected to the airbag wiring harness or connection loose.

LH side airbag not connected Check connections or side airbag pigtail not and wiring harness for connected to the airbag damages. If problem wiring harness or connection persists try replacing loose. the airbag or wiring harness.

ERR_LOW_RES_ SQUIB (1)

Low resistance in the Co-driver Pretensioner line.

Shorting in the wiring harness. Internal error in Pretensioner.

Check the wiring harness for shorting and replace if necessay. If problem persists, replace wiring harness or Pretensioner.

ERR_LOW_RES_ SQUIB (2)

Low resistance in the driver Pretensioner line.

Shorting in the wiring harness. Internal error in Pretensioner.

Check the wiring harness for shorting and replace if necessay. If problem persists, replace wiring harness or Pretensioner.

ERR_LOW_RES_ SQUIB (3)

Low resistance in the driver airbag line.

Shorting in the wiring harness. Internal error in Pretensioner.

Check the wiring harness for shorting and replace if necessay. If problem persists, replace wiring harness or airbag.

ERR_LOW_RES_ SQUIB (4)

Low resistance in the co-driver airbag line.

Shorting in the wiring harness. Internal error in airbag line.

Check the wiring harness for shorting and replace if necessay. If problem persists, replace wiring harness or airbag.

ERR_LOW_RES_ SQUIB (9)

Low resistance in the RH side airbag line.

Shorting in the wiring harness. Internal error in side airbag line.

Check the wiring harness for shorting and replace if necessay. If problem

DIAGNOSTICS

14

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AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN persists, replace wiring harness or side airbag.

ERR_LOW_RES_ SQUIB (12)

Low resistance in the LH side airbag line.

Shorting in the wiring harness. Internal error in side airbag line.

Check the wiring harness for shorting and replace if necessay. If problem persists, replace wiring harness or side airbag.

ERR_CAP_NOT_ CHARGED (1)

ECU internal capacitor not charged.

Malfunction of the internal ECU power circuit.

Check the battery voltage to the ECU. If the problem persists change the ECU.

Malfunction of the internal ECU power circuit.

Check the battery voltage to the ECU. If the problem persists change the ECU.

ERR_CAPACIATANCE ECU internal capacitor error. _CAP(1)

ERR_BATTERY_ VOLTAGE

Vehicle battery voltage too high Battery overcharged or or too low. undercharged. Leakage of battery voltage.

Check the vehicle battery voltage. Acceptable voltage range- 10.5 to 16 Volts.

ERR_CHILDSEAT_OC

Error in resistance of PAB inhibition switch.

Check the PAB inhibition connections. Check resistance of Inhibition switch as per drawing. Replace if necessary.

Passenger airbag inhibition switch not connected or resistance values not in drawing limits.

ERR_WLAMP_LEAK_ Warning lamp voltage not OK. VBAT

Warning lamp not connected Check the warning or the lamp has fused. lamp and its proper connection. Replace the lamp if necessary.

ERR_BLAMP_LEAK_ VBAT

LED not connected or the lamp has fused.

PAB inhibition LED voltage not OK.

Check the PAB inhibition LED and it’s connection. Replace the wiring harness or DIAGNOSTICS

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15

AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN Inhibition switch if necessary.

ERR_WLAMP_LEAK_ SRS lamp on instrument cluster Shorting in the wiring GND shorted to Vehicle Ground. harness or in the cluster.

Check wiring harness for shorting and replace if necessary.

ERR_BLAMP_LEAK_ GND

PAB inhibition LED shorted to Vehicle Ground.

Check wiring harness for shorting and replace if necessary.

ERR_LOWER_ TRANSISTOR(1)

Fault in the Co-driver Internal fault in ECU. Pretensioner firing circuit in the ECU. Firing of the Pretensioner inhibited.

Replace the ECU

ERR_LOWER_ TRANSISTOR(2)

Fault in the driver Pretensioner firing circuit in the ECU. Firing of the Pretensioner inhibited.

Internal fault in ECU.

Replace the ECU

ERR_LOWER_ TRANSISTOR(3)

Fault in the driver airbag firing Internal fault in ECU. circuit in the ECU. Firing of the airbag inhibited.

Replace the ECU

ERR_LOWER_ TRANSISTOR(4)

Fault in the co-driver airbag firing circuit in the ECU. Firing of the airbag inhibited.

Internal fault in ECU.

Replace the ECU

ERR_LOWER_ TRANSISTOR(12)

Fault in the LH side airbag firing circuit in the ECU. Firing of the side airbag inhibited.

Internal fault in ECU.

Replace the ECU

ERR_LOWER_ TRANSISTOR(9)

Fault in the RH side airbag firing circuit in the ECU. Firing of the side airbag inhibited.

Internal fault in ECU.

Replace the ECU

ERR_UPPER_ TRANSISTOR(1)

Fault in the Co-driver Internal fault in ECU. Pretensioner firing circuit in the ECU. Firing of the Pretensioner inhibited.

Replace the ECU

ERR_UPPER_ TRANSISTOR(2)

Fault in the driver Pretensioner firing circuit in the ECU. Firing of the Pretensioner inhibited.

Replace the ECU

Shorting in the wiring harness or in the Inhibit switch.

Internal fault in ECU.

DIAGNOSTICS

16

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AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN

ERR_UPPER_ TRANSISTOR(3)

Fault in the driver airbag firing circuit in the ECU. Firing of the airbag inhibited.

Internal fault in ECU.

Replace the ECU

ERR_UPPER_ TRANSISTOR(4)

Fault in the co-driver airbag firing circuit in the ECU. Firing of the airbag inhibited.

Internal fault in ECU.

Replace the ECU

ERR_UPPER_ TRANSISTOR(12)

Fault in the LH side airbag firing Internal fault in ECU. circuit in the ECU. Firing of the side airbag inhibited.

Replace the ECU

ERR_UPPER_ TRANSISTOR(9)

Fault in the RH side airbag firing Internal fault in ECU. circuit in the ECU. Firing of the side airbag inhibited.

Replace the ECU

ERR_RAM_ERROR

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_CPU_ BEHAVIOUR

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_EEPROM_NOT_ ECU Malfunction PROG

Internal fault in ECU.

Replace the ECU

ERR_EEPROM_OUT_ ECU Malfunction OF_ORDER

Internal fault in ECU.

Replace the ECU

ERR_CALIBRATION_ EEPROM

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_COMPENSATION ECU Malfunction _OFFSET

Internal fault in ECU.

Replace the ECU

ERR_EXTERNAL_ WATCHDOG

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_INTERNAL_ WATCHDOG

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_AD_ CONVERTER

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_ENABLE_LOW_ AT_STARTUP

ECU Malfunction

Internal fault in ECU.

Replace the ECU

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17

AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN

ERR_CRASH_ CONFIRMATION

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_CHARGE_ SEQUENCE

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_ACCEL_X_ ERROR

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_ACCEL_Y_ ERROR

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_SAFING_X_ ERROR

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_CRSH_SPY_ DATA

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_ACCELERO_ SATURATION

ECU Malfunction

Internal fault in ECU.

Replace the ECU

ERR_NO_COMM_ DRV_SAT

LH side Remote sensing unit connection open

Fault in wiring harness.

Check the wiring harness connections for damage. Replace the wiring harness if problem persists.

ERR_NO_COMM_ PSNG_SAT

RH side remote sensing unit connection open.

Fault in wiring harness.

Check the wiring harness connections for damage. Replace the wiring harness if problem persists.

ERR_DRV_SAT

RH Remote sensing unit malfunction.

Internal Fault in Remote sensing.

Replace the RSU

ERR_PSNG_SAT

LH Remote sensing unit malfunction.

Internal Fault in Remote sensing.

Replace the RSU

Internal Fault in Remote sensing.

Check the battery supply. If problem persists try replacing the ECU or RSU.

ERR_DRV_SAT_VOLT Insufficient supply to driver Remote sensing unit.

DIAGNOSTICS

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AIRBAG FAULTCODE & REPAIR GUIDELINE

FAULT CODES

DESCRIPTION

POSSIBLE CAUSE

ACTION TO BE TAKEN

ERR_PSNG_SAT_ VOLT

Insufficient supply to Co-Driver Remote sensing unit.

Internal Fault in Remote sensing.

Check the battery supply. If problem persists try replacing the ECU or RSU

ERR_RSU_ SATURATION

Malfunction of the remote control unit.

Internal Fault in Remote sensing.

Replace the RSU

DIAGNOSTICS

INDEX

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19

DIAGNOSTICS ABS

CONTENTS : 1) General A) Salient Features

2

2) Detailed Description A) Electrical

3

3) Specification A) Laptop/Desktop B) Vehicle Interface Unit

3

4) Installation and Operating Procedure A) Installation B) Operating Procedure

4

5) Maintenance A) Trouble shooting

8

6) ABS Fault Code List

9

7) ABS Repair Guidelines

26

DIAGNOSTICS

1

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DIAGNOSTICS ABS 1.

GENERAL :

The ABS Diagnostic tester is developed for field Diagnostics Antiskid braking system. The ABS system is from M/s Bosch . The Diagnostic tester ensures the error free operation of the system. The tester can clear the errors stored in the ECU memory. To check the proper operation of ABS components, the tester supports actuation of the different valves and pump motor .

A.

SALIENT FEATURES

The Diagnostic tester for ABS ECU module has a capability to communicate with the ECU on a serial K-line interface . The Tester comprises a vehicle interface unit and custom built GUI (graphical user interface) . The system software is a user friendly.The user can load it on laptop/Desktop. The vehicle interface unit is light weight and compact in size to facilitate easy portability. This works on vehicle battery supply. This tester will execute all the commands supported by ECU , which help in diagnostic of the ABS system. This diagnostic unit is capable of performing the following functions : 1)

DIAGNOSTICS

Read Complete ECU Status •

No of DTC’s

•

Valve Relay

•

Motor Relay

•

Wheel Speed

•

Warning Lamp

•

Brake Light Switch

•

Valve Status

2)

Read DTCs i.e. Error Codes

3)

Clear DTCs

4)

Actuate Components Like (Motor, Inlet Valves front & Rear , Outlet Valves front & Rear)

2

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DIAGNOSTICS ABS 2.

DETAILED DESCRIPTION : A.

Electrical Required power supply : Power supply for the Laptop/Desktop.The Vehicle Interface Unit does not require any external power supply . It works on vehicle battery, provided through the OBD cable .

PC/Laptop (with software)

Serial cable

RS232 COM Port

Vehicle Interface Unit

Connect the RS232 cable to the Laptop/ Desktop COM port

OBD Cable

To vehicle wiring Harness

The OBD cable is connected to the Diagnostic connector of the wiring harness.Fig. 2, 3 & Fig. 6.

Fig 1.

3.

SPECIFICATION : A.

Laptop / PC (Fig. 4) Operating system

:

WIN 98/ WIN 2000 /WIN XP or later version

CPU Speed

:

933 Mhz or greater

RAM

:

128 MB

Video Display

:

800 x 600 resolution with 24 bit colour

RS232 port

:

Minimum 1No. CD ROM Drive Printer Port (optional)

Fig 2. Diagnostic connector under co-driver seat

The software works with the above features of a Desktop/ Laptop . Any other combination of speed and RAM less then specified will slow down the response of the software.

B.

Vehicle Interface Unit (Fig. 5) Interface unit from M/s Silicon Engines, USA OBD cable RS232 cable DIAGNOSTICS

Fig 3. Diagnostic connector cap removed 3

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DIAGNOSTICS ABS Diagnostic Equipment Components :

Fig 4. Laptop

Fig 5. Interface Unit

DIAGNOSTICS

Fig 6. OBD cable connected to diagnostic

connector

4

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DIAGNOSTICS ABS 4.

Installation and Operating Procedure: A. Installation of Software The Installation CD of the software is supplied with the kit . Follow the following steps to install the software: Installation Procedure:1) Insert the CD in the CD Rom . 2) Set-up will start running automatically . 3) After this the program will guide you for further installation. 4) After successful installation, a short-cut to program will appear on desk-top. 5) This program will be loaded in following directory ‘C:/Program files/TATA MOTORS’ 6) When user clicks the short-cut, screen will appear as shown in Fig.7

Fig 7.

MID and Site code values in Fig.7 are for example. These values are machine dependent. These values will be different for every machine.The Application status will be‘LOCKED’,for unlocking the program user has to send MID and Site code by Email on following E-mail ID - [email protected] 7) After this we will send you Init code on mail. Please enter that code in Init code box. 8) Then Application status will change to ‘LICENSED’ .Click continue to start the application. 9) Now your application is unlocked.

Fig 8.

B. Operating Procedure i.

Main Menu : This is the main form for the application All the functions catering to the Diagnostic of the ECU can be performed through the tester. To perform any function press the respective button.This also gives context sensitive help for the system. Just Press ‘F1’ on any button, the help for the particular button will be displayed .

To start the communication between the ECU and the Tester press the “START” button. This initialises the ECU communication and enables the other commands.

DIAGNOSTICS

5

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DIAGNOSTICS ABS

Fig 9. The Following operations can be performed with the help of these commands

•

No Of DTC’s Gives the number of Diagnostic trouble codes

a]

Read ECU status

•

Relay status gives the relay status of the Relay

b]

Actuate the components

•

c]

Read the Diagnostic Trouble Codes (DTC’s)

Motor Status gives state of the Pump motor. In default condition Pump Motor should be ‘OFF’ .

d]

Clear the Diagnostic Trouble Codes (DTC’s)

•

a]

On clicking the ‘Read ECU status’ the frame as shown in Fig. 9 is displayed.

Valve status give the condition of the valves, normally the Inlet valves are ‘ON’ and Outlet valves are ‘ OFF’

•

After applying the Brake , and clicking the ‘Brake light SW’ , the Status bar Display’s ‘BRAKE SWITCH ON’

•

After clicking the ‘WHEEL SPEED’ button, the following frame appears which shows the wheel speed data .This is the real time data for the wheels .

Fig 10.

DIAGNOSTICS

6

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DIAGNOSTICS ABS b. Actuate the components : After clicking ‘ ACTUATE COMPONENTS following frame will appear . User can actuate Pump Motor , All Inlet & Outlet valves by using this . e.g . Click on the ‘MOTOR’to actuate the motor. After clicking the status bar will display “ Actuation in process , please wait….. . ” After actuation it displays the motor actuation status. If it was actuated it gives ‘ MOTOR ACTUATED ’

Fig 11.

If the motor is not actuated it displays ‘MOTOR NOT ACTUATED ’

c. Read DTCs : Click this to read Errors in the ABS system. If Errors are stored in the ECU memory they are displayed in the frame shown in Fig.12 Status bar displays “ ERRORS ARE DISPLAYED IN THE LIST ”

d. Clear DTCs : This function clears the errors from the ECU memory . After clearing the errors tester reads the errors again & then displays the error status. If there are errors in the system then Status bar displays “ THERE ARE ERRORS IN THE SYSTEM PLEASE CLEAR THEM PHYSICALLY “ If there are no errors in the system then Status bar displays “ THERE ARE NO FAULTS IN THE SYSTEM “

Fig 12. DIAGNOSTICS

7

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DIAGNOSTICS ABS 5.

Maintenance : a.

Troubleshooting Problem

ECU communication error

Cause 1) LEDs status On the Silicon Engines interface unit.

Remedy - Check the OBD cable connection with Diagnostic Connector of wiring harness. - Check the OBD cable connection with Multi protocol Interface module. - Check the ‘DSR’ and ‘DTR’ LEDs on Silicon Engines module. If both are red re-initialise the unit.

2) Com port connection

- Check the com settings. - Connect RS232 cable to COM Port. - If Laptop dosen’t support COM Port, change com port settings from the file Conf.ini located in the directory C:\program file\TATA MOTORS

Software Not Working

Corrupt version of software

Reinstall the software.

For software support or assistance please visit the following website : http://ed.tatamotors.com

DIAGNOSTICS

8

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ABS FAULTCODE LIST Faultcode List Table of Contents: Fault path RepairFaultGuideline No. code Code (DTC) List of Diagnostic Trouble DTC

Fault detection by

Remarks

Fault path:

page

C1101

Battery voltage over volt (>16V)...................................................................... .................................. 9

C1102

Battery voltage low volt (<8V).......................................................................... .................................. 9

C1161

Brake light Switch ........................................................................................................................................ 10

C1604

Hardware ........................................................................................................................................................ 11

C2114

Disturbance(Including Valve failures). ................................................................................................. 12

C2402

Electrical (Pump motor) ............................................................................................................................. 13

C1203

FR Wheel sensor: Line fault ...................................................................................................................... 14

C1200

FL Wheel sensor: Line fault ....................................................................................................................... 15

C1209

RR Wheel sensor: Line fault ...................................................................................................................... 16

C1206

RL Wheel sensor: Line fault ....................................................................................................................... 17

C1245

Wheel-speed frequency error. ................................................................................................................. 18

C1204

FR Wheel sensor Range/Performance: Plausibility fault .................................................................. 19

C1201

FL Wheel sensor Range/Performance: Plausibility fault ................................................................. 20

C1210

RR Wheel sensor Range/Performance: Plausibility fault ................................................................. 21

C1207

RL Wheel sensor Range/Performance: Plausibility fault .................................................................. 22

C2112

Main Relay, fuse ............................................................................................................................................ 23

C1274

G Sensor Signal ............................................................................................................................................. 24

C1275

G Sensor Range/Performance Plausibility fault .................................................................................. 24

DIAGNOSTICS

9

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

C1101

Battery vltg. Over volt (>16V)

1

C1102 Low volt (<8V)

Fault detection by

Remarks

• Monitoring is activated after running of cut-in test and when the vehicle has exceeded 6km/h. The battery voltage is measured continously and cyclically assessed.

• If battery voltage is below 8.2V when ABS regulation is active (brake operation and ABS control as well as pressure increase with a vehicle dynamic regulation occur.) • If battery voltage is not in range of minimum 9.4V and maximum 17.4V when ABS regulation is inactive (brake, operation and ABS control as well as pressure increase with vehicle dynamic regulation does not occur). Effects: • Correct function of ABS solenoid valves & of return pump motor is no longer guaranteed. • ABS is passive during the time span but not switched off. • ABS warning lamps are switched on. • EBD is switched off at below 6.9V. Note: The solenoid valves are switched to passive during under or over voltage, a possible return flow of the return pump is suppressed during the time span.

DIAGNOSTICS

10

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

Fault detection by

Remarks

C1161

Brake light Switch

2

• With ignition ON (after running of cut-in test) an open circuit detects an intermediate level on the BLS line. • An open circuit is detected when voltage at brake light switch is in the range of 55 to 75% of battery voltage. • If voltage at brake light switch is above 75% of battery voltage for more than 60 seconds while accelerator pedal is actuated, the vehicle speed is above 3 m per second, the pressure in the hydraulic unit is below 10 bar and is not in ABS regulation. Effects: • ABS and EBD functions are not switched off.

DIAGNOSTICS

11

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

Fault detection by

C1604

Hardware (ECU)

3

• ABS module internal failure, e.g. RAM, ROM etc.

Remarks

Effects: • ABS and EBD are switched off. • ABS and EBD warning lamps are switched on.

DIAGNOSTICS

12

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

Fault detection by

Remarks

C2114

Disturbance (Including Valve failures)

4

• A permanent or short term break, earth or open circuit between the solenoid valve of the affected brake circuit and the control unit is recognised directly after ignition ON. • A shorted coil of solenoid valve or contact with other solenoid valve lines during start of journey is recognised at approx. 12 km/h. • A fault within the solenoid path in the control unit during the entire operation.

Effects: • Solenoid relay has failed! No solenoid valve actuation possible. • ABS and EBD are switched off. • ABS and EBD warning lamps are switched on.

Note: EBD function immediately switches off on failure of solenoid relay.

DIAGNOSTICS

13

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

Fault detection by

C2402

Electrical (Pump Motor)

5

• Return pump motor still not running 80ms after driving pump motor relay via control unit.

Remarks

• Return pump motor does not start. Not even if actuated again after 700ms and this is repeated again 3 times. • Return pump motor runs for more than 2.5 seconds, without the pump motor relay being actuated by control unit. • On return of actuation response is below 80 to 140ms (depended on supply voltage).

Effects: • ABS and EBD* are switched off. • ABS warning lamps are switched on. * EBD function at least after start of journey and exceeding 12 km/h.

DIAGNOSTICS

14

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

C1203

FR Wheel Sensor:

6

Line fault

Fault detection by

Remarks

• A direct current is injected in the wheel-speed sensor by a power source in the input amplifier of the control unit. If the WSS circuit is broken, the input of the amplifier recognise a potential shift caused by the injected current and a fault is detected.

Effects: • Control of the corresponding wheel is no longer possible. • If a sensor fault occurs on a front wheel, pressure is increased; on a rear wheel pressure is decreased (until switch off).

DIAGNOSTICS

15

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

C1200

FL Wheel Sensor: Line fault

7

Fault detection by

Remarks

• A direct current is injected in the wheel-speed sensor by a power source in the input amplifier of the control unit. If the WSS circuit is broken, the input of the amplifier recognise a potential shift caused by the injected current and a fault is detected.

Effects: • Control of the corresponding wheel is no longer possible. • If a sensor fault occurs on a front wheel, pressure is increased; on a rear wheel pressure is decreased (until switch off ).

DIAGNOSTICS

16

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

C1209 RR Wheel Sensor: Line fault

RepairGuideline No.

8

Fault detection by

Remarks

• A direct current is injected in the wheel-speed sensor by a power source in the input amplifier of the control unit. If the WSS circuit is broken, the input of the amplifier recognise a potential shift caused by the injected current and a fault is detected.

Effects: • Control of the corresponding wheel is no longer possible. • If a sensor fault occurs on a front wheel, pressure is increased; on a rear wheel pressure is decreased (until switch off).

DIAGNOSTICS

17

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

C1206

RL Wheel Sensor: Line fault

9

Fault detection by

Remarks

• A direct current is injected in the wheel-speed sensor by a power source in the input amplifier of the control unit. If the WSS circuit is broken, the input of the amplifier recognise a potential shift caused by the injected current and a fault is detected.

Effects: • Control of the corresponding wheel is no longer possible. • If a sensor fault occurs on a front wheel, pressure is increased; on a rear wheel pressure is decreased (until switch off ).

DIAGNOSTICS

18

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ABS FAULTCODE LIST Faultcode List Faultcode

C1245

Fault path

Wheel Speed frequency error

RepairGuideline No.

Fault detection by

Remarks

10

• If the vehicle reference speed is above 12 km/h after initial movement of the vehicle, the speed of the affected wheel remains at 2 km/h. • If no speed is detected on the affected wheel within 20ms at a vehicle speed above 40km/h.

Effects: • ABS and EBD are switched off • ABS warning lamps are switched on Note: With fault recognition on one of the front wheels,pressure is increased, on the rear axle decreased (until switching off ). With fault recogniton on a wheel that is in ABS regulation or with an under corrected intervention, switch off will occur at the end of regulation. With simultaneous fault recognition on a number of wheels, ABS will also only be switched off at the end of regulation. EBD remains switched on as long as it can generate wheel speeds as a signal value to the vehicle speed and wheel slip.

DIAGNOSTICS

19

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

Fault detection by

C1204

FR Wheel Sensor Range/ Performance Plausibility fault

11

• If the vehicle reference speed is above 12 km/h after initial movement of the vehicle, the speed of the affected wheel remains at 2 km/h.

Remarks

• If no speed is detected on the affected wheel within 20ms at a vehicle speed above 40km/h.

Effects: • ABS and EBD are switched off • ABS warning lamps are switched on Note: With fault recognition on one of the front wheels,pressure is increased, on the rear axle decreased (until switching off ). With fault recogniton on a wheel that is in ABS regulation or with an under corrected intervention, switch off will occur at the end of regulation. With simultaneous fault recognition on a number of wheels, ABS will also only be switched off at the end of regulation. EBD remains switched on as long as it can generate wheel speeds as a signal value to the vehicle speed and wheel slip.

DIAGNOSTICS

20

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

C1201 FL Wheel Sensor Range/ Performance Plausibility fault

RepairGuideline No.

Fault detection by

Remarks

12 • If the vehicle reference speed is above 12 km/h after initial movement of the vehicle, the speed of the affected wheel remains at 2 km/h. • If no speed is detected on the affected wheel within 20ms at a vehicle speed above 40km/h.

Effects: • ABS and EBD are switched off • ABS warning lamps are switched on Note: With fault recognition on one of the front wheels,pressure is increased, on the rear axle decreased (until switching off ). With fault recogniton on a wheel that is in ABS regulation or with an under corrected intervention, switch off will occur at the end of regulation. With simultaneous fault recognition on a number of wheels, ABS will also only be switched off at the end of regulation. EBD remains switched on as long as it can generate wheel speeds as a signal value to the vehicle speed and wheel slip.

DIAGNOSTICS

21

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

C1210

RR Wheel Sensor Range/ Performance Plausibility fault

RepairGuideline No.

13

Fault detection by

Remarks

• If the vehicle reference speed is above 12 km/h after initial movement of the vehicle, the speed of the affected wheel remains at 2 km/h. • If no speed is detected on the affected wheel within 20ms at a vehicle speed above 40km/h.

Effects: • ABS and EBD are switched off • ABS warning lamps are switched on Note: With fault recognition on one of the front wheels,pressure is increased, on the rear axle decreased (until switching off ). With fault recogniton on a wheel that is in ABS regulation or with an under corrected intervention, switch off will occur at the end of regulation. With simultaneous fault recognition on a number of wheels, ABS will also only be switched off at the end of regulation. EBD remains switched on as long as it can generate wheel speeds as a signal value to the vehicle speed and wheel slip.

DIAGNOSTICS

22

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

C1207

RL Wheel Sensor Range/ Performance Plausibility fault

RepairGuideline No.

Fault detection by

Remarks

14 • If the vehicle reference speed is above 12 km/h after initial movement of the vehicle, the speed of the affected wheel remains at 2 km/h. • If no speed is detected on the affected wheel within 20ms at a vehicle speed above 40km/h.

Effects: • ABS and EBD are switched off • ABS warning lamps are switched on Note: With fault recognition on one of the front wheels,pressure is increased, on the rear axle decreased (until switching off ). With fault recogniton on a wheel that is in ABS regulation or with an under corrected intervention, switch off will occur at the end of regulation. With simultaneous fault recognition on a number of wheels, ABS will also only be switched off at the end of regulation. EBD remains switched on as long as it can generate wheel speeds as a signal value to the vehicle speed and wheel slip.

DIAGNOSTICS

23

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

RepairGuideline No.

C2112

Main Relay, fuse

15

Fault detection by

Remarks

• Valve relay switches off due to detected under voltage on contact of valve relay to power supply of solenoid valves. • Valve relay supplies no power response larger than 9.4V to control unit of UVR while activating 3 times. • Power response of valve relay detected relay decrease. Effects: • Solenoid relay has failed! No solenoid valve actuation possible. • ABS and EBD are switched off. • ABS warning lamps are switched on.

DIAGNOSTICS

24

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ABS FAULTCODE LIST Faultcode List Faultcode

Fault path

C1274 G Sensor Signal Signal failure C1275

G Sensor Plausibility fault

RepairGuideline No.

16

Fault detection by

Remarks

Monitoring for open circuit • Monitoring includes line short to ground, line short to supply voltage and mutual line short. Monitoring of lateral accelerator offset when standing • When standing over a longer period and without driving, an AY offset value appears which exceeds > 7 m/sec2. Monitoring of lateral acclerator offset while driving • During normal driving over a longer period while driving straight an AY offset appears which exceeds 2.25 m/s2. Monitoring of acceleration range • The lateral accelerator signal is outside permissible range and exceeds 15 m/s2 for more than 800 ms. Effects: • ABS and EBD are not switched off.

DIAGNOSTICS

25

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ABS REPAIR GUIDELINES TableRepair of Contents: Guideline Work Instructions No. Tester-Display List of Diagnostic Trouble Code (DTC) Guideline No.

DTC

Set Value

Fault Codes

Connection

Fault path:

Page

1

C1101

Battery voltage over volt (>16V) .................................................................................... 26

1

C1102

Battery voltage low volt (<8V) ........................................................................................ 26

2

C1161

Brake like switch .................................................................................................................. 27

3

C1604

Hardware (ECU) .................................................................................................................... 28

4

C2114

Disturbance (Including Valve failures) .......................................................................... 29

5

C2402

Electrical (Pump motor) .................................................................................................... 30

6

C1203

FR Wheel Sensor: Line fault .............................................................................................. 31

7

C1200

FL Wheel Sensor: Line fault .............................................................................................. 33

8

C1209

RR Wheel Sensor: Line fault ............................................................................................. 35

9

C1206

RL Wheel Sensor: Line fault .............................................................................................. 37

10

C1245

Wheel speed frequency error ......................................................................................... 39

C1204 C1201

FR Wheel Sensor Range/Performance: Plausibility fault ......................................... 40 Set Value : Causation : FL Wheel Sensor Range/Performance: Plausibility fault ......................................... 41

13

C1210

RR Wheel Sensor Range/Performance: Plausibility fault ........................................ 42

14

C1207

RL Wheel Sensor Range/Performance: Plausibility fault ........................................ 43

15

C2112

Main Relay, fuse .................................................................................................................. 44

16

C1274

G Sensor Signal, Signal failure ......................................................................................... 45

16

C1275

G Sensor Range/Performance Plausibility fault ......................................................... 45

11 Troubleshooting : 12

DIAGNOSTICS

26

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display 1

Battery voltage Over volt (>16V) Low volt (<8V)

Work Instructions Ignition on Vehicle standing

Set Value 9.4V - 16 V when pump motor running and

Set Value :

Troubleshooting : Ignition on Activate motor relay via diagnosis tester

Pump motor running and battery voltage minimum 9.4 V

as above

Connection

C1101 C1102

UBatt (+) 18 (17) UBatt(-) 19 Term (Ignition) 15 against ground valves actuated (chassis)

Causation : •

Battery discharged; defective

•

Voltage regulator (electric system) defective Ground and contact resistance on fuses (20A, 40A), plug connections and chassis

•

Voltage measurement using multimeter • Switch voltmeter to DC voltage • Connect adapter or pin-out box between 26-pin plug connector • Voltage measurement between pin 18 (17)and pin 19 (ground ECU) • Voltage measurement between pin 15 (ignition) and ground (chassis) or pi 16

Fault Codes

as above

DIAGNOSTICS

27

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display 2

Brake light switch malfunction

Work Instructions

•

Brake actuated

Fault Codes C1161

Ignition on Brake not actuated

Switch inactive,0V

Brake actuated

Switch active,12V

Set Value :

Troubleshooting :

Ignition on • Brake not actuated

Set Value

• •

0V Brake lights must not illuminate

• 12V (UBatt) • Brake lights, left, middle and right illuminate

Connection BLS (pin14)

Causation :

• Positive short with line BLS 14 or with line switch “NC side”, or line to rear lights.

• • • • •

Fuse defective Open circuit in line between fuse and switch “connection side” Switch defective Open circuit in line between switch NC side and ECU pin BLS 14 Open circuit in line between switch NC side and brake lights

DIAGNOSTICS

28

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display 3

ECU is defective

Work Instructions Ignition ON,

• • •

Fault Codes

ECU w/o failure Vehicle standing.

Set Value :

Troubleshooting :

• •

Set Value

Connection

C1604

-

Causation :

•

ABS-/EBD and brake • ECU damage; ECU exchange. warning lamp illuminate

•

All warning lamps illuminate and switch off after a short time

Ignition OFF Disconnect 26-pin plug from ABS unit and remove assembly from vehicle. Install new ABS unit Connect 26-pin plug to ABS unit. Ignition ON and control the warning lamps.

DIAGNOSTICS

29

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

4

Disturbance (Including Valve failures)

Work Instructions

Ignition on, Vehicle standing

Set Value

Fault Codes

All valves inactive

C2114

Connection

Refer to “Note”

Note: On ABS the control unit terminals for the solenoid valves are marked as not accessible in the current flow diagrams and also not accessible on the plug connector of the ABS unit. Testing of the solenoid valve internal resistance is therefore not possible. Reason: The connections, supply voltage to the solenoid valves as well as to the output stages are contained within the electronics unit.

Troubleshooting :

• • • • • •

Ignition OFF • Disconnect 26-pin plug from ABS unit and remove assembly from vehicle. Install new ABS unit. Connect 26-pin plug to ABS unit. Ignition ON Check the ABS version and control the warning lamps. •

Set Value :

ABS,- /EBD and Brake warning lamp illuminate

Causation :

• •

Inlet-,outlet- solenoid valve’s damage. ABS unit exchange.

All warning lamps illuminate and switch off after a short time

DIAGNOSTICS

30

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

5

Work Instructions

Electrical pump motor circuit failure

Ignition on

• Initiation fault

First, not during a regulation Second, actuated pump motor with diagnostictester.

•

Running-on fault

Set Value

Only running during a regulation

C2402

Ground pin 16

Positive pin 17 Motor relay, Inside ECU Pump motor pin 2

Set Value :

Troubleshooting :

Connection

Fault Codes

Causation :

• Ignition on • Is pump-motor running?

•

• Start pump motor with diagnostic tester. • End of running

• •

Pump motor is not actuated Pump motor is running Pump motor runs out with dischargespeed (not stopped directly)

•

Pump motor is defect

•

ECU defect

•

Elimination: Replace ABS unit completed

DIAGNOSTICS

31

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

6

FR Wheel Sensor: Line fault

Work Instructions

Ignition on With vehicle jacked up, slowly turn FR wheel by hand OR Drive vehicle (test bench)

Set Value

Fault Codes

Connection

no interrupted the speed wheel sensor

C1203

FR sensor (pin5) Ground FR(pin4)

more than 2 km/h

Important Notes : • Ignition OFF before the plug connector will dividedfrom the speed wheel sensor • Don’t exchange the connection- pins of the speed wheel sensor inside the 26pin connector.

Set Value :

Troubleshooting :

• Ignition on

•

• Ignition off • Disconnect the 26pin connector of the control-unit and the connector of the speed wheel sensor • Connect ohmmeter between plug K1 and terminals pin 5 and 4 • Check internal resistance from ECU (FR) to wheel speed connector (FR). • Move cable around by hand especially in area of wheelarch. Observe continous display of reading. • Connect ohmmeter between plug K1 wheel speed sensor terminals FR & to ground or positive.

ABS,EBD and brake warning lamps illuminate

Causation :

• •

Short circuit Speed Wheel Sensor control Unit Line rupture Sensor fault

Correct correlation lines WSS(FR) and Wire lines(FR) • Internal-resistance (1,00KOhm to

•

Exchange sensor lines

•

• Line no interrupt

•

Repair and exchange the wiring harness and connectors when possible 1,90Kohm) Exchange wheel speed sensor FR

•

•

Repair and exchange the wiring harness.

•

Greater 100 Kohms

•

DIAGNOSTICS

32

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

6

Work Instructions

Set Value

FR wheel sensor: Line fault

Fault Codes

Connection

C1203

Set Value :

Troubleshooting : (Continue)

Causation :

• Set voltmeter to AC voltage. • Connect voltmeter to control unit plug (connection: FR sensor wheel) • Turn FR wheel by hand at approx. 1 revolution per second.

• exceeding 120mV (AC voltage)

•

Open circuit in line betwwen control unit plug and wheel speed sensor FR

•

Air gap between sensor and impulse wheel too large.

DIAGNOSTICS

33

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

7

FL Wheel Sensor: Line fault

Work Instructions

Set Value

Fault Codes

Ignition on no interrupted the With vehicle jacked up, speed wheel slowly turn FL wheel by sensor lines (FL) hand OR Drive vehicle (test bench) more than 2 km/h

C1200

Connection

FL sensor (pin7) Ground FR(pin6)

Important Notes : • Ignition OFF before the plug connector will dividedfrom the speed wheel sensor • Don’t exchange the connection- pins of the speed wheel sensor inside the 26pin connector.

Set Value :

Troubleshooting : •

Ignition on

• •

Ignition off Disconnect the 26pin connector of the control-unit and the connector of the speed wheel sensor Connect ohmmeter between plug K1 • and terminals pin 7 and 6

•

•

•

Check internal resistance from ECU (FL) to wheel speed connector (FL)

•

Move cable around by hand • especially in area of wheelarch. Observe continous display of reading. Connect ohmmeter between plug K1 • wheel speed sensor terminals FL & to ground or positive.

•

•

ABS,EBD and brake warning lamps illuminate

Causation : • • •

Short circuit Speed Wheel Sensor control Unit Line rupture Sensor fault

Correct correlation lines WSS(FL) and Wire lines(FL) Internal-resistance (1,00KOhm to

•

Exchange sensor lines

•

Line no interrupt

•

Repair and exchange the wiring harness and connectors when possible 1,90Kohm) Exchange wheel speed sensor FL

Greater 100 Kohms

•

Repair and exchange the wiring harness.

DIAGNOSTICS

34

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

7

Work Instructions

Set Value

FL wheel sensor: Line fault

Fault Codes

Connection

C1200

Troubleshooting : (Continue)

Set Value :

Causation :

• Set voltmeter to AC voltage. • Connect voltmeter to control unit plug (connection: FL sensor wheel) • Turn FL wheel by hand at approx. 1 revolution per second.

• exceeding 120mV (AC voltage)

•

Open circuit in line betwwen control unit plug and wheel speed sensor FL

•

Air gap between sensor and impulse wheel too large.

DIAGNOSTICS

35

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

8

RR Wheel Sensor: Line fault

Work Instructions

Set Value

Ignition on no interrupted the With vehicle jacked up, speed wheel slowly turn RR wheel by sensor lines (RR) hand OR Drive vehicle (test bench) more than 2 km/h

Fault Codes

Connection

C1209

RR sensor (pin3) Ground FR(pin1)

Important Notes : • Ignition OFF before the plug connector will dividedfrom the speed wheel sensor • Don’t exchange the connection- pins of the speed wheel sensor inside the 26pin connector.

Set Value :

Troubleshooting : • Ignition on

•

• Ignition off • Disconnect the 26pin connector of the control-unit and the connector of the speed wheel sensor • Connect ohmmeter between plug K1 and terminals pin 3 and 1. • Check internal resistance from ECU (RR) to wheel speed connector (RR). • Move cable around by hand especially in area of wheelarch. Observe continous display of reading. • Connect ohmmeter between plug K1 wheel speed sensor terminals RR & to ground or positive.

ABS,EBD and brake warning lamps illuminate

Causation : • • •

Short circuit Speed Wheel Sensor control Unit Line rupture Sensor fault

• Correct correlation lines WSS(RR) and Wire lines(RR) • Internal-resistance (1,00KOhm to

•

Exchange sensor lines

•

•

Line no interrupt

•

Repair and exchange the wiring harness and connectors when possible 1,90Kohm) Exchange wheel speed sensor RR

•

Greater 100 Kohms

•

Repair and exchange the wiring harness.

DIAGNOSTICS

36

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

8

Work Instructions

Set Value

RR wheel sensor: Line fault

Fault Codes

Connection

C1209

Troubleshooting : (Continue)

Set Value :

Causation :

• Set voltmeter to AC voltage. • Connect voltmeter to control unit plug (connection: RR sensor wheel) • Turn RR wheel by hand at approx. 1 revolution per second.

•

exceeding 120mV (AC voltage)

•

Open circuit in line betwwen control unit plug and wheel speed sensor RR

•

Air gap between sensor and impulse wheel too large.

DIAGNOSTICS

37

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

9

RL Wheel Sensor: Line fault

Work Instructions

Set Value

Ignition on no interrupted the With vehicle jacked up, speed wheel slowly turn RL wheel by sensor lines (RL) hand OR Drive vehicle (test bench) more than 2 km/h

Fault Codes

Connection

C1206

RL sensor (pin9) Ground FR(pin8)

Important Notes : • Ignition OFF before the plug connector will dividedfrom the speed wheel sensor • Don’t exchange the connection- pins of the speed wheel sensor inside the 26pin connector.

Set Value :

Troubleshooting :

• Ignition on

•

• Ignition off • Disconnect the 26pin connector of the control-unit and the connector of the speed wheel sensor • Connect ohmmeter between plug K1 and terminals pin 7 and 6. • Check internal resistance from ECU (RL) to wheel speed connector (RL). • Move cable around by hand especially in area of wheelarch. Observe continous display of reading. • Connect ohmmeter between plug K1 wheel speed sensor terminals RL & to ground or positive.

ABS,EBD and brake warning lamps illuminate

•

Causation :

•

Short circuit Speed Wheel Sensor control Unit • Line rupture • Sensor fault

Correct correlation lines WSS(RL) and Wire lines(RL) • Internal-resistance (1,00KOhm to

•

Exchange sensor lines

•

•

Line no interrupt

•

Repair and exchange the wiring harness and connectors when possible 1,90Kohm) Exchange wheel speed sensor RL

•

Greater 100 Kohms

•

Repair and exchange the wiring harness.

DIAGNOSTICS

38

INDEX

GROUP INDEX

NEXT

PREVIOUS

ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

9

Work Instructions

Set Value

RL wheel sensor: Line fault

Fault Codes

Connection

C1206

Troubleshooting : (Continue)

Set Value :

Causation :

• Set voltmeter to AC voltage. • Connect voltmeter to control unit plug (connection: RL sensor wheel) • Turn RL wheel by hand at approx. 1 revolution per second.

• exceeding 120mV

• Open circuit in line betwwen control unit

(AC voltage)

plug and wheel speed sensor RL • Air gap between sensor and impulse wheel too large.

DIAGNOSTICS

39

INDEX

GROUP INDEX

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

Work Instructions

10

Ignition on

Wheel speed frequency error

Set Value

Fault Codes

Impulse wheel with 47 teeth

C1245

Connection

refer to teststep 6-9 and 11-14

Correction installation of the speed wheel sensor

Note : Speed sensors are fitted to all four wheels. The fitting conditions(air gap, position and location) can be taken from OEm documents. The terminal designations can be taken from test steps 6 to 9 and 11 to 14, repair guideline for wheel speeds.

Troubleshooting :

Set Value :

Causation :

Refer to rapir guideline, test step 6 to 9 and 11 to 14.

DIAGNOSTICS

40

INDEX

GROUP INDEX

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

11

FR Speed Sensor Range/Performance Plausibility fault

Work Instructions

Ignition on With vehicle jacked up, slowly turn FR wheel by hand OR drive vehicle

Set Value

Fault Codes

Connection

C1203

FR sensor(pin5) Ground FR(pin4)

more than 40 km/h (26 m/h) OR diagnostic-tester display approaching speedometer display

Important Notes: • Ignition OFF before the plug connector will divided from the wheel- speed sensor.

Set Value :

Troubleshooting :

• Couple the diagnostic tester, Ignition on

•

ABS and brake

• Read the DTC.

Causation :

•

•

• Check the wheel-speed and correlation of the wheel to the sensors

•

Wheel- speed by wheel FR

•

• Check wheel-speed signal of the correct min value

• Wheel- speed must be always existent.

•

Speed Wheel Sensor or lines interrupted warning lamp (temporary or static) illuminate Impulse Wheel fault Intermittent contact between wheelspeed sensor to cable harness(connector)

Air gap between sensor and impulse wheel. • Wheel speed more than 2 km/h(under test-bench wheel speed the same as the rollers)

DIAGNOSTICS

41

INDEX

NEXT

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

12

FL Speed Sensor Range/Performance Plausibility fault

Work Instructions

Set Value

Fault Codes

Connection

Ignition on With vehicle jacked up, slowly turn FL wheel by hand OR drive vehicle

more than 40 km/h (26 m/h)

C1201

FL sensor(pin7) Ground FL(pin6)

OR diagnostic-tester display approaching speedometer display

Important Notes: • Ignition OFF before the plug connector will divided from the wheel- speed sensor.

Set Value :

Troubleshooting :

• Couple the diagnostic tester, Ignition on

• Read the DTC. • Check the wheel-speed and correlation of the wheel to the sensors • Check wheel-speed signal of the correct min value

•

ABS and brake warning lamp

•

Wheel- speed by wheel FL

•

Wheel- speed must be always existent.

Causation :

•

• •

• •

Speed Wheel Sensor or lines interrupted (temporary or static) illuminate Impulse Wheel fault Intermittent contact between wheelspeed sensor to cable harness(connector) Air gap between sensor and impulse wheel. Wheel speed more than 2 km/h(under test-bench wheel speed the same as the rollers)

DIAGNOSTICS

42

INDEX

GROUP INDEX

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

13

RR Speed Sensor Range/Performance Plausibility fault

Work Instructions

Set Value

Fault Codes

Connection

Ignition on With vehicle jacked up, slowly turn RR wheel by hand

more than 40 km/h (26 m/h)

C1210

RR sensor(pin3) Ground RR(pin1)

drive vehicle

OR OR display approaching speedometer display

diagnostic-tester

Important Notes: • Ignition OFF before the plug connector will divided from the wheel- speed sensor.

Set Value :

Troubleshooting :

• Couple the diagnostic tester, Ignition on

•

ABS and brake warning lamp illuminate

• Read the DTC.

Causation :

•

Speed Wheel Sensor or lines interrupted (temporary or static)

•

Impulse Wheel fault

• Check the wheel-speed and correlation of the wheel to the sensors

•

Wheel- speed by wheel RR

•

Intermittent contact between wheelspeed sensor to cable harness(connector)

• Check wheel-speed signal of the correct min value

•

Wheel- speed must be always existent. Wheel speed more than 2 km/h(under test-bench wheel speed the same as the rollers)

•

Air gap between sensor and impulse wheel.

•

DIAGNOSTICS

43

INDEX

GROUP INDEX

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

14

RL Speed Sensor Range/Performance Plausibility fault

Work Instructions

Set Value

Fault Codes

Connection

Ignition on With vehicle jacked up, slowly turn RL wheel by hand OR drive vehicle

more than 40 km/h (26 m/h)

C1201

RL sensor(pin9) Ground RL(pin8)

OR diagnostic-tester display approaching speedometer display

Important Notes: • Ignition OFF before the plug connector will divided from the wheel- speed sensor.

Set Value :

Troubleshooting :

• Couple the diagnostic tester, Ignition on

•

ABS and brake warning lamp

Causation :

•

•

Speed Wheel Sensor or lines interrupted (temporary or static) illuminate Impulse Wheel fault

•

Read the DTC.

•

Check the wheel-speed and correlation of the wheel to the sensors

•

Wheel- speed by wheel RL

•

Intermittent contact between wheelspeed sensor to cable harness(connector)

•

Check wheel-speed signal of the correct min value

•

Wheel- speed must be always existent. Wheel speed more than 2 km/h(under test-bench wheel speed the same as the rollers)

•

Air gap between sensor and impulse wheel.

•

DIAGNOSTICS

44

INDEX

GROUP INDEX

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

15

Main relay, fuse

Work Instructions

Ignition on

Set Value

Fault Codes

The valve- power relay is energised when system has not shut- down

C2112

Connection

positive (pin17,18)

Note: • The valve relay is contained within the control unit and is not exchangeable. The relay contact on the no side is within the the control unit and is not routed out on the 26-pin plug of the unit. The voltage on the contact (e.g. after an actuation) cannot be measured with a multimeter. A relay actuation via diagnosis tester is not possible.

Set Value :

Troubleshooting :

Causation :

Ignition off • Replace ABS Unit Ignition on

•

ABS and brake

•

Control unit(valve relay circuit) warning lamp must illuminate and switch off

DIAGNOSTICS

45

INDEX

GROUP INDEX

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ABS REPAIR GUIDELINES Repair Guideline No. Tester-Display

16

G Sensor Signal Signal fault

Plausibility fault

Work Instructions

Ignition On Vehicle standing, positioned on even surface Lift vehicle at one side or drive onto ramp

Set Value

Connection

Fault Codes

a= - 0.11 to 0.11 g

C1274 C1275

a exceeding -0.11 to 0.11 g

GND 30 AY 10

U5V sensor 28

Note : The sensor is sensitive to shock acceleration against the housing and consequently against the sensor element. Disturbances of this kind e.g. through hammer blows during body repairs are not permitted.

Troubleshooting :

Set Value :

Ignition Off • Disconnect 3-pin cable harness plug from acceleration sensor. Ignition On • Using mult imeter, measure voltage at cable harness plug terminal 28 (positive) against terminal 30(ground) Ignition Off Ustab = 5V + 0.1V • Connect pin-out box between 3-pin cable harness plug and sensor. Ignition On • Using multimeter, measure signal 0.65 to 4.35V DC voltage at terminal 10 against vehicle on even terminal 30(ground) surface.

Causation :

•

•

•

Open circuit in line between cables from wiring harness and plug’s,terminal 30,10,28 Excessive line and contact resistance at plug contact.

Sensor defective; relace.

DIAGNOSTICS

46

INDEX

GROUP INDEX

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DIAGNOSTICS EMS CONTENTS : 1) General

2

A) Salient Features

2

2) Detailed Description

3

A) Electrical

3

B) Diagnostics Equipment Details

3

C) Explanation of Buttons of HDM

4

3) Trouble Shooting of Sensors

5

A) Diagnosis with HDM

5

B) HDM Data (during idling)

5

C) Test switch mode

6

D) Read memory switch mode (blink code)

6

E) Blink code cable

7

4) ECU Handling Care

8

DIAGNOSTICS

1

INDEX

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DIAGNOSTICS EMS 1. GENERAL : The Engine Management System ECU controls the complete functioning of Engine. The Microcontroller inside the ECU, evaluates continuously the signal from the all the sensor. Based on this data the ECU controls parameters like air / fuel proportion. A. SALIENT FEATURES The Diagnostic tester (Hitachi diagnostic monitor (HDM 2000)) has a capability to communicate with the ECU. This user friendly diagnostic kit makes trouble shooting simpler. The tester is light weight and compact in size to facilitate easy portability. This works on vehicle battery supply. This HDM 2000 can also be used as : a) Multimeter b) Oscilloscope This tester will execute the commands supported by ECU & provides the diagnostic data for efficient trouble shooting. The diagnostic unit is capable of performing following functions : 1.

Read dynamic data like a. Iignition data b. 02 sensor information c. Engine sensors information d. Engine information e. Fuel injection information

2.

Read failure codes

3.

Clear failure codes

4.

Functioning of few components

5.

Store history of earlier failure.

DIAGNOSTICS

2

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DIAGNOSTICS EMS 2.

DETAILED DESCRIPTIONS

A.

ELECTRICAL (Required Power Supply) The diagnostic tester does not require any external power supply. It works on the vehicle battery, provided through the intermediate cable.

B.

Power Monitor Lamp

Display Screen

Rubber Jacket

Key Pad

Power Switch

DIAGNOSTIC EQUIPMENT DETAILS 1. HITACHI DIAGNOSTIC MONITOR ( HDM 2000 ) should be loaded with the cartridge TATA Indica Version 1.2. Fig. 1.

Wrist Strap

Cartridge LED Display

2. Intermediate cable.

Strap Hook

Connecting the Diagnostic Equipment : Note : Connect the HDM only with the Ignition switch in “OFF” position.

Fig. 1

HDM 2000 is given with an intermediate cable,one end of it is connected to HDM 2000 and the other end to the female socket below the co-driver's seat Fig. 2.

Fig. 2 Female socket below co-driver seat

DIAGNOSTICS

3

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DIAGNOSTICS EMS C.

EXPLANATION OF BUTTONS of HDM :

On this instrument, you can select each mode from the menu display screen using the cursor.The following table shows the main functions of the keys.These key functions vary depending on the selected mode.

Moves up the cursor, and scrolls up the display screen. Increments a numeric value.

Moves down the cursor, and scrolls down the display screen. Decrements a numeric value.

Moves left the cursor, and scrolls left the display screen. Increments a numeric value.

Moves right the cursor, and scrolls right the display screen. Decrements a numeric value.

Use this key for item selection, deselection, execution, confirmation, etc.,

Use this key for item deselection, function turn-off, etc.

Goes back to the previous display screen or function.

Provides the shift function.

These keys for carrying out individual functions on each display screen.

DIAGNOSTICS

Fig. 3 4

INDEX

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DIAGNOSTICS EMS 3. A.

TROUBLE SHOOTING OF SENSORS USED IN MPFI

B.

DIAGNOSIS (with HDM)

Value changes in accordance with the change in engine temperature.

During diagnosis this instrument provides data in graphical form. Also allows measurement and recording of data for analysis and efficient trouble shooting.

HITACHI DIAGNOSTIC MONITOR DATA :

TYPICAL DATA DURING NORMAL IDLING :

SR. NO.

PARAMETER

VALUE

1.

Battery Voltage

14.0 V

2.

Vehicle Speed

0.0 kmph

3.

Engine Speed

750 rpm

The error codes are stored in two areas :

4.

Coolant Temperature

850C

1. Current Error Codes – to diagnose exiting faults.

5.

Ignition Timing

9-100 BTDC

2. History of Error Codes – to diagnose previous stored faults.

6.

Throttle Position Sensor Volt

0.50 V

7.

Fuel Injection # 1 Pulse

2.30ms

8.

ISC Valve Step

23.5 Step

9.

Engine Load

34.4%

10.

Front O2 Sensor

0.24 to 0.68V

11.

Max. Value of O2 Sensor

0.76v

12.

Min. value of O2 Sensor

0.10v

13.

A/F Correction # 1

-2.3 to -3.9%

14.

CPC Valve Duty Ratio

0%

15.

Manifold Absolute Pressure

280/300 mm Hg

16.

Intake Air Temperature

28oC

17.

Ignition Switch

ON

18.

Test Mode Signal

OFF

19.

Read Memory Signal

OFF

20.

Idle Switch

ON

21.

A/C Switch

OFF

22.

A/C Relay

OFF

23.

Fuel Pump Relay

ON

24.

CPC Solenoid Valve

OFF

25.

Front O2 Rich Signal

OFF/ON

26.

Crank Shaft Position Signal

ON

Stores ‘No Good’ conditions of Sensors/Actuators as listed in Read Memory Switch’s diagnostic mode. That is in E C U’s memory.

NOTE : At the end of each diagnosis and rectification of the fault,‘HISTO RY CODES’isto be erased by opting ‘CLEAR MEMORY’ option in the menu and check for normal functioning of Engine/Vehicle

DIAGNOSTICS

5

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DIAGNOSTICS EMS C.

TEST SWITCH MODE :

Method No. 2 This mode is used to check the functioning of the following components. 1. Canister Purge Valve 2. Fuel pump relay 3. A/C Compressor TROUBLE SHOOTING PROCEDURE : 1. Turn the ignition ‘ON’ 2. Short the terminals of the connector (Test Switch connector) below co-drivers seat using a suitable connector. Fig. 4

Fig. 4 Test switch mode connector in shorted condition (Black Socket)

3. Switch ‘ON’ the blower and A/C Switch 4. Physically ascertain the functioning of A/C compressor, intank fuel pump and canister purge valve by hearing the respective relay sound, otherwise that particular component should be checked. NOTE :

At the end of each diagnosis and rectification of the fault, ‘HISTORY CODE’ is to be erased by opting for “CLEAR MEMORY” it in HDM 2000 or by removing the battery supply for atleast 3 minutes. Method No. 3

D.

READ MEMORY SWITCH MODE (BLINK CODE) :

Read memory switch mode method (Blink code method) is a manual diagnostic method used to check the malfunctioning of the following parts. 1. 2. 3. 4. 5. 6. 7.

DIAGNOSTICS

Water temperature sensor Air temperature sensor Manifold air pressure sensor Idle speed control valve Throttle position sensor Lambada sensor Vehicle speed sensor

Fig. 5 Read memory switch mode white connector in shorted condition. DIAGNOSTIC TESTER

READ MEMORY

To check through this mode,we have to short the terminals of the Read Memory Switch mode connector which is situated below the co-driver’s seat as shown in Fig. 5. Blink Code checks the functioning of the Sensors/Actuators as indicated in the Blink code table.

WHITE CONNECTOR

TEST SWITCH

BLACK CONNECTOR

Fig. 6

6

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DIAGNOSTICS EMS TROUBLE SHOOTING PROCEDURE : 1. Short the terminals of the connector using suitable connector and OBSERVE the following : 2. Turn the ignition ‘ON’ a. If the ‘CHECK ENGINE’ lamp on the dash board blinks cyclically at every 0.5 secs, Then there is ‘NO TROUBLE’ with the engine sensors. b. Otherwise the lamp blinking frequency is correlated to a trouble code and corresponding sensor/actuator is indicated to be faulty.

E. BLINK CODE TABLE : Read memory switch mode connector in following shorted condition. Item

Code

Water temperature Sensor

31

Pressure Sensor

33

ISC Valve

34

Air Temperature Sensor

36

Throttle Sensor

41

O2 Sensor

42

Vehicle Speed Sensor

43

For Example : If the “Check Engine” lamp gives 3 slow blinks (of 1.2 Secs each) representing the first digit of the failcode viz.,”3" followed by 1 fast blink (of 0.16 Secs each) representing the second digit of the failcode viz.,”1" in a cyclic fashion, thus flashing the code “3 1” indicating that the water Temp Sensor is faulty (from the table below). If there are two or more sensors faulty, then the blink codes are repeated cyclically. For example, if the water temperature sensor and lambda sensor are faulty then the blinking codes will be repeated like ..31….42….31….42…. N OTE:

At the end of each diagnosis and rectification of the fault, ‘HISTORY CODE’ is to be erased by opting‘CLEAR MEMORY’ option in HDM 2000 or by removing the battery supply for atleast 3 minutes. DIAGNOSTICS

7

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DIAGNOSTICS EMS l

Do not use an ECU which has been dropped once.

Earth (Ground) Connection

l

Do not try to repair the ECU.

l

l

Use standard harness for circuit connections.

l

Ensure that Do not try to insert any thing into the ECU case.

l

The installation should be done in such a way as to keep the connector side down and the wiring done accordingly (to avoid water penetration into the ECU through the wiring).

l

Take care to avoid any bending of the connector pins while inserting the connector.

l

Ensure that the connector is inserted in the end after all the installation is complete.

l

To carry out welding job on the car the ECU should be disconnected.

4.

l l

ECU HANDLING CARE : Connect GND - P, GND - I, GND - C each to the engine block. The above mentioned GND should be connected firmly using screws. Ensure that the ignition coil GND and ECU GND - C are connected firmly together to the engine block by screws; and ensure that even if these are detached from the engine block, they are not detached from each other.

Power Supply l

The power for the ECU should be taken through the Main Relay. Do not take out the connector from the ECU for at least 5 sec after IGNITION OFF. Never take out the connector from the ECU during IGNITION ON.

l

Ensure that key SW is in OFF position while plugging - in the connector to the ECU.

l

Do not plug - in the connector again to the ECU for at least 100 sec after disconnecting it.

Input l

Ensure that the Input signal line is as far as possible from noise sources such as High Tension Cable, Horn relay, Motor etc.

l

Ensure that sealed wire are used for input line of O2 Sensor and Crank Angle Sensor, and the wiring is as far as possible from the noise sources similar to the ones above (Unsealed wire may be used for O2 sensor if the noise level is small enough so as not to affect the Air/Fuel control).

Output l

Take care to avoid dead - short (solenoid short - circuit etc.) and similar circuit misconnection while checking ( to avoid any damage to the Output Power Transistor). Use a solenoid which does not use a fly - back diode (reverse polarity may damage the Output Power Transistor).

Installation l

Ensure that the ECU is secured firmly to the body using screws.

l

Ensure that there is no water seepage into the ECU.

DIAGNOSTICS

8

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