WorkshopManual Indica PDF

WORKSHOP MANUAL
INDICA
GROUP INDEX
All specifications are given in C.G.S. System (Metric Reproduction or translation of the whole or part of the
System) unless otherwise specified. workshop manual without our written approval is
prohibited.
Created by :
Tata Motors Ltd. Subject to modification in Design, Specification and
PCBU - International Business. Equipment.
Mumbai
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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, Air-
conditioning 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 : The right is reserved to make changes in design,
This manual is divided into 16 groups. specification and equipment at any time without
Each group includes : notice.
• Technical specifications For any further technical advice or clarification please
• Tightening torques contact or write to :
• List of special tools
• Disassembly / Assembly procedures Tata Motors Ltd.
• Use of special tools Passenger Car Business Unit,
• Inspection of parts International Business,
• Trouble shooting. Shivsagar Estate, Block-A,
Dr. Annie Besant Road,
The corresponding pages of each group are marked with Worli,
black tabs & these lines up with one of the thumb index Mumbai - 400 018.
tab on the group index page. You can quickly find the India.
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.
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GROUP INDEX
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 G
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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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
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 Fig. 1
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.
Fig. 2
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. 3
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l 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.
nif ke
ma inta
old
To
r
te
nis
Ca
To
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
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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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GENERAL
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
Towing hook front
control the car.
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.
Rear tow hook

Cover tow hook
Fig. 11b
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GENERAL
LIFTING AND JACKING POINTS
Rear LH
Rear RH
Front RH Front LH
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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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.
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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. Serial No. to start every

(Model, execution year with 00001 on First
wheel base etc.) April
Year of Production Drive Type - R - For RHD
L - For LHD
Year Code Plant location

1.4.2003 to 31.3.2004 4 P For K Block, Pune
1.4.2004 to 31.3.2005 5
1.4.2005 to 31.3.2006 6
1.4.2006 to 31.3.2007 7
1.4.2007 to 31.3.2008 8
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
VIN No. No. Engine
Number
Fig. 14 Fig. 15
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GENERAL
AGGREGATE NUMBERING SYSTEM Barrel 1
: Indicates basic model
& LOCATION: (for location see fig. 15) 21 For TA 65 Transaxle
Barrel 2 : First digit indicates control of vehicle as
ENGINE : Numbering below :
1 - For normal control vehicle
XXXXX XX X X XX X XXXXX 3 - Full forward control vehicle
Second digit indicates first and second
1 2 3 4 5 6 7
gear speed ratio with version of gear box
Barrel 1 : Indicates engine model as below -
475 SI : For MPFI engine Eg. : F - for first gear ratio 3.42 / second gear ratio
1.95 with 5 gear version, Gear final 65/14
Barrel 2 : Variation in basic model with speedo ratio 19/17.
45 : 475 SI Injected type petrol engine, 85 PS, Barrel 3 : Indicates year of production
@ 5500 rpm, MPFI, meeting EURO-III emis- 3 for - 2003
sion norms. 4 for - 2004
5 for - 2005
Barrel 3 : ‘L’ in case of LHD executions
6 for - 2006
Punching of ‘L’ is not required if engine is
7 for - 2007
same for RHD and LHD executions.
Barrel 4 : Indicates plant location
Barrel 4 : Month of production. P for ‘K’ Block Pune
Barrel 5 : Indicates Serial no. of Transaxle, consists of
Month Code Month Code Month Code
5 digits and commences from serial no.
January A May E Sept. J 00001 and will start every year on first
February B June F October K January.
Example - 211F 3P 00005
March C July G Nov. L
BODY SHELL : Numbering
April D August H Dec. M XX X X XXXXX
1 2 3 4
Barrel 5 : Year of production Barrel 1 : - Indicates, Basic model
WZ - For 2003 M1 for Indica MPFI - Euro III
VZ - For 2004 Barrel 2 : - Indicates year of production
UZ - For 2005 3 for 2003
4 for 2004
TZ - For 2006 5 for 2005
SZ - For 2007 6 for 2006
7 for 2007
Barrel 6 : Indicates plant location.
Barrel 3 : - Indicates plant location
P - for ‘K’ block, pune
P for K Block Pune
Barrel 7 : Serial No. Indicates Serial No. Of engine. Barrel 4 : - Indicates cumulative serial number to
The barrel consists of 5 digits and start every year with 00001 on first January.
commences from serial number 00001 &
will start every year 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 XXXXX
Transaxle Number
1 2 3 4 5
Fig. 16
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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 Petrol Engine, Water cooled multi
multi point fuel injection point fuel injection system with
system 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 62.5 KW @ 5500 rpm
as per ISO 1585 as per ISO 1585
Maximum Torque : 110 Nm@ 3000 rpm 115 Nm @ 3000 rpm
as per ISO 1585 as per ISO 1585
Compression Ratio : 9.5:1 9.5:1
Firing Order : 1-3-4-2 1-3-4-2
2. CLUTCH
Single plate dry friction Single plate dry friction
diaphragm type. diaphragm type.
Outside diameter of : 190 mm 190 mm
Clutch lining
Friction Area : 285 sq.cm. 285 sq.cm.
3. TRANSAXLE
Front wheel drive through Front wheel drive through
constant velocity joints constant velocity joints
Model : TA 65-5/3.42 (5 speed) TA 65 -5/3.42 (5 speed)
with overdrive with overdrive
Type : Synchromesh on all Synchromesh on all
forward gears. Sliding forward gears. Sliding
mesh for reverse gears mesh for reverse gears
No. of gears : 5 forward 5 forward
1 reverse 1 reverse
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GENERAL
Gear ratios : 1st - 3.42 3.42
2nd - 1.95 1.95
3rd - 1.36 1.36
4th - 0.95 0.95
5th - 0.77 0.714
REV. - 3.58 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)
5. SUSPENSION
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
6. STEERING
Type : Hydraulic assisted Powerl Rack Hydraulic assisted power Rack
& Pinion Steering Gear & Pinion Steering Gear
with collapsible with collapsible
steering column steering column
Steering Wheel : 380 mm dia. 380 mm dia.
7. BRAKES
Service Brakes : Dual circuit, diagonal Dual circuit, diagonal split
split hydraulic brakes hydraulic brakes through
through tandem tandem master cylinder, vacuum
master cylinder. assisted 9'' Booster. ABS :Standard
(can be optional)
Front Brakes : 231 mm dia., 17mm thick, 231 mm dia., 20mm thick.
ventilated disc brake 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)
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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
9. FUEL TANK
Capacity : 37 litres 37 litres
10. BODY : Semi-mono Volume, Semi-mono Volume,

Mini size, 5 door hatchback, Mini size, 5 door hatchback,
steel monocoque body with steel monocoque body with
coated sheets coated sheets
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
Other standard Equipment : Starter Motor 0.8 kW Starter Motor 0.8 kW
12. PERFORMANCE
Max. speed at rated GVW : 155 Kmph 160 Kmph
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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 : 1665 1665
b) Over outer rear view : 1915 1915
mirror in folded
condition
Overall Height (Unladen) : 1485 - Unladen 1500 - Unladen
Minimum Turning Circle Dia : 9.8 m 9.8 m
Minimum Turning : 10.2 m 10.2 m
Clearance Circle Dia
Ground Clearance (Unladen) : 166 mm - unladen 165 mm - unladen
14. WEIGHTS (kg) (TOLERANCES AS PER EEC 92/21)

Complete vehicle kerb : 1005 1045
weight as per ISO : 1176
(with spare wheel & tools)
Gross Vehicle Weight : 1405 1445
Payload : 400 400
15. LUGGAGE SPACE

Net inside loadings space : 0.22 Cubic Meter 0.22 Cubic Meter
Upto rear seat back rest Upto rear seat back rest
0.61 Cubic Meter 0.61 Cubic Meter
Upto front seat back rest Upto front seat back rest
when rear seats folded when rear seats folded
16. PASSENGER CAPACITY : 2 Front + 3 Rear 2 Front + 3 Rear
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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) : Standard Standard
Intermittent working
Motorised Head lamp : Standard Standard
levelling device
Halogen head lamps : Clear Lens Clear Lens
with turn signal lamp
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 : Provision in Provision in wiring harness Available
player wiring harness Available
Windshield mounted : Standard Standard
internal antenna
Tripmeter : Standard Standard with Markings in Kms
Digital Clock (Quartz) : Standard Standard
Water Temperature indicator : Standard Standard
Engine oil low pressure : Standard Standard
indicator lamp
Brake fluid low level : Standard Standard
warning lamp + Parking
brake warning lamp.
RPM Meter : Standard Standard
Panel light dimmer : Instrument light Instrument light
and facia switches dimmer & dimmer & facial switches standard
facial switches standard
Seat belt warning : Not provided Standard + Audo warning
lamp for Driver (with Reduced Volume)
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Rear fog lamp : Not Provided Standard
Key IN, Parking lamp : Not Provided Standard
ON Audio Warning
Side repeater lamp : Standard Standard clear lens with Amber bulbs
Fuel Gauge : Standard Standard
Battery charge : Standard Standard
indication lamp
Horn : High & Low tone High & Low tone
REAR WIPER/WASHER : Standard Standard
with Defogger on Rear Glass
Motorised Head lamp : Not Provided Standard
levelling device
High Mounted stop : Standard Standard
lamp (Spoiler mounted)
Low Fuel warning lamp : Standard Standard
Immobiliser : Standard with Standard with
Remote Sense Remote Sense
Tail lamp and rear : Standard Registration Plate Lamp Standard
registration plate lamp 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
19. EXCLUSIVE BODY FITMENTS

Remote release for tailgate : Standard Standard
opening
Remote Release for fuel : Standard Standard
filler cap
Vanity Mirror on Sunvisor on : Standard Standard
co-driver side
Ash Tray : Front : Standard Standard
Ash Tray : Rear : Not provided Standard
Console : Full size Full size
Height adjustable front : Standard Standard
headrest
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VEHICLE LEi & LSi LX & LXi GENERAL
Integral Head Rest for : Standard Standard

Rear Seats
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 40:60 Split Type with Integral Head
Integral Head Rest, Double Folding and Cushion
Rest, Double Folding and
Cushion
Front seat belt with : Standard Standard
retractor
Inner rear view mirror : Anti Glare Anti Glare
Central Locking : Not provided Standard
Heating element on tailgate : Provided Standard
glass & rear wiper with wash
Power windows - : Not provided Standard (For Both Front & Rear)
Front & Rear
Air Conditioner : - Parts of HVAC
Heating Demisting : Standard for LEi version Parts of HVAC
Heating : Standard (for LSi version) Comprehensive HVAC system with
Ventilation & cabin air outlet valve
Air Conditioning (HVAC)
Cigarette Lighter : - Provision through power socket
Reflex Reflectors on the : Standard Standard
doors
Child safety lock on rear : Standard Standard
doors.
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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Fig. 17
MAIN CHASSIS DIMENSIONS
GENERAL
INDEX
unladen
1485 mm (LEi/LSi)
& 1500 mm (LX/LXi)
2400 mm 490 mm 1400 mm (LEi/LSi)
785 mm 1380 mm (LX/LXi)
GROUP INDEX
1665 mm
1380 mm (LEi/LSi)
1374 mm (LX/LXi)
3675 mm
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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
1.5 41 - 51 4.1 - 5.1

M10
1.0 46 - 56 4.6 - 5.6
Bolt 8.8
Nut 8.0 1.75 72 - 88 7.2 - 8.8
M12
1.5 75 - 91 7.5 - 9.1
2.0 113 - 138 11.3 - 13.8
M14
1.5 126 -154 12.6 - 15.4
2.0 176 - 215 17.6 - 21.5
M16
1.5 189 - 231 18.9 - 23.1
M6 1.0 12 - 14 1.2 - 1.4
1.25 29 - 35 2.9 - 3.5
M8
1.0 32 - 39 3.2 - 3.9
1.5 58 - 70 5.8 - 7.0
M10
1.0 64 - 78 6.4 - 7.8
Bolt 10.9
Nut 10.0 1.75 99 - 121 9.9 - 12.1
M12
1.5 104 - 127 10.4 - 12.7
2.0 162 - 198 16.2 - 19.8
M14
1.5 176 - 215 17.6 - 21.5
2.0 248 - 303 24.8 - 30.3
M16
1.5 266 - 325 26.6 - 32.5
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
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 (TUBELESS) PRESSURE

TYRE SIZE
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
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GENERAL
FUEL, LUBRICANTS & COOLANTS (Details)
Fuel : For Petrol car (with catalytic converter) Transaxle :
Unleaded regular grade petrol conforming to SABS 1598 Use recommended brand of gear oil 75W90 GL4 Synthetic
(or equivalent) and octane rating not less than 91 RON
Grease for axle bearings :
(RON stands for Research Octane Number) is
recommended to be used as fuel. Lithium base complex grease
Do not use leaded petrol in a car fitted with catalytic Brake fluid :
converter.
IS 8654/DOT 4
Even single fill of leaded petrol will seriously damage the
Power Steering :
catalytic converter.
ATF 206/ Dexron
Coolants :
Lubricants:
Presence of dirt in the coolant chokes up passages in the
Engine oil (Petrol Engine) :
radiator,
Recommended grade of engine oil conforming to 10W40
cylinder head and cylinder block, thereby causing
API SL (ACEA A2/B2) specification and range of ambient
insufficient
temperature at which these can be used are given in the
table below. cooling of engine.
Ambient Temp. Engine oil grade To prevent rust formation and freezing of coolant inside
in deg. C the
passages of radiator, cylinder block and cylinder head, use
-20 deg. to 40 deg. SAE 10W/40 only
Below -20 deg. SAE 5W/30 or Lower viscosity branded premixed engine coolant.
grade Engine Coolant Antifreez :
Coolant as per class II, JIS K 2234
19
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GENERAL G
GENERAL
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)
NEXT
GROUP INDEX
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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.
i
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ENGINE 475 SI MPFI
CONTENTS
Sr. No. Description Page No. ENGINE
1. Technical specifications 1
2. List of special tools 2
3. Tightening torques 3
4. Carburetted engine vs MPFI engine 6
5. MPFI engine advantages 7
6. MPFI schematic circuit diagram 8
7. Features of MPFI engine 9
8. MPFI sensors / actuators 12
9. Intank fuel pump 26
10. Ignition Coil Assembly 27
11. ECU 30
12. Trouble shooting of MPFI sensors 32
13. ECU Handling & care 36
14. Preliminary inspection of engine 37
15. Exploded Views 40
16. Removal & installation of engine from the car 58
17. Radiator, removal and installation 60
18. Alternator/Power steering pump & A. C. compressor belts removal, inspection, & fitment
a. For 85 PS Engine 61
b. For 75 PS Engine 63
19. Timing belt Removal / Fitment 64
20. Cylinder Head Sub-assembly
a. Disassembly, inspection of Rocker shafts & arms, spark plug
camshaft, valves, valve guides, valve seats and valve seat inserts 67
b. Assembly of cylinder head 82
c. Valve clearance adjustment 84
21. Cylinder block sub assembly
a. Disassembly, inspection & assembly of : Pistons & piston rings, Connecting rods, 87
Crankshaft, cylinder block, oil pump, water pump, thermostat assembly
b. Removal, installation & machining of cylinder liners 101
22. Lubrication system 103
23. Cooling system 105
24. Air intake system 113
25. Air cleaner 114
26. Accelerator Cable 115
27. Assembly Foot Control 116
28. Engine Testing 117
29. Evaporative Emission Circuit 118
30. Trouble Shooting 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 l For 75 PS : 42, 50, 57 & 63. Please also check page no. 65 for selection of camshaft.
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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) : 85 PS (62.5 kw) at 5500 rpm as per ISO : 1585
(For LEi & LSi) : 75 PS (55.2 kw) at 5500 rpm as per ISO : 1585
Max. torque
(For LX & LXi) : 115 Nm at 3000 rpm as per ISO : 1585
(For LEi & LSi) : 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
1
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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 2932 9900 60 54
and Telco cartridge 1.20
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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 ENGINE
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 Description Torque in mkg.

No.
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 2.5
4. Cylinder head cover bolts M6 1.0 #
5. Oil sump Screw M6 x 1 0.6 to 0.7 #
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 4+60 0 #
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 4.5 #
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
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ENGINE 475 SI MPFI
Serial Description Torque in mkg.

No.
ENGINE
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 1.0 #
30. Assembly Strainer to oil pump M6 x 1 1.0
31. Assembly oil filter to cylinder crankcase M12 x 1.5 Ref. Note @ #
32. Oil pressure switch on cylinder crankcase M20 x 1.5 3.0
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
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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ENGINE 475 MPFI - EURO II
Cylinder Oil Filling

Cylinder Oil Filling Cap
INDEX
Cap Head Cover
Head Cover
Inlet Inlet
Manifold Throttle
Manifold
Exhaust Body
Exhaust
Throttle Manifold
Manifold
Body
ENGINE 475 SI MPFI
Timing
Timing Cover
Cover
AC
Compressor Cylinder Block
AC
GROUP INDEX
Compressor Cylinder Block
Vibration Damper Vibration Damper Alternator

Alternator
Power Steering Power Steering

Pump Pump
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85 PS ENGINE 75 PS ENGINE
PREVIOUS
5
ENGINE
ENGINE 475 SI MPFI
CARBURETTED ENGINE V/s MPFI ENGINE Primary main jet

Typically a carburetted engine differs from petrol injected Slow
ENGINE engine in following aspects. air hole no. 1
l Fuel Metering
Primary
l Ignition System slow jet
l Cold Start
l Change in Atmospheric Condition Response
(Altitude, Temperature etc.) Bypass
port
Carburetted Engine : (Fig 1).
Primary main jet
l In this case fuel metering is done by carburettor i.e.
fuel quantity is controlled by fuel jet and air flow
Idle port
into the engine due to the vacuum available at the
venturi. Fuel quantity is a continuously variable Fig. 1 Carburettor system - illustration
function with respect to air flow.
2
l Ignition system consists of a Distributor driven by a 1. Fuel
camshaft. The Distributor timing is a continuously 2. Air 1
5
variable function as engine speed and load changes. 3.Throttle valve
4. Intake manifold
Due to Mechanical make/break system, the Ignition 5. Injector
energy is low (low dwell time) at high speeds. 6. Engine 3
Petrol Injected Engine :

l In this case fuel delivery to the engine is through 4
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 6
continuously variable function but a discrete
SINGLE POINT FUEL INJECTION (THROTTLE BODY
function as ECU calculates optimum fuel quantity
INJECTION)
required for any speed and load condition of the
engine. The correction in fuel quantity is almost 2
1. Fuel
instantaneous (less than one cycle time).
2. Air
3.Throttle valve 3
l Ignition system of Petrol Injection engine consists
4. Intake manifold 4
of Ignition Coil with built in Power Switch and 5. Injectors
the spark timing is controlled by ECU. Ignition 6. Engine
timing is varied discretely, depending upon the
1
engine speed and load. This system maintains
optimum Ignition energy levels for a good spark
5
in both low and high speed of the engine. No
wear parts like points, Distributor cap etc., and
hence better reliability.
6
M U LTI POINT FUEL INJECTION
Fig. 2
6
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ENGINE 475 SI MPFI
Manifold pressure
ENGINE
sensor
Throttle
body
Cylinder head
cover
LTRS
arrangement
Blow
ISC Valve
by hose
Fuel Canister
rail purge
valve
Cylinder
head Intake Ignition
manifold coil
Fig. 3 Intake Manifold with throttle body
475 SI MPFI ENGINE ADVANTAGES speed is increased as a function of Water and Air
temperature inputs to the ECU.
475 MPFI engine uses HITACHI multipoint fuel injection
system. Seven sensors located at various points in the l Emission :
engine, sense important parameters of the engine The petrol injection engine has low emissions because
operation & send signals to a ECU located under the air fuel ratio is controlled to stoichiometric using
dashboard. Based on predetermined engine mapping, lambda sensor. Faster warm up from cold start ensures
the ECU precisely controls the fuel delivery injection early operation of catalytic converter in turn reducing
timing to ensure optimum fuel utilisation with the emission.
minimum emission.
l Fuel Economy :
MPFI engine provides the following advantages :
The petrol injection engine has a better fuel economy
l Better Engine Performance : because the engine is optimised at each operating
Optimum fuel quantity and Spark timing is calculated point, discretly.
by ECU for any operating condition. l Quick Response :
l Better Cold Starting and Warm up : The petrol injection engine will have a better
ECU identifies cranking condition and quick starting is driveability and better acceleration since the fuel
ensured by providing sufficient fuel quantity and delivery and spark timing are controlled by ECU,
optimum spark timing. For quicker warm up, idling which quickly responds to engine/Driver demands.
7
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ENGINE 475 SI MPFI
ENGINE
MPFI SCHEMATIC CIRCUIT DIAGRAM
8
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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 Good Cold starting
with very high value and
drops as cranking rpm, Air & Water
temperature increases.
Divided fine injection Further total pulse width is Low Emissions

pulse width method divided into fine pulse widths
for efficient mixture formation
Fuel is cut if Throttle When throttle valve is Good startability in all

valve is opened opened more than 700 ECU conditions
cuts the fuel by reducing pulse (both hot & cold)
width to very low value
Ignition timing for ECU identifies cranking Good startability in all

starting is calculated mode and calculates spark conditions (both hot &
timing depending upon water cold)
temperature and engine speed.
A/C Compressor is kept ECU identifies cranking Good startability due to

‘OFF’ mode and switches ‘OFF’ reduced engine load
the A/C relay.
Fuel pump is kept ‘ON’ If the engine is not started Safety

during Cranking only or stalls due to absence of
NOT OTHERWISE rpm signal, Fuel pump is cut ‘OFF’.
Canister Purge Valve is ECU identifies cranking Good startability

kept ‘OFF’ mode and switches ‘OFF’ CPV
IDLING MODE :
Idle speed is dependent on Based on inputs to ECU Better Idle stability
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 ISC Valve position (steps) Better Idle stability
the previous position is continuously memorised whenever Idle state
(Learned Function) and renewed in memory. changes.
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ENGINE 475 SI MPFI
ENGINE
‘LIMP HOME’ Idle Speed When the following sensors Flexibility and user
are ‘No Good’, then idle convenience
speed assumes default value
for Throttle position sensor,
MAP Sensor, Vehicle speed
sensor, air temperature sensor,
water temperature sensor.
‘LIMP HOME’ ISC Valve When ISC Valve fails in User convenience
closed condition, open throttle
marginally to start the engine.
Engine Stall protection When engine rpm is as low Better Idle stability and
as 650 rpm, ECU cuts A/C user convenience
relay.
ACCELERATION MODE :
High Engine Speed Fuel is cut beyond 6500 rpm Engine safety
Control
High Vehicle Speed Fuel is cut beyond Vehicle Safety

Control 165 Kmph
Zero Vehicle Speed Fuel Fuel is cut if ‘no load Better fuel economy
cut acceleration’ is sustained
beyond certain time say,
180 sec.
Variable Acceleration Four levels of acceleration Better Fuel economy

Enrichment is detected depending upon Better Emissions
throttle position and vehicle Better Overtaking ability
speed and injected quantity
is varied.
Anti Surge Function Ignition timing is varied to Driving comfort

dampen sudden torque
variations.
High water temperature ECU cuts A/C relay when the Engine Safety
A/C cut ‘OFF’ water tempeture increases
beyond 1100c.
A/C compressor is kept A/C relay is cut-off depending Better over taking ability
‘OFF’ during ‘rapid’ upon vehicle speed
acceleration and throttle position.
DECELERATION MODE :
Fuel Cut during ECU cuts the fuel depending upon Better fuel economy
deceleration throttle position and rate of
change of rpm.
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ENGINE 475 SI MPFI
Anti-Surge Function Ignition timing is varied to Driving comfort ENGINE

dampen sudden torque
variations.
STEADY STATE MODE :
Accurate Basic Map High resolution data on a Best compromise for

Data for efficient 16 x 16 matrix Driveability and Fuel
Injection and Ignition economy
control
Closed Loop Air/Fuel Lambda sensor input to Emission Compliance

ratio control ECU maintains
Stoichiometric Air/Fuel
ratio
‘LIMP HOME’ mode ECU assumes default Safety and Comfort

When one or many values
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.
Inertia Switch (Fig. 4). When the Vehicle collision Safety (Fire Protection)
occurs, inertia switch cuts
‘OFF’ fuel pump
Immobiliser (If fitted) Remote operated Safety (Anti-theft device)
Immobiliser cuts supply to
Main Relay and Fuel Pump.
Fig. 4 Inertia switch under driver’s seat
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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 Fig. 5 Crank angle sensor
signals to ECU when placed over rotating flywheel
with 7 holes, located at different angular dispositions.
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-) Fig. 6 Crank angle sensor
Measure resistance across pin
20 & 21
System Diagnosis :
Use Hitachi Diagnostic Tester
Check for crankshaft position signal “ON” during
cranking.
Electrical Circuit :
SENSOR SHIELD
W 0.75 EWH
CRANK ANGLE SENSOR 21 CRANK
FWH
(CR+) ANGLE
SENSOR
B 0.75 EWH [ MAKE HITACHI ]
CRANK ANGLE SENSOR 20
FWH
(CR-)
CRANK ANGLE SENSOR SHIELD 19 FWH
EWH
(CRS) W/Y AV 0.75
ECU
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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.
This sensor provides air temperature or water
temperature input to ECU when placed in air/water Fig. 7 Air temperature sensor
stream.
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
Fig. 8 Water temperature sensor
Air temperature sensor :
ECU 18 TA
18 26
ECU 26 TAG
Measure the resistance across pins 18 & 26
EWH
Water temperature sensor : R/G 0.75 WATER

WATER TEMP. SENSOR 24 TEMP.
Sensor end Pin assignment SIGNAL (TW) FWH
SENSOR
ECU 24 TW
[ MAKE HITACHI ]
BR/W 0.75
24 32 WATER TEMP. SENSOR 32
ECU 32 TWG
GND. (TWG) FWH EWH
Measure the resistance across pins 24 & 32 AIR TEMP SENSOR 18

W/P 0.75
AIR
SIGNAL (TA) FWH
TEMP.
System Diagnosis : SENSOR
BR/B 0.75 [ MAKE HITACHI ]
Use Hitachi Diagnostic Monitor AIR TEMP.SENSOR 26
FWH
GND. (TAG)
Check for ‘Air Temp’ or ‘Water Temp’ values during ECU
Idling.
13
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ENGINE 475 SI MPFI
MANIFOLD AIR PRESSURE SENSOR (MAP)

(Fig. 9 & 10)
ENGINE Type :
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
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)
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) Fig. 10 Manifold air pressure sensor (Top view)
ECU 31 supply, VCC
31 22 112
ECU 22 signal, PM
ECU 112 ground, GNDS
Measure signal volt at pin 22 & 112 with sensor Electrical Circuit :
connected to wiring harness.
EWH
System Diagnosis : SENSOR POWER SUPPLY 31
W/Y AV 0.75
FWH EWH
(+5V)(VCC)
PRESSURE/MAP
Use Hitachi Diagnostic tester W/O 0.75 SENSOR
PRESSURE SENSOR 22
FWH EWH [ MAKE HITACHI ]
SIGNAL (PM)
Check for ‘Intake manifold pressure’ value during
BR/R 0.75
cranking. SENSOR GND. 112
(GNDS)
FWH EWH
0.75
ECU
To Throttle Position
Sensor
14
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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.
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
Use Multimeter
With ignition “ON”.
Supply volt » 5.12 vdc
Signal volt » 0.5 vdc at Idle position
= 4.5 + 0.15 vdc at WOT position
Sensor end Pin Assignment Fig. 12 Throttle Position Sensor (Side view)
ECU 31 Supply VCC
ECU 23 Signal THS
31 23 30
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
Check for ‘Throttle sensor’ voltage by pressing the Sensor
accelerator pedal in and out. THROTTLE

V/R 0.75 EWH POSITION
THROTTLE SENSOR 23 FWH SENSOR
SIGNAL (THS)
[ MAKE HITACHI ]
BR/G 0.75 EWH
THROTTLE SENSOR GND 30
FWH
ECU
15
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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.
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
Use Multimeter
Heater function
(Coil resistance : 4.2 Wat 300C)
A Heater (+)
A B 17
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.
Check for ‘Front O2 Sensor’ value at idling. LAMBDA SENSOR
(A +ve)
(200mv to 600mv continuously varying due to lambda (B -ve) GY/O
control function). 17 LAMBDA SENSOR(O2)
0.75
GND(ENGINE) 25 LAMBDA SENSOR SHIELD
ECU
16
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ENGINE 475 SI MPFI
LAMBDA SENSOR :
l Lambda oxygen sensor located in exhaust pipe Fig. 5 7 6 4
15. 8 ENGINE
1. Special ceramic coat

2. Electordes
3. Contact
4. Housing
5. Exhaust pipe 3
6. Ceramic Shield (porous)
7. Exhaust gas.
8. Air 1 2
Fig. 15 Lambda Sensor
l Lambda (oxygen) sensor voltage curve at 6000C

operating temperature Fig. 16
mV
a) Rich mixture (air deficiency) a b
b) Lean mixture (excess air) 1000
Oxygen-sensor voltage
800
600
400
200
0
0.8 0.9 1 1.1 1.2
Excess-air factor
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
17
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ENGINE 475 SI MPFI
VEHICLE SPEED SENSOR (VSS) Fig. 18 & 19

Type :
ENGINE 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.
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 Fig. 18 Instrument cluster (rear view)
per km.
Fitment Data :
This reed switch is integral part of instrument cluster
and is driven by Speedometer cable Fig. 18.
Use Multimeter
Manually rotate the speedometer cable and check for
VSS
contact make & break pulses 4 times/rev.
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)
Check for Vehicle speed sensor ‘Value’ during driving.
NG condition : 2 km/hr irrespective of vehicle speed.
R/Y PIN NO:1

VEHICLE SPEED PULSE 6
INST CLUST
(SPD) FWH
[ MAKE PRICOL/VDO ]
ECU
TO VEHICLE SPEED SENSOR
18
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ENGINE 475 SI MPFI
ISC VALVE (IDLE SPEED CONTROL VALVE)

Fig. 20
Type : ENGINE
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.
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 Fig. 20 Throttle Body showing Idle Speed control valve fitted
Idle Speed for various engine loads ISC Valve in inset
e.g. : A/C idle speed = 800 rpm
Engine water temp dependent Speed, say at 300C =
1100 rpm.
0.75
0.75
Fitment Data : P1 P2
LG/B 0.75
This actuator is part of Integral Throttle Body which is fitted FWH
2 ISC S/M ØA (ISCA)
on inlet manifold upstream side. Fig. 20
G/R 0.75
Stand Alone Diagnosis : FWH
3 ISC S/M ØA (ISCA)
Use Multimeter R/L 0.75

M FWH
9 ISC S/M ØB (ISCB)
Single Phase coil resistance = 49 W
W/V 0.75
Actuator end Pin assignment FWH
10 ISC S/M ØB (ISCB)
ECU 2 Coil A STEPPING MOTOR

ECU
2 P1 3 P1 Supply (+) TYPE ISC VALVE

ECU 3 Coil A’ [ MAKE HITACHI ]
9 P2 10
P2 Supply (+)
ECU 10 Coil B’
Measure coil resistance across pins = P1 & 2, P1 & 3, P2 & Fig. 21 Electric Circuit of ISC Valve
9, P2 & 10
System Diagnosis :
Use Hitachi Diagnostic tester Throttle Body
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.
600
500
400 Air Cleaner Air Outlet
Stepper
300 Motor
200
100 Air Inlet Throttle Plate Intake Manifold
0
0 20 40 60 80 100 120
Step Number Fig. 22 ISC valve illustration
19
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ENGINE 475 SI MPFI
INTEGRAL THROTTLE BODY

Type :
ENGINE 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.
This Integral Throttle Body is with a throttle valve
(See Illustration) in the air flow path (of ø 38 mm). The Fig. 23
throttle is actuated by the lever and the shaft assembly
which in turn operates Throttle position sensor to
provide engine load signal.
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
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.
ECU provides drive signal to this solenoid valve to purge Fig. 25 Location of purge valve
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.
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
Use Multimeter
Solenoid coil resistance = 26 W @ 200 C
Actuator end Pin assignment Fig. 26 Purge valve
P supply (+) main relay
P 11
ECU 11 CP
Measure the resistance across pin P & 11
CANISTER PURGE VALVE
Check for CPC solenoid ‘ON/OFF’ condition by freely 0.75 Y/L
11 CANISTER PURGE
accelerating the engine from idle to 4000 rpm. EWH EWH FWH (CP)
[ MAKE HITACHI ]
ECU
21
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ENGINE 475 SI MPFI
CANISTER PURGE VALVE - ILLUSTRATION :

ENGINE 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
Fig. 27
3.5
3.0
2.5
0.2
FLOW IN M3 / H
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
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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
Injectors
ball type seating valve acts as a good anti-deposit.
ECU provides drive signal to Injector (normally closed Fig. 29 Fuel Injectors location in the engine
valve) to open and remain in open condition (pulse width-
ms) 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.
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 Fig. 30 Fuel Injector
Stand Alone Diagnosis : System Diagnosis :
Use Hitachi Diagnostic tester.
Use multimeter
Check for ‘Fuel injection 01 pulse
Injector coil resistance 8.6 W Values during idling : 2.0 to 2.5 ms
Actuator end Pin assignment NOTE :
1 Power supply, main Pulse width will continuously vary to maintain
1 101 relay stoichiometric Air/Fuel ratio.
ECU 101 Injector 1 & 4 Electrical Circuit :
or ECU 102 Injector 2 & 3 L/G
1.0 R/B 1 CYL 0.75
101 INJECTOR (IJ1)
Measure the resistance across the pin P and ECU101 EWH
4 CYL
EWH
FWH
1CYL, 4CYL.
0.75
(or ECU 102). With ignition ON, measure the supply voltage 2 CYL 0.75
Y/G
102 INJECTOR (IJ2)
FWH 2CYL, 3CYL
w.r.t. engine ground at the wiring harness end by removing 3 CYL
EWH
0.75
ECU
all injector connectors. INJECTOR 8.6_ X 4
[ MAKE HITACHI ]
(+ ve)
23
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ENGINE 475 SI MPFI
FUEL INJECTOR - ILLUSTRATION :

ENGINE
FUEL IN
FILTER
(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.
Intank fuel pump provides fuel at very high flow rates
to common fuel rail where pressure regulator Fig. 32 Fuel 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.
Fitment Data :
This regulator is fitted on the Fuel rail. Fig. 32
Check for leaking diaphragm. Leakage is confirmed if
fuel traces are noticed on vacuum side.
System Diagnosis :
Fig. 33 Fuel pressure regulator
Check for ‘Front O2 sensor’ value for variations since VC PIPE AIR
lambda control is in progress to maintain CHAMBER
stoichiometric Air / Fuel ratio.
DIAPHRAGM FUEL IN
VALVE
TO FUEL OUTLET PIPE

TANK
Fig. 34 Fuel pressure regulator illustration
25
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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.
Fitment Data : Fig. 35
This Intank pump is fitted inside the fuel tank by immersing

the pump’s suction end in the fuel. Fig. 35
Use Multimeter
Motor armature resistance = 20W @ 200C
Actuator end (Pump) Pin assignment
1 2 1 from relay
2 car body
Measure the coil resistance across Pin 1&2
Actuator end (Relay) Pin assignment
P Supply (+)
P 108 Fig. 36 Intank Fuel Pump
ECU 108 FP
System Diagnosis :
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
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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.
ECU provides the trigger pulse to switch ON/OFF the power Fig. 37 Ignition coil with built in power switch
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.
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
Fig. 38
Use Multimeter
Check for 12 V power supply P/G on wiring harness Measure supply volt across pin P and G on wiring harness
with Ignition ON. Measure secondary coil resistance across
Firing order (1,3,4,2) & HT cable connections (See High tension terminals of cyl. 1 & cyl. 4 (or cyl. 2 & cyl. 3).
Illustration)
System Diagnosis :
Secondary coil resistance = 13 k W
Actuator end Pin assignment
Check for ‘Ignition timing value’ during idling.
ECU 16 supply (use for cyl. 2&3)
G ground (engine)
15 G 16 P
ECU 15 signal (use for cyl. 1&4)
P Power supply
27
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ENGINE 475 SI MPFI
ENGINE FROM IGNITION
H.T. CABLE
0.75
H.T. CABLE
H.T. CABLE
AV 0.75
[ MAKE ANU/DELTRONIX ] 15 IGNITION1(IG1)
EWH
H.T. CABLE 1CYL, 4CYL
SPARK
PLUGS H.T. CABLE 0.75
BODY EARTH AV 0.75
1 2 [MAKE MICO] 3 4 EWH

16 IGNITION2(IG2)
2CYL, 3CYL
ECU
IGNITION COIL
[ MAKE HITACHI ]
GND (ENGINE)
ENIGNE GND
28
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ENGINE 475 SI MPFI
IGNITION COIL ILLUSTRATION :

ENGINE
PRINCIPLE OF OPERATION OF IGNITION COIL
IGN RELAY VCC IGNITION COIL
91 W 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
29
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ENGINE 475 SI MPFI
ENGINE CONTROL UNIT (ECU) Fig. 41 & 42

Type :
ENGINE 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 Fig. 41
functions for optimum functioning of the engine, which
in turn provides best fuel consumption/Emissions.
Fitment Data :
ECU is fitted below the steering column in the driver
cabin. Fig. 41
Use Multimeter.
Perform continuity check only on ECU connection at
wiring harness end to any sensor/actuator depending
upon engine symptom.
System Diagnosis :
Check for all data when engine starting and idling
normally (typical data for normal idling are given on Fig. 42 Electronic control unit
page no. 34)
30
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ENGINE 475 SI MPFI
ENGINE CONTROL UNIT - ILLUSTRATION :

Block Diagram :
ENGINE
Input Control Unit Output
Crank angle sensor Injector * 4

Speed sensor CPU : H8 Ignition Coil * 1
Air temp.Sensor ISC solenoid
CPU
Throttle Position Signal
Fuel pump relay
Sensor ROM RAM
Condi- Buffer
Water temp. sensor Diagnosis Lamp
tioner A/D I/O
Battery Others
Oxygen Sensor
D/N Switch
A/C switch Voltage Watch dog

Others Regulator 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
Diagnosis level :
Clock Speed :
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.
31
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ENGINE 475 SI MPFI
TROUBLE SHOOTING OF SENSORS USED IN

Power Display
MPFI : Monitor Screen Rubber
Jacket
Lamp
ENGINE Method No. 1
Key
HITACHI DIAGNOSTIC MONITOR ( HDM 2000 ) should Pad Power
be loaded with the cartridge TATA Indica Version 1.2. Switch
Fig. 44
This is an user – friendly diagnostic kit, makes the Trouble
Shooting simpler.
This HDM 2000 can also be used as : Cartridge Wrist
Strap
1. A multimeter LED
Display
2. An Oscilloscope Strap
Hook
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 ENGINE
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.
Fig. 46
33
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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) :
Fig. 48 Read memory switch mode white connector in
Read memory switch mode method (Blink code shorted condition.
method) is a manual diagnostic method used to check
the malfunctioning of the following parts. DIAGNOSTIC TESTER
1. Water temperature sensor
2. Air temperature sensor
3. Manifold air pressure sensor
READ TEST
4. Idle speed control valve MEMORY SWITCH
5. Throttle position sensor
6. Lambada sensor
7. Vehicle speed sensor
WHITE BLACK
To check through this mode, we have to short the CONNECTOR CONNECTOR
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.
Fig. 49
34
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ENGINE 475 SI MPFI
TROUBLE SHOOTING PROCEDURE : HITACHI DIAGNOSTIC MONITOR DATA :

1. Short the terminals of the connector using suitable TYPICAL DATA DURING NORMAL IDLING :
connector and OBSERVE the following : ENGINE
Value changes in accordance with the change in engine
2. Turn the ignition ‘ON’ temperature.
a. If the ‘CHECK ENGINE’ lamp on the dash board SR. NO. PARAMETER VALUE
blinks cyclically at every 0.5 secs, Then there is
‘NO TROUBLE’ with the engine sensors. 1. Battery Voltage 14.0 V
b. Otherwise the lamp blinking frequency is 2. Vehicle Speed 0.0 kmph

correlated to a trouble code and corresponding 3. Engine Speed 750 rpm
sensor/actuator is indicated to be faulty.
4. Coolant Temperature 850C
BLINK CODE TABLE : 5. Ignition Timing 9-100 BTDC
Read memory switch mode connector in following 6. Throttle Position Sensor Volt 0.50 V
shorted condition. 7. Fuel Injection # 1 Pulse 2.30ms
Item 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
For Example :
17. Ignition Switch ON
If the “Check Engine” lamp gives 3 slow blinks (of 1.2 Secs
each) representing the first digit of the failcode viz.,”3" 18. Test Mode Signal OFF
followed by 1 fast blink (of 0.16 Secs each) representing
19. Read Memory Signal OFF
the second digit of the failcode viz.,”1" in a cyclic fashion,
thus flashing the code “3 1” indicating that the water Temp 20. Idle Switch ON
Sensor is faulty (from the table below).
21. A/C Switch OFF
If there are two or more sensors faulty, then the blink
22. A/C Relay OFF
codes are repeated cyclically. For example, if the water
temperature sensor and lambda sensor are faulty then 23. Fuel Pump Relay ON
the blinking codes will be repeated like 24. CPC Solenoid Valve OFF
..31….42….31….42….
25. Front O2 Rich Signal OFF/ON
N OTE:
26. Crank Shaft Position Signal ON
‘HISTORY CODE’ is to be erased by opting‘CLEAR MEMORY’
option in HDM 2000 or by removing the battery supply for
atleast 3 minutes.
35
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ENGINE 475 SI MPFI
ECU HANDLING CARE : l Do not try to repair the ECU.

Earth (Ground) Connection l Use standard harness for circuit connections.
ENGINE
l Connect GND - P, GND - I, GND - C each to the engine l Ensure that Do not try to insert any thing into the ECU
block. case.
l The above mentioned GND should be connected l The installation should be done in such a way as to
firmly using screws. keep the connector side down and the wiring done
accordingly (to avoid water penetration into the ECU
l Ensure that the ignition coil GND and ECU GND - C through the wiring).
are connected firmly together to the engine block
by screws; and ensure that even if these are l Take care to avoid any bending of the connector pins
detached from the engine block, they are not while inserting the connector.
detached from each other. l Ensure that the connector is inserted in the end after
Power Supply all the installation is complete.
l The power for the ECU should be taken through the l To carry out welding job on the car the ECU should
Main Relay. Do not take out the connector from the be disconnected.
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
NEXT
INDEX GROUP INDEX
PREVIOUS
ENGINE 475 SI MPFI
PRELIMINARY INSPECTION OF ENGINE : gradually with left foot. If the engine stalls, it means
Before proceeding to carry out actual overhauling of that clutch does not slip.
engine it is desirable to have a preliminary inspection OR ENGINE
of engine to ascertain whether an engine overhaul is
Drive the car with weight equal to GVW in 3rd gear
necessary and to what extent.
on level ground and let the speed drop down to
Most common reasons for which engine is overhauled approximately 15 kmph. Now press accelerator pedal
are : fully. With slipping clutch, the car speed will not pick
up and also clutch burning smell will be noticed. If
1. Loss of power
this does not occur and car picks up speed, it
2. Excessive engine oil consumption indicates that clutch does not slip.
3. Extremely low engine oil pressure e. BRAKE BINDING
4. Mechanical failures During driving apply brake number of times and then
shift the gear to neutral position Check brake drums
To know exact reason and general condition of engine,
for over-heating and if necessary jack up the car and
proceed as follows : check the wheels for free rotation.
1. LOSS OF POWER f. CHECKING ENGINE COMPRESSION PRESSURE
Loss of engine power may be due to : If loss of power is not on account of defective fuel
a. Defective Ignition system system, lack of air, choked exhaust silencer, clutch
slipping and brake binding. check engine
b. Defective Fuel system compression as follows :
c. Clogged air cleaner/choked catalytic converter 1. Warm up engine preferably by road drive to get
exhaust silencer 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. Install Compression gauge (Range about 0 to 25
a. IGNITION SYSTEM kg/cm2) into one of the spark plug hole.
Check all the sensors for proper function by Note :

using diagnostic monitor. Replace defective Use adaptor which is available commercially to
sensors. suit the size of the spark plug threads.
b. 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
Fig. 50
37
NEXT
INDEX GROUP INDEX
PREVIOUS
ENGINE 475 SI MPFI
5. Disengage clutch (to reduce starting load on engine) 4. Take a clean vessel, place it below the drain plug of
and depress accelerator pedal all the way to make oil sump.
throttle valve open fully.
ENGINE 5. Drain the hot oil into the clean vessel. Drain it fully.
6. Crank engine with fully charged battery, and read
6. Screw in oil sump drain plug and tighten it.
the highest pressure on compression gauge.
7. Weigh the vessel along with oil let this weight be
7. Carry out steps 5 to 7 on each cylinder to obtain
‘w1’, gms.
compression pressures. The specified
compression pressure is 9.5 bar minimum. 8. Refill the weighed oil into the oil sump. Do not spill
any oil. The vessel used for draining should not be
8. Variation in compression pressure between cylinders
used for any other purposes.
should not be more than 0.5 bar.
9. Drive the vehicle approx. 200 - 300 km. This drive
9. Low compression pressure may be due to leakage
should include at least 30 - 40 kms. of highway
past valves / piston rings/blown cylinder head gasket.
or similar road, vehicle running at about 60 kmph.
To ascertain the point of leakage, spray small quantity
of clean engine oil in to the cylinder showing low Let this drive distance be ‘D’ kms.
pressure and re-check compression pressure. If it 10. Immediately after the test drive, place the vehicle
improves, wear in piston rings/cylinder bore is at the same spot from where it started.
indicated. If it does not, leakage past the valves is
indicated. If compression pressure of adjacent 11. Place the same previously used vessel below the
cylinder is also on lower side, it may be due to blown oil sump, unscrew the drain plug and drain off
cylinder head gasket. oil into the vessel. Drain the sump fully.
2. EXCESSIVE ENGINE OIL CONSUMPTION 12. Weigh the vessel along with oil, now for the
second time. Let this weight be ‘w2’ gms.
High engine oil consumption may also lead to overhauling
of the engine but before proceeding to overhauling, check 13. Find out standard oil consumption as -
following points : (w1 - w2)(wt. of oil consumed, gms) x 1000
Std. oil consumption
=
1. Make sure that there is absolutely no external oil ‘C’ (litres/1000km) sp. wt. of oil (gm/cm3) x ‘D’ (drive dist. in km.)
leak (i. e. from the camshaft oil seal, crankshaft oil
seal, oil sump gasket, oil pump gasket, cylinder head w1 - w2
‘C’ = litres/1000km
cover gasket etc.) 0.88 x D
2. If no external leakage is found, determine the exact 3. EXCESSIVE LOW OIL PRESSURE EXTREMELY
engine oil consumption, as per following procedure. Check the following :
DETERMINING EXACT ENGINE OIL CONSUMPTION : a. External leakages.
CAUTION : b. Oil level in sump upto maximum mark on
Do not make a rough estimate of engine oil consumption by dipstick.
noting the kilometers covered by the car at any random stage c. Oil pressure transducer for proper functioning.
and finding oil consumed from the topped up position
d. Functioning of pressure relief valve on oil pump.
taking into consideration dipstick level and oil sump
capacity. e. Oil pump performance using a suitable pressure
gauge.
PROCEDURE :
Oil pressure found to be less than 2.8 bar at maximum
1. Once it is doubted that engine oil consumption is speed and 1.2 bar at idling speed, may be due to
higher, place the car on a level ground. improper functioning of oil pump or defective oil
2. Top up oil sump to its capacity of 4 litres. pump relief valve.
3. Warm up the engine so that oil temperature is 75 - If low oil pressure is not on account of above factors,
800 C. wear of journals/bearings is indicated for which
overhaul of engine may be considered.
38
NEXT
INDEX GROUP INDEX
PREVIOUS
ENGINE 475 SI MPFI
Checking oil pressure :

Procedure for checking
ENGINE
Before conducting the test ensure :
1. Engine oil level is at high mark on dipstick, otherwise
top up.
2. No leakage.
3. 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.
39
NEXT
INDEX GROUP INDEX
PREVIOUS
ENGINE
40
SR. NO. PART DESCRIPTION
01 ASSY.ENGINE COVER
02 ASSY.RUBBER GROMMET (ENGINE COVER MTG)
03 CR CSK SCREW M6X16
INDEX
04 ASSY.ENGINE COVER MTG.BKT. (FRONT)
05 PAN HD SCR M6X8
06 ASSY.BUFFER (FOR ENG.COVER MTG.)
07 HEX FL NUT
08 ASSY.LIFTING HOOK REAR
09 HEX.FL.SCREW M8X18
ENGINE 475 SI MPFI
GROUP INDEX
NEXT
2.5 ENGINE COVER MOUNTING
PREVIOUS
(same for 85 PS & 75 PS engines)
- Specified Torque in Kgm MOVING PARTS (For 85 PS engine)
# Allowed Tolerance of ±5%
® -Non Reusable Part
INDEX
®
ENGINE 475 SI MPFI
5.5 #
GROUP INDEX
01 ASSY.CRANKSHAFT WITH PIN - NORMAL
01-a CRANKSHAFT-NORMAL 08 KEY
01-b CYL PIN 8m6X16 09 ASSY.FLYWHEEL COMPLETE. 13 ASSY.CONNECTING ROD
02 ASSY.GEAR (FOR CRANKSHAFT) (SINTERED) 09-a DOWEL 13-a BOLT (FOR CONNECTING ROD)
(FOR CLUTCH ON FLYWHEEL)
03 PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)
NEXT
13-b NUT (FOR CONNECTING ROD)
10 HEX.BOLT (FOR FLYWHEEL)
04 PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC) 13-c SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
11 SET MAIN BEARING SHELLS NORMAL
05 HEX FL BOLT M8X38 14 PISTON SET WITH RINGS GRADE A (IP)
(BIMETAL)
PREVIOUS
06 HEX.BOLT (FOR CRANKSHAFT GEAR) 14-a PISTON SET WITHOUT RINGS GRADE A (IP)
12 SET THRUST WASHERS (BIMETAL)
07 WASHER (FOR CRANKSHAFT GEAR) 14-b SET PISTON RINGS ABC STD (IP)
41
ENGINE
ENGINE
42
- Specified Torque in Kgm MOVING PARTS (For 75 PS engine)
# Allowed Tolerance of ±5%
INDEX
®
ENGINE 475 SI MPFI
5.5 #
GROUP INDEX
01 ASSY.CRANKSHAFT WITH PIN - NORMAL
01-a CRANKSHAFT-NORMAL 08 KEY
01-b CYL PIN 8m6X16 09 ASSY.FLYWHEEL COMPLETE. 13 ASSY.CONNECTING ROD
02 ASSY.GEAR (FOR CRANKSHAFT) (SINTERED) 09-a DOWEL 13-a BOLT (FOR CONNECTING ROD)
(FOR CLUTCH ON FLYWHEEL)
03 PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)
NEXT
13-b NUT (FOR CONNECTING ROD)
10 HEX.BOLT (FOR FLYWHEEL)
04 PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC) 13-c SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
11 SET MAIN BEARING SHELLS NORMAL
05 HEX FL BOLT M8X38 14 PISTON SET WITH RINGS GRADE A (IP)
(BIMETAL)
PREVIOUS
06 HEX.BOLT (FOR CRANKSHAFT GEAR) 14-a PISTON SET WITHOUT RINGS GRADE A (IP)
12 SET THRUST WASHERS (BIMETAL)
07 WASHER (FOR CRANKSHAFT GEAR) 14-b SET PISTON RINGS ABC STD (IP)
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
INDEX
1 TIMING BELT
2 OIL SEAL (CAMSHAFT-FRONT)
3 TIMING GEAR (CAMSHAFT)
4 WASHER (FOR CAMSHAFT GEAR)
5 HEX BOLT (CAMSHAFT GEAR MTG.)
6 ASSY.TENSIONER (TIMING BELT)
ENGINE 475 SI MPFI
7 SPACER(TIMING BELT TENSIONER)

8 HEX FL BOLT M10X65
9 ASSY.IDLER (FOR TIMING BELT)
10 SPACER
12 CAM SHAFT * 1.0
13 ROCKER ARM
14 ADJUSTING SCREW (FOR ROCKER ARM)
GROUP INDEX
15 ROCKER NUT
16 .ASSY.ROCKER SHAFT WITH SEALING CAP ®
17 SPRING (ROCKER ARM SHAFT)
18 ROCKER SPRING SEAT
19 SCREW-ROCKER SHAFT HOLDER.
20 CAM THRUST PLATE (FRONT)
21 CAP SCREW M6X20
4.5
NEXT
PREVIOUS
- Specified Torque in Kgm
43
ENGINE
ENGINE
44
FUEL INJECTION EQUIPMENT (same for 85 PS & 75 PS engines)
INDEX
ENGINE 475 SI MPFI

01 ASSY.FUEL RAIL (CASTING)
02 HEX FL SCREW M8X18
03 HOSE (PR.REGULATOR TO I.MANIFOLD)205
04 SPRING CLIP (10)
GROUP INDEX
05 SUPPORT BRACKET - CANISTER PURGE VALVE
07 CANISTER PURGE VALVE
08 RUBBER SLEEVE (CANISTER PURGE VALVE)
09 CLAMP - CANISTER PURGE VALVE
11 RUBBER HOSE-CARBON CANISTER TO CPV (380)
12 RUBBER HOSE-CPV TO INTAKE MANIFOLD (240)
13 SPRING CLAMP (14)
NEXT
14 SPRING CLIP (10)
15 ASSY.ACT.CARBON CANISTER (KOEL)
16 ASSY.BRACKET (FOR CARBON CANISTER MTG.)
PREVIOUS
17 HEX FL SCREW M6X16 - Specified Torque in Kgm
CYLINDER BLOCK ASSY. (same for 85 PS & 75 PS engines)
# Allowed Tolerance of ±5% 1.0 #
® 3.5
®
INDEX
5.5 # ®
1.0
®
2.0
ENGINE 475 SI MPFI
1.0 #
1.0 ®
®
1.0
0.6 to 0.7#
GROUP INDEX
1.0 ®
3.5
®
SR. PART DESCRIPTION 1.0

NO. 06 ASSY.DIPSTICK
01 ASSY.CYLINDER CRANKCASE 07 ASSY.OIL SUMP COMPLETE
01-a HOLLOW DOWEL 14h6x10.5x14L 07-a ASSY.OIL SUMP W/O DRAIN PLUG 20 HEX SCREW M6X20
01-b DOWEL SLEEVE (FRONT HALF TO INT.PLATE (2) ) 07-b MAGNETIC DRAIN PLUG 21 WASHER A6.4 IS5370
01-c HOLLOW DOWEL 10h6x8.4x8L 07-c SEALING WASHER (OIL SUMP DRAIN PLUG) 22 RUBBER BUFFER (FOR MTG.TIMING COVER)
01-d HOLLOW DOWEL 8h6x6.5x8L 08 OIL SUMP GASKET 23 INSERT TUBE (FOR MTG.TIMING COVER)
01-e SEALING PLUG M14X1.5 09 HEX FL SCREW M6X14 (for oil sump) 24 ASSY.OIL PUMP
01-f SEALING WASHER 14X20 IS3175-CU 10 ASSY.TIMING COVER - REAR (LH BOTTOM) 25 GASKET (FOR OIL PUMP)
01-g HEX.BOLT (FOR M.B.CAP) 11 ASSY.TIMING COVER - REAR (RH BOTTOM) 26 ASSY HEX SCREW M6X25
27 OIL SEAL-CRANKSHAFT (FRONT)
NEXT
01-h DOWEL 6h6x10 (1-no screw behind) 12 HEX FL SCR M10X14 (for timing cover)
01-i HOLLOW DOWEL 8h6X6.5X8L (6) 13 ASSY.FRONT COVER(LOWER)(TIMING COVER) 28 ASSY.STRAINER (FOR OIL PUMP)
02 .ASSY.REAR COVER CRANKCASE WITH OIL SEAL 14 HEX FL SCREW M6X14 29 GASKET (FOR OIL PUMP STRAINER)
02-a REAR COVER - CRANKCASE (HOLLOW DOWEL) 15 COVER (TIMING BELT-FRONT) 30 STUD CM6X16
31 HEX FL NUT BM6
PREVIOUS
02-b 0IL SEAL-CRANKSHAFT (REAR) 16 SEALING STRAP
03 GASKET (REAR COVER CRANKCASE) 17 SHOULDER BOLT (FOR TIMING COVER) 32 ADAPTOR (OIL FILTER)
04 ASSY HEX SCREW M6X20 (6-for rear cover) 18 BRIGHT WASHER 10.5 33 ASSY.OIL FILTER
05 ASSY.DIPSTICK TUBE 19 RUBBER BUSH (TIMING COVER)
45
ENGINE
ENGINE
46
CYLINDER HEAD & COVER (same for 85 PS & 75 PS engines)
SR. PART DESCRIPTION

NO.
01 ASSY.CYL.HEAD COMP(WITH VAL,RO.ARM,SP.PL
01-a VALVE GUIDE SEAL
INDEX
01-b INTAKE VALVE 1.0
01-c EXHAUST VALVE
01-d SPRING SEAT
01-e VALVE SPRING
01-f VALVE SPRING RETAINER
01-g LOCK HALF
01-h SPARK PLUG ASSEMBLY.(M/S CHAMPION)
01-i ASSY.CYLINDER HEAD (WITHOUT VALVES)
01-i-a CYLINDER HEAD
01-I-B STUD CM8X25 (FOR INTAKE MANIFOLD)
01-I-C STUD CM8X20 (FOR PURGE VALVE MTG. BRACKET.)
01-I-D STUD CM8X25 (FOR EXHAUST MANIFOLD)
ENGINE 475 SI MPFI
02 GASKET (FOR CYL.HEAD)(1.1THK.)

03 HEX BOLT (FOR CYL.HEAD)
04 WASHER (FOR CYL.HEAD BOLT)
05 ASSY.CYLINDER HEAD COVER COMPLETE (LMM)
05-a BAFFLE GASKET
05-b BAFFLE PLATE
05-c SCREW 6.5
06 RUBBER HOSE (BLOWBY) (HEADCOVER-AIR FIL)
07 HOSE CLAMP 25
08 HOSE CLAMP 16 08
09 'T' - CONNECTOR
®
10 RUBBER HOSE-BLOW
BY-HD.COVER TO MANIFOLD
11 HOSE CLAMP 25 1.0
12 HOSE CLAMP 20 1-i-d 09
13 GASKET (FOR CYL.HEAD COVER) 1.0 07
14 STUD (FOR CYL.HD.COVER)
GROUP INDEX
15 SPACER TUBE 11
(FOR CYL.HD.COVER)
16 ASSY.RUBBER BUSH
(FOR CYL.HD.COVER)
17 DOMED CAP NUT
(FOR CYL.HEAD COVER MTG.) 10
®
18 SEALING WASHER
(FOR CYL.HEAD COVER)
19 OIL FILLER CAP
20 GASKET 12
21 VALVE GUIDE 21
22 VALVE INSERT
NEXT
®
®
22
-Non Reusable Part
PREVIOUS
®
GASKET KIT (same for 85 PS & 75 PS engines)
INDEX
®
®
®
®
ENGINE 475 SI MPFI
®
®
®
®
NO.
1 Rear Gasket
®
2 Oil Sump Gasket

3 Cylinder Head Gasket
®
®
GROUP INDEX
4 Cylinder Head Cover Gasket
5 Oil Filler Cap Gasket
6 Throttle Body Gasket
®
7 Inlet Manifold Gasket

®
8 Exhaust Manifold Gasket

®
9 Front Cover Gasket
®
10 Oil Pump Strainer Gasket
11 Water Pump Gasket
12 Gasket
NEXT
13 Gasket Elbow
14 Rear Crankshaft Oil Seal
(Rear Crankcase Cover)
PREVIOUS
15 Camshaft Front Oil Seal
16 Front Crankshaft Oil Seal
47
ENGINE
ENGINE
48
AIR INTAKE SYSTEM (same for 85 PS & 75 PS engines)
INDEX
®
®
SR. PART DESCRIPTION ®
NO.
01 ASSY AIR FILTER MPFI
02 ASSY.FILTER ELEMENT
ENGINE 475 SI MPFI
03 ASSY.ISOLATOR (FOR AIR FILTER)

04 ISOLATOR (FOR AIR FILTER)
05 ASSY.ADAPTER (BLOWBY CONN.ON AIR FILTER)
06 SEALING WASHER 14X18 CU
07 SEALING WASHER 12X15.5 CU
08 ASSY.BRACKET FRONT (FOR AIR FILTER MTG.)
09 BRACKET REAR (A/F MTG.ON BATTERY TRAY)
12 ASSY.BRACKET (FOR RESONATOR BOX MTG.)
14 RESONATOR BOX
15 ASSY.ISOLATOR (FOR RESONATOR)
GROUP INDEX
16 RUBBER GROMMET (FOR RESONATOR BOX)
18 AIR INTAKE SNORKEL
19 ASSY.CLAMP (FOR SNORKEL MTG.)
20 HEX FL SCREW M6X14 (FOR SNORKEL MOUNTING)
21 HOSE (RESONATOR BOX)
22 HOSE CLAMP (42 DIA.)
23 INTAKE DUCT (FROM AIR INTAKE SYSTEM)
24 HOSE (AIR FILTER TO INTAKE DUCT)
25 HOSE CLAMP (72 DIA.)
26 HEX FL NUT AM6 8C (FOR SNORKEL MOUNTING)
27 PLUG (ON THROTTLE BODY)
NEXT
28 GASKET (FOR INTEGRATE THROTTLE BODY)
29 HEX FL NUT AM6 8C
30 RUBBER BELLOW (AIR FILTER TO THRO.BODY)
PREVIOUS
31 HOSE CLAMP ( 53 DIA.)
32 HOSE CLAMP (72 DIA.) ® -Non Reusable Part
INTAKE & EXHAUST MANIFOLDS (same for 85 PS & 75 PS engines)
INDEX
06
ENGINE 475 SI MPFI
1234
1234
1234
1234
1234
®
NO.
GROUP INDEX
01 ASSY.INTAKE MANIFOLD COMPT (FOR LTRS)
®
02 BRACKET (FOR ACC.CABLE MTG) (LTRS)
03 CYL PIN 4m6X8 IS2393
05 ASSY.CABLE LEVER COMPLETE (FOR LTRS) 2.0
06 STICKER (FOR SPARK PLUG CONNECTION)
®
07 STUD CM6X45 (FOR THROTTLE BODY)

08 GASKET (FOR INLET MANIFOLD)
09 SELF LOCKING NUT
NEXT
10 EXHAUST MANIFOLD
11 GASKET EXHAUST MANIFOLD
12 .ASSY.HEAT SHIELD (FOR EXHAUST MANIFOLD)
PREVIOUS
14 STUD CM8X32
49
ENGINE
ENGINE
50
® -Non Reusable Part ENGINE ELECTRICAL EQUIPMENT (75 PS)
2.0
INDEX
2.0
3.0
ENGINE 475 SI MPFI
1.5
®
4.0
2.5
GROUP INDEX
2.0
8.0
SR. PART DESCRIPTION 11 HEX THIN NUT M12

NO. 08-a ASSY.CLAMP ROD (COMPLETE) 172 mm 12 LOW OIL PRESSURE SWITCH
01 BRACKET (FOR 75 AMP ALT.& PSTG.) 08-a-a ASSY.CLAMP ROD WITH SILENT BLOCK 13 POLY-V BELT (4 GROOVES-875)
02 STUD (FOR A.C. & ALT. BRACKET) 08-a-b ASSY.CLAMPING PIECE 14 ALTERNATOR 12V 75A W/IEM W/O VP-OFFER
03 HEX FL SCREW M8X18 08-a-b-a CLAMPING PIECE 22 POWER STEERING PUMP
NEXT
04 HEX FL NUT AM8 08-a-b-c CYL PIN 8m6X25 IS2393 23 HEX FL SCREW M8X18
05 HEX FL BOLT M8X125 08-b ASSY.BRACKET (ALTERNATOR - UPPER) 24 PULLEY (POWER STG.PUMP) 4 GROOVES
06 BRIGHT WASHER 8.4 08-c HEX FL BOLT M10X40 25 HEX FL.NUT AM12X1.25
PREVIOUS
07 NYLOC NUT M8 9 HEX FL SCREW M8X18
08 ASSY.CLAMP ROD COMP.WITH BRACKET (172mm) 10 HEX FL BOLT M8X45
ENGINE ELECTRICAL EQUIPMENT (85 PS)
NO.
01 BRACKET (ALTERNATOR,IDLER & PSTG.MTG.)
INDEX
04 SUPPORT BKT.(FOR ALT.BKT.& TOP SUPPORT)
06 BRACKET (FOR ALT.TOP SUPPORT) 2.0
08 SLIDER (FOR TENSIONER MTG.) (ALUMINIUM)
ENGINE 475 SI MPFI
09 WASHER (FOR AC COMPRESSOR IDLER)

2.0
10 SLIDER SCREW (FOR TENSIONER)
11 ASSY.SHAFT W/H DUST SHIELD-
FOR TENSIONER
12 ASSY.TENSION PULLEY.
(FOR A/C COMP.)(INA) 2.0
13 HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)
14 POLY VEE BELT (5 PK-1095)
2.0
15 ALTERNATOR 12V 90A W/VP W/IEM
GROUP INDEX
16 PULLEY-PSTG.PUMP (5-GROOVES)
2.3
4.0
2.3
NEXT
PREVIOUS
51
ENGINE
ENGINE
52
ENGINE ELECTRICAL/A.C. EQUIPMENT
INDEX
ENGINE 475 SI MPFI
2.4
Sr. Part Description

No.
02-a-a ASSY.TENSION PULLEY(FOR A/C COMP)INA.
02-a-b SPACER(FOR A/C BELT TENSIONER)-M/S INA.
02-d HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)
02-e DUST CAP
15 STARTER MOTOR 0.8KW. MALE TER.-M/S LTVS
GROUP INDEX
16 SET ASSY.COMPRESSOR MTG.(HALLA-110CC)DLX
5.0 16-a BRACKET(MTG.A/C COMPRESSOR)(HALLA-110CC)
2.5 16-b ASSY.AIR COMPRESSOR (with sealed connector)
®
2.5 16-c HEX FL SCREW M8X30
17 STUD (FOR A.C. & ALT. BRACKET)
18 HEX FL NUT AM8
20 POLY-V BELT (4-GROOVES-730)
21 SET ASSY.IDLER (AUTOLEC)
21-a ASSY.IDLER (FOR A/C COMP.) (AUTOLEC)
NEXT
21-b DUST CAP
-Non Reusable Part 21-c SLIDER (FOR MTG.OF A/C IDLER)
PREVIOUS
®
21-d SCREW (FOR A/C COMP TENSIONER)
- Specified Torque in Kgm 21-e NYLOC NUT M8
EMS KIT COMPONENTS
- Specified Torque in Kgm 1.0
INDEX
12
11
ENGINE 475 SI MPFI
1.0
08 09
10
GROUP INDEX
1.4
NOTE : Vehicles speed sensor, one of EMS component, is a part of instrument cluster. (not shown)
NO. 04 BRACKET (FOR CRANK ANGLE SENSOR)
01 KIT-EMS BHARAT STAGE-II FE (HITACHI) 05 CR CSK SCREW M6X16
01-a ASSY.COIL WITH IGNITOR (HITACHI) 01-e-bINSULATOR (FOR FUEL INJECTOR) 06 CYL PIN 6m6X14
NEXT
01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-e-c RUBBER RING (FOR FUEL INJECTOR) 07 HEX FL BOLT M6X20
01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-f INTEG.THROTTLE BODY(HITACHI) NEW PR.SEN. 08 MANIFOLD AIR PRESSURE SENSOR
01-c CRANK ANGLE SENSOR (HITACHI) 01-g ASSY.PRESSURE REGULATOR (HITACHI). 09 THROTTLE POSITION SENSOR
PREVIOUS
01-d WATER/AIR TEMP.SENSOR (HITACHI) 01-g-a O-RING (FOR PR.REGULATOR) 10 ISC VALVE
01-e ASSY.FUEL INJECTOR (HITACHI) 02 HEX FL SCREW M5X12 11 WATER TEMPERATURE SENSOR
01-e-a O-RING (FOR FUEL INJECTOR) 03 ASSY HEX SCREW M6X25 (Ignition coil) 12 LAMBDA SENSOR
53
ENGINE
ENGINE
54
ENGINE COOLING SYSTEM (same for 85 PS & 75 PS engines)
NOTE : Please read this view in conjunction with view of Radiator (next page), as both are related.
®
1.0
INDEX
1.0
FROM RADIATOR TOP
®
®
2.0 TO AUX. TANK
ENGINE 475 SI MPFI
1.5
®
®
48 ®
®
1.5
GROUP INDEX
2.0
1.0
SR. PART DESCRIPTION TO HEATER

NO.
10 ASSY.ADAPTER (FOR HEATER CONNECTION) 39 THERMOSTAT HOUSING 49 SEALING WASHER 14X18
11 WASHER (18X22X2-Cu) 40 O-RING 42.52X2.62 A NITRILE 50 STUD CM6X16
12 ASSY.BANJO BOLT WITH NIPPLE (FOR HEATER) 41 HEX FL NUT AM8 51 ASSY.TUBE WATER BYPASS
13 HOSE (FROM CYL.HEAD TO HVAC UNIT) 42 STUD CM6X25 52 GASKET (FOR WATER BYPASS TUBE)
NEXT
14 SPRING BAND CLAMP FORM A 12X23D TS17665 43 ASSY.COVER (THERMOSTAT) 53 HEX FL NUT BM6
15 ASSY.TUBE(CYL.HEAD VENT) 44 ASSY.THERMOSTAT (82 DEG.SOT ) 54 ASSY.HOSE (WATER BYPASS) (SPR.BAND)
16 SPRING BAND CLAMP FORM A 12X14D TS17665 45 SEAL THERMOSTAT 55 HOSE CLAMP 35
PREVIOUS
36 ASSY.WATER PUMP (OFFER DRG.) 46 HEX FL NUT AM6 56 ASSY.ELBOW (FOR WATER INLET
37 GASKET (FOR WATER PUMP) 47 SEALING WASHER 12X15.5 57 GASKET (FOR WATER INLET ELBOW)
38 ASSY HEX SCREW M6X20 48 TEMPERATURE TRANSDUCER-M/S PRICOL 58 HEX FL SCREW M8X18
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.
FROM HEATER 06
TO WATER ELBOW
08
*
INDEX
07 1.0 17
Fitted on Body 08 18
19
1.0 1.5
Fitted on Body
09
ENGINE 475 SI MPFI
CK
TO BLO
*
To Heater
1.5
T
TA
OS
M
ER
GROUP INDEX
TH
TO
1.5

NO.
01 ASSY.INT.RUBBER HOSE
02 RUBBER HOSE (INTEGRAL HOSE TO AUX.TANK)
03 HOSE CLAMP (53 DIA.) 18 CLAMP FRONT (CYL.HEAD VENT HOSE) 29 ASSY.RADIATOR W/H TH.SW.(AC/NON AC) TOYO
04 SPRING BAND CLAMP FORM-A 12X28D 19 HEX FL SCREW M8X12 29-a ASSY.THERMOSWITCH
05 SPRING CLIP (25) 20 RUBBER HOSE (RADIATOR VENT)TOYO RAD.ONLY 29-b DRAIN PLUG WITH WASHER
06 HOSE CLAMP (26 DIA.) 21 SPRING BAND CLAMP FORM A 12X14D 30 ASSY.SHROUD WITH FAN & MOTOR
07 HEX FL NUT BM6 22 SPRING BAND CLAMP FORM A 12X19D 31 HEX FL SCREW M6X14
NEXT
08 ASSY.CLAMP (FOR INT.HOSE AUX.TANK BR.) 23 RUBBER HOSE-COVER THERMOSTAT TO RADIATOR 32 RUBBER GROMET (RAD MOUNT)
09 HEX FL SCREW M6X10 24 SPRING BAND CLAMP FORM A 15X49D 33 ASSY.BKT.RAD.MTG.TOP RH COMPL
14 SPRING BAND CLAMP FORM A 12X23D 25 ASSY.AUX.WATER TANK W/H PR.CAP 34 ASSY.BKT.RAD.MTG.TOP LH COMPL
PREVIOUS
15 ASSY.TUBE(CYL.HEAD VENT) 26 ASSY.BRACKET-REAR (FOR AUXILLIARY TANK) 35 HEX FL SCREW M6X12
16 SPRING BAND CLAMP FORM A 12X14D 27 HEX FL SCREW M6X12 59 SCREW FOR TOP MOUNTING BRACKET (AUX. TANK)
17 HEX FL SCREW M6X10 28 ASSY HEX SCREW M6X16
55
ENGINE
ENGINE 475 SI MPFI
ENGINE SUSPENSION (85 PS)

ENGINE
®
4.0
2.5
2.5
c
b
®
a 4.5
2.5
2.5
3.5
2.0
a
® b
3.0
NO.
01 LIFTING HOOK (FRONT)
03 ASSY.BRACKET ENG MTG. WITH STUDS 8.0
03-a BRACKET (FOR ENG.MTG.ARM)
03-b STUD BM10X50
03-c STUD BM10X60
NO.
06 ENGINE MTG.ARM (FRONT) 19 ASSY.BRACKET ENGINE STOPPER (FABRICATED)
07 HEX FL NUT AM10 20 HEX FL SCR M12X30
08 ASSY.ENGINE MOUNT-A(HYDRAULIC) 21 HEX FL BOLT M8X38
09 NYLOC NUT M10 22 ASSY.RUBBER STOPPER
10 BRIGHT WASHER 10.5 23 HEX NUT M12
11 ASSY.MOUNTING PLATE (B-MOUNT) 24 ASSY.C LINK & BODY MTG BKT COMPLETE
12 ASSY.STOPER(ON B-MOUNT PLATE) 24-a ASSY.MOUNT INTERMEMEDIATE LINK (REAR)
13 HEX FL BOLT M8X25 24-b ASSY.BODY MTG.BRACKET (FOR C-MOUNT)
14 ASSY.ENG.MOUNT-B (ON GEAR BOX) 25 HEX FL BOLT M10X55
15 NYLOC NUT M12X1.5 26 NYLOC NUT M10
16 WASHER (FOR B-MOUNT) 27 ASSY HEX SCR M12X1.25X30
17 .HEX FL NUT BM8 28 HEX FL BOLT M10X75
18 ASSY.ENGINE MOUNT-C (TC) 29 HEX FL NUT AM10
56
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ENGINE 475 SI MPFI
ENGINE SUSPENSION (75 PS)

® ENGINE
4.0
2.5
2.5 c
b
®
a
4.5
2.5
2.5
3.5
2.0
a
® b
3.0
NO.
01 LIFTING HOOK (FRONT)
03 ASSY.BRACKET ENG MTG. WITH STUDS 8.0
03-a BRACKET (FOR ENG.MTG.ARM)
03-b STUD BM10X50
03-c STUD BM10X60
NO.
06 ENGINE MTG.ARM (FRONT) 19 ASSY.BRACKET ENGINE STOPPER (FABRICATED)
07 HEX FL NUT AM10 20 HEX FL SCR M12X30
08 ASSY.ENGINE MOUNT-A(HYDRAULIC) 21 HEX FL BOLT M8X38
09 NYLOC NUT M10 22 ASSY.RUBBER STOPPER
10 BRIGHT WASHER 10.5 23 HEX NUT M12
11 ASSY.MOUNTING PLATE (B-MOUNT) 24 ASSY.C LINK & BODY MTG BKT COMPLETE
12 ASSY.STOPER(ON B-MOUNT PLATE) 24-a ASSY.MOUNT INTERMEMEDIATE LINK (REAR)
13 HEX FL BOLT M8X25 24-b ASSY.BODY MTG.BRACKET (FOR C-MOUNT)
14 ASSY.ENG.MOUNT-B (ON GEAR BOX) 25 HEX FL BOLT M10X55
15 NYLOC NUT M12X1.5 26 NYLOC NUT M10
16 WASHER (FOR B-MOUNT) 27 ASSY HEX SCR M12X1.25X30
17 .HEX FL NUT BM8 28 HEX FL BOLT M10X75
18 ASSY.ENGINE MOUNT-C (TC) 29 HEX FL NUT AM10
57
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ENGINE 475 SI MPFI
REMOVAL OF 475 MPFI ENGINE FROM THE CAR :

It is recommened to used two post hoist for removing
engine from the car.
ENGINE
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.
Fig.51
Disconnect exhaust pipe from exhaust manifold
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
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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. 2702 5890 24 01
Remove starter motor.
Fig. 54
Disconnect transaxle Assembly from engine. (Ref. transaxle
group)
Remove alternator and its mounting bracket. ‘C’ MOUNT
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 FRONT
recommended brand.
‘A’ MOUNT ‘B’ MOUNT
l Fill coolant in the cooling system through aux. tank
l Crank the engine momentarily. Let oil and coolant Fig. 55
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.
l Confirm whether engine oil pressure indicator light
is switching off when engine is started.
l Check for leakage, rectify if any.
l Top up coolant upto FULL mark in auxiliary tank, if
necessary.
Fig. 56
59
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ENGINE 475 SI MPFI
REMOVAL OF RADIATOR FROM CAR

1.
(Front bumper, Splash guard already removed - For
procedure refer Body group of this manual) 2.
ENGINE
1. Drain the coolant.
2. Remove all the hose connections i. e.
i. From the thermostat
ii. From the auxiliary tank. 3.
iii. To the outlet elbow.
3. Disconnect the electrical connections,
1. ASSY. RADIATOR COMPLETE
i. To the condenser fan (For AC version)
ii. To the temperature sensor of cooling fan. 2. CROSS MEMBER RADIATOR MOUNTING
4. i. Unscrew the 2 M8 bolts & remove the radiator 3. RUBBER GROMET

bottom mounting member along with the
radiator. Fig 57
ii. Remove upper support bracket. Fig. 57
SPECIFICATIONS
AUXILLIARY TANK AUXILLIARY TANK CAP
Leakage testing pressure : 1.5 bar
Auxillary Tank Cap Fig. 58
Pressure valve opening : 1 bar
Vacuum valve opening : 0.05 bar (max)
(suction)
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
Fig. 58
mounting bolts.
ii. Fit upper mounting bracket. a. Fill branded premixed ready to use coolant in the
2. Fit back the 3 hose connections. auxiliary tank after ensuring all the hoses are secured
3. Connect the electrical connections for temperature and leak proof.
sensor & condenser fan (For AC version) b. During filling, keep the hose clamp loose at
Fill branded coolant as per specification. thermostat housing.
Top up coolant through auxiliary tank cap upto ‘Full”mark. c. During coolant filling, ensure that the air in the
Fit Auxillary tank cap. system is removed from this then tighten the hose,
Run engine for short duration and top up coolant if using a screwdriver.
necessary. Remove the trapped air though venting d. Start the engine & slowly raise the engine speed &
screw. wait for the temperature to reach 850 C to 900 C to
Bleeding procedure for cooling system : allow the thermostat to open up. Engine running at
idling speed, open the bleeding screw by using a
(For refilling or during reconditioning after complete screwdriver to allow any trapped air in the system to
draining) escape. Tighten the bleeding screw & top up with
coolant to max. level.
60
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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 SLIDER SCREWS
thumb pressure applied. 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.
SPAN
2. Inspect pulley grooves.
ALTERNATOR BELT TENSIONER BOLT

Fig. 60
61
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ENGINE 475 SI MPFI
FITMENT
SPAN
1. Install the belt over crankshaft and A. C. compressor
ENGINE pulleys.
2. Press the tensioner against the belt and tight the
tension bolt to specified torque.
3. Check belt tension.
BELT
4. The belt tension to be adjusted such that on the TENSIONER
ROLLER
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. BELT TENSION
ADJUSTING SCREW
Fig. 61
62
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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 3

4 5 6
ENGINE
Crankshaft
Removal :
Pulley
l Loosen alternator upper mounting Bolt and bottom
2
mounting bolt Fig. 61a. For vehicles with power 10-11mm
steering please refer 61b.
l Slightly loosen banjo bolt connections on vacuum
pump
l Reduce alternator belt tension by loosening of tension
Alternator
adjusting nut and by pushing alternator towards 1
engine.
l Remove alternator belt.
Inspection :
Engine with Alternator (without power steering)
l Inspect alternator belt for wear, cracks and signs of
failure. Replace, if necessary. 1. Alternator mounting bottom bolt
Fitment : 2. Alternator mounting upper bolt
l Install alternator belt over crank shaft, power steering 3. Clamping piece
pully and alternator pulleys (Fig. 61b). 4. Clamping bolt
Note : incase of vehicle without power steering, power 5. Adjusting nut
steering pulley will not be there Fig-61a). 6. Lock nut
l Pull alternator away from engine for specified tension
& tighten the nut to specified torque. Fig. 61a
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.
Alternator
INSPECTION Crankshaft Pulley
1. Inspect the A. C. compressor belt for wear cracks, and
signs of failures. Replace if necessary.
2. Inspect pulley grooves.
8-9 mm
FITMENT
1. Install the belt over crankshaft and A. C. compressor
pulleys.
2. Press the tensioner againsts the belt and tight the Compressor
tension bolt to specified torque. Tensioner Tensioner
8-9
3. Check belt tension. Bolt mm
Power Steering
4. A. C. Compressor belt tension is correcrt if it can be Pump
depressed by 8-9 mm with thumb pressure applied in
the middle of its length between compressor and Fig. 61b
crankshaft pulleys.
63
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ENGINE 475 SI MPFI
TIMING BELT :
Removal :
ENGINE
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
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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 Fig. 65
l Cracked tooth bottom
l Side of belt cracked
l Side of belt excessively worn
l Excessively worn teeth
l Missing tooth
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
Check that the cam gear is “Just” freely rotating on the gear is “Just” freely rotating on camshaft. Fit the camshaft
camshaft with mounting bolt in hand loose gear washer lock plate as shown in Fig. 65
condition. Check now that both the flywheel and camshaft are in
locked in timing position.
Slacken all valve tappet clearance setting screws to
such an extent that the screw bottom radius is just Fit timing belt on Crank shaft gear, water pump, tensioner
riding on the valve tips & tighten the locknuts. roller and camshaft gear.
NOTE : Adjust the timing belt tension, by rotating tensioner roller
clockwise and tighten the mounting screw, while
This is to reduce the valve spring load on Camshaft, while tightening the mounting screw ensuring that the
rotating the camshaft. tensioner roller does not rotate further in clockwise
Using appropriate spanner on camshaft gear fixing bolt, direction. This will prevent overtensioning of timing
rotate camshaft in clockwise direction with timing pin belt.
placed on the cylinder head reference hole, until the Tighten the cam shaft gear fixing bolt to a lower tightening
camshaft is locked in timing position. (Fig. 116) torque of 1 mkg.
65
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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.,
Fig. 67
Inlet - 3 & 4 and Exhaust - 2 & 4
Rotate crankshaft in clockwise direction by more bolt. This is to prevent severe damage to cylinder head,
revolution and check whether flywheel and camshaft camshaft timing slot and subsequent problem of very low
are in locked timing position. oil pressure (due to increased bearing clearance on bearing
No. 5 of cylinder. head).
NOTE :
Special ‘C’ tool should be used whenever cam gear fixing
In this procedure timing pin locking the camshaft is bolt is to be tightened or loosened.
removed from the cylinder head timing reference
hole, whenever camshaft is subjected to very high Never use the timing pin in locked timing position to hold
looserning and tightening torque through the gear fixing the camshaft during tightening or loosening process.
LOCK NUT
(VALVE TAPPET CL. SCREW)
ROCKER ARM Cylinder Head Ex-
ROCKER SCREW
SPRING RETAINER
ploded
LOCK
HALF
SPRING
VALVE GUIDE SEAL
VALVE
GUIDE
ROCKER
SHAFT
CYLINDER HEAD
CAM SHAFT
TIMING
GEAR
EXHAUST VALVE
INTAKE VALVE
Fig. 68
66
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ENGINE 475 SI MPFI
CYLINDER HEAD : (Engine on workstand)

Disassembly:
Remove electrical cable connections for : ENGINE
l 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
67
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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
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ENGINE 475 SI MPFI
l Exhaust manifold Fig. 75

l 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
69
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ENGINE 475 SI MPFI
Also remove
l Timing belt Fig. 78
l Dip stick clamping screw
ENGINE
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
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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 ENGINE
setting screws. In this condition do not attempt
to rotate the cam shaft, if you do so valve tips
will be damaged. (Fig. 81)
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
71
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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
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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. Fig. 89
73
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ENGINE 475 SI MPFI
2. Pull out the spark plug cables by gripping at the

connector.
ENGINE 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 Fig. 90
damage the threads in the cylinder head. A loose spark
plug can affect combustion and cause engine damage.
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
Fig. 91 Fig. 92
(stationary engine). Replace spark plugs.
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
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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
ENGINE
misfire. Replace spark plugs.
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 : Over-
advanced 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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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
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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 ENGINE
(150 x 150) : cross wise 0.015 mm
length wise 0.030 mm.
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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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
ENGINE
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 Fig. 102
be less than 0.85 mm.
INLET VALVE EXHAUST VALVE

VALVE STEM
B
B
VALVE SEAT
C C C C
D
D A
0
A
45
VALVE SEAT ANGLE 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
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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 0.2 0.2

to valve steam mm
Valve seat dia C mm 35 29.2
Valve seat end distance from valve face D mm 2.65+0.1 2.82+0.1
Maximum run out of valve seat with 0.030 0.030

respect to valve steam
Valve seat dia in cylinder head mm 34 28.0
Distance between cylinder head mating 14.4+0.05 14+0.05

surface with crank case to valve seat in
cylinder head mm
Maximum run out of valve seat in cylinder 0.030 0.030

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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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 Valve guide Valve guide Valve guide

bore in cyl. head OD,mm ID,mm length, mm
+ 0.015
Normal 12.99+0.008/-0.01 13.0 + 0.046 7 - 0 (Inlet)
+ 0.016
+ 0.028 7 + 0.004 (Exhaust) 39.5 (Inlet)
+ 0.015
Normal 1 13.09+0.008/-0.01 13.1 + 0.046 7 - 0 (Inlet) 46 (Exhaust)
+ 0.016
+ 0.028 7 + 0.004 (Exhaust)
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND suitable puller. In order to avoid damaging machined
WITHOUT ANY CHATTER MARKS cylinder head mating surface with crank case, place any
If necessary lap valve seats to a smooth and even finish by soft protective sheet metal under supports of puller.
using suitable hand pump grinder or a lapping paste and Measure valve seat insert bore in cylinder head & then
valve itself. 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
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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.
Fig. 108
l 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 Valve seat inside dia in insert
Inlet - 6.5 + 0.05 mm Inlet - 32 + 0.1mm
Exhaust - 6.5 + 0.05 mm Exhaust - 26 + 0.1mm
Valve seat insert & bore dia. in cyl. head
Stage Valve seat insert bore Valve seat insert

diameter in cyl. head (mm) out side diameter (mm)
INLET
- Normal 38/38.03 38.13/38.155
- Normal 1 38.23/38.28 38.43/38.455
EXHAUST
- Normal 32.99/33.021 33.13/33.155
- Normal 1 33.29/33.321 33.43/33.455
CAM SHAFT INSPECTION

Carry out visual inspection of cam shaft for : Check hardness of cam shaft journals and cam lobes. It
l Overall heating of journals, which is indicated by should be 40 HRC min.
bluish/brown colour Check cam shaft runout at 2nd, 3rd & 4th journal by
l Deep scoring marks on journals and cam lobes supporting it on V-block at 1st and 5th journal. Fig. 108
l Cracks, which should be checked on a magnetic Check cam shaft journal dimensions.
crack detector.
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Cam shaft journal & bearing bore dimensions (mm) :

Journal No. Cam shaft bearing journal Cam shaft bearing
ENGINE
bore diameter in cylinder head journal diameter.
1 42.000 - 42.025 41.925 - 41.950
2 41.500 - 41.525 41.425 - 41.450
3 41.000 - 41.025 40.925 - 40.950
4 40.500 - 40.525 40.425 - 40.450
5 40.000 - 40.025 39.925 - 39.950
Maximum permissible run out of cam shaft bearing journal 0.025 mm
Maximum permissible axial play of cam shaft in installed condition 0.1/0.25 mm
Runout of oil seal mating diameter. 0.02 mm
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
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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 ENGINE
different).
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:
- 0.016
Rocker shaft dia. :15 mm
+ 0.011
Rocker bore dia. : 15 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 GASKET
PROJECTION THICKNESS, Fig. 112
mm mm
0.04 - 0.26 1.1
MAXIMUM DIFFERENCE BETWEEN PISTON PROJECTIONS

OF ANY TWO PISTONS IN CRANK CASE SHOULD NOT
EXCEED SPECIFIED VALUE.
Fig. 113
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Ensure that cylinder head locating hollow dowel is in

position on crank case (Block).
Ensure that flywheel locking pin 2702 5890 0605 is
ENGINE
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 4 8
1 2 3 4
10 6 2 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
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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 ENGINE
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.
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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l Rotate the crankshaft by one rotation in the

clockwise direction and insert the flywheel
locking pin.
ENGINE
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
Specified 0.20 0.30
Assemblies Fig. 120
l Spark plug. Fig. 121
Fig. 121
l Exhaust manifold Fig. 122
Fig. 122
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l Inlet manifold with throttle body and gasket.

Fig. 123
l Spacer tube on cylinder head cover mtg. studs. ENGINE
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. Fig. 123
l Bracket supporting fuel lines.
l Spark plug leads.
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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ENGINE 475 SI MPFI
Remove :
l Vibration damper Fig. 126.
ENGINE
Fig. 126
l Crankshaft gear Fig. 127.

l Water pump
l Timing belt tensioner
l Timing belt rear cover
Fig. 127
l Oil filter by using spanner (2702 5890 1802)

Fig. 128
l Engine mtg. bkt. (intermediate)
Fig. 128
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l Oil sump by extended socket (2702 5890 0603)

Fig. 129
ENGINE
Fig. 129
l Oil pump strainer Fig. 130a

l 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. 130b Fig. 131
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ENGINE 475 SI MPFI
Remove connecting rod bearing caps with bearing shells.

Push these piston assemblies out of cylinders using the
ENGINE 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
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Unscrew flywheel mounting screws Fig. 135a

Remove flywheel locking pin.
Remove flywheel. ENGINE
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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ENGINE 475 SI MPFI
PISTON AND PISTON RINGS :

PISTON AND CYLINDER BORE SIZES :
ENGINE
Type Grade Cylinder bore Piston
Diameter mm Diameter mm
A 75.00/75.01 74.96
Standard B 75.01/75.02 74.97
C 75.02/75.03 74.98
PISTON RINGS :
Type of ring Axial clearance Butt clearance
in piston groove in cylinder bore
1st Compression 0.03 / 0.07 mm 0.15 / 0.3 mm
ring Fig. 138
2nd Compression 0.02 / 0.06 mm 0.2 / 0.35 mm
ring
3rd Oil control - 0.2 / 0.6 mm
ring
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. 20.00/19.996 mm

Piston Pin length 59.00/58.7 mm
Piston Pin bore in piston 19.998/20.003 mm
Height of Piston 52.5 mm
Piston to bore clearance 0.040 - 0.050 mm
Max. permissible difference in
weights of pistons with pin &
rings of an engine 3 gms.
Fig. 140
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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, ENGINE
complete ring set should be replaced.
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 Fig. 141
plier.Ensure‘TOP’marking is towards the piston crown.
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. Fig. 142
Ensure that centre distance between small end & big
end is maintained within specified limit.
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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CONNECTING ROD (DIMENSIONS) :

Connecting rod small end
ENGINE Stage parent bore bush outside
diameter mm 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 0.004 mm

small end parent bore and cylindricity 0.008 mm
Connecting rod small end bush inside diameter 20.0+0.020/0.007 mm

finished after installation) (Piston pin oiled has
thumb push fit in small end bush).
Maximum permissible out of parallelism (bend) between 0.050 mm

connecting rod small end and big end parent bores.
Centre to centre distance between connecting rod small 141.65+-0.3 mm

end and big end parent bores.
Maximum permissible twist of connecting rod 0.050 mm
Connecting rod big end parent bore diameter 48.655 /48.671 mm
Maximum permissible taper and ovality of connecting rod 0.005 mm

big end parent bore and cylindricity 0.01 mm
Bearing shells to be selected such that clearance is maintained as 0.024 to 0.075 mm
Pre-tension of connecting rod big end bearing shells 0.013-0.051 mm
Maximum permissible difference in weight of 5 gms

connecting rods in one engine
Connecting rod big end axial play 0.05 - 0.35 mm
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NOTE :
Ensure that the identification numbers for connecting rod
& connecting rod bearing cap are matched & notches for ENGINE
bearing shells are on same side.
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 Fig. 144
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.
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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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
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Crank shaft (dimensions)
Stage Crank case main bearing bore Crank shaft main bearing journal
diameter with bearing shell mm diameter mm ENGINE
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 Crank pin journal diameter mm
diameter with bearing shell (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 Thickness of 4th main
journal (mm) 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 Pre-tension of main bearing shells 0.018-0.040 mm
Fillet radius of main bearing journals 2.5-0.5 mm Hardness of crank shaft main 50-60 HRC
bearing and crank pin journals
Fillet radius of crank pin journals 2.5-0.5 mm
Main bearing parent bore dia in 53.8 +0.019 mm
Width of 1st, 2nd, 3rd and 5th 24.0+0.2 mm
crank case + 0.00 mm
main bearing journals
Maximum permissible taper of 0.005 mm
Width of crank pin journals 24.0+0.2 mm
main bearing parent bore
Maximum permissible cylindricity 0.0025 mm
Maximum permissible ovality of 0.005 mm
Ovality of main brg. journal 0.005 mm main bearing parent bore.
Max. permissible ovality of crank pin 0.005 mm Crank shaft journal to main 0.026 / 0.085 mm
Maximum permissible run out of 0.02 mm bearing clearence
2nd, 3rd and 4th main bearing journals
when supported at 1st and 5th main
bearing journals
Maximum permissible out of parallelism 0.010 mm
between crank pin and main
bearing journal axis
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4th main bearing journal
CRANK SHAFT :
Clean and carry out visual inspection of crankshaft for the
following
ENGINE
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. 152
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. 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
99
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ENGINE 475 SI MPFI
Measure the main bearing bore.

BOLT TIGHTENED BOLT LOOSENED
IF MAIN BEARING PARENT BORE DIMENSION IS
ENGINE
MAINTAINED WITHIN SPECIFIED LIMITS, PROPER MAIN
BEARING BORE DIMENSION IS AUTOMATICALLY ACHIEVED.
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 PRETENSION
GAP
on opposite side of bearing shell lug (This is to be done on
ÞÞ
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), SURFACE PLATE
change & select new shell.
MAIN BEARING SHELLS ARE PRECISION FINISHED AND
SHOULD NOT BE BORED OR SCRAPED. Schematic Sketch : Main bearing shell pretension checking
Select a new pair of thrust washer according to crank Fig. 155

shaft 4th main journal width. Refer Fig. 149
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
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PREVIOUS
ENGINE 475 SI MPFI
REMOVAL, INSTALLATION AND MACHINING OF approximately at 100-120 rpm and approx. 50 double
CYLINDER LINERS strokes per minute. Under these conditions leave about
0.02 mm materials for second stage honing. Anticlock
REMOVAL
wise direction of rotation of tool will be prefered if possible. ENGINE
1. Keep cylinder block upside down on hydraulic press Stage II

such that bore from which liner is to be removed lies
clear in machine table slot. Base honing
The honing should be approx. 50-60 rpm & 25 double strokes
2. Ensure that the block is resting squarely on machine per minute.The opration should be completed in 5 to 8 double
bed. strokes with low pressure of 2.0 to 3.0 kg/cm2.
3. Press out liners individually using drift, (Pt. No. 2702 Anticlock wise rotation will be preferred if possible.
5890 0201 and a suitable distance piece between press
ram and the drift. Make sure that the distance piece is Note : Adjust honing stick travel project by approx. 20-25
also seating squarely between the drift and the ram. mm from top and bottom of bore during honing. Use plenty
of kerosene during honing operation. At bottom 20 mm
INSTALLATION OF LINERS IN CYLINDER BLOCK overtravel, care must be taken that stick holder will not hit
Thoroughly clean bores of the cylinder block. to MB faces.
Thoroughly clean liners. Clean cylinder block thoroughly and if engine assembly is
not to be taken up immediately, apply grease on machined
Place cylinder block on hydraulic press ensuring that oil surface of cylinder block.
sump mating face is resting evenly and squarely on the
Special Tools Required :
horizontal bed.
Drift for installation of cylinder liner - 2702 5890 02 01
DO NOT SMEAR CYLINDER BORE OF BLOCK OR LINER Drift for removal of cylinder liner - 2702 5890 02 02
OUTSIDE SURFACE WITH OIL.
Place liner with proper orientation (matching minimum /
maximum ovality axis) in the cylinder bore and make it at 78+0.02
right angles to cylinder block top surface in longitudinal
and crosswise directions using precision tri-square. 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.
Similarly, press all other liners. 75+0.01
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
Fig. 156b
101
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ENGINE 475 SI MPFI
Cylinder Block (Dimensions) - in mm

C
Height of crank case 265.8/265.6 D
ENGINE
(Dimension A&B) Fig. 157
Maximum permissible unevenness
of crank case mating surface with cylinder
B
head 150x150 : cross wise ‘D’ Fig. 157 0.015 A
: length wise ‘C’ Fig. 157 0.030
Maximum permissible out of 0.2

parallelism between crank case top and
bottom machined surface
Maximum permissible shift in 0.25 mm

perpendicularity of cylinder bore Fig. 157
from crank shaft axis when
checked from crank shaft centre line
Maximum permissible taper and 0.007
ovality of cylinder bore
102
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ENGINE 475 SI MPFI
LUBRICATION SYSTEM : Pump rpm Minimum flow rate in Ipm

OIL PUMP 4000 28
ENGINE
Unscrew screws holding oil pump to cyl. block and remove 2000 14
the oil pump assembly Check oil pump for flow rate at
specified rpm. Check for any leakage at sealing plugs. 800 5.6
Check functioning of Pressure relief valve. If the Engine oil pressure with coolant temperature of 700 C at
performance of the pump is not satisfactory, then replace idling speed
the oil pump assembly. 800+50 rpm - 1 bar
Fit oil pump assembly with new gasket. at 5000 rpm - 3 bar
Flow rate measured against back pressure of 3kg/cm2 Oil Pressure Switch
should be as follows using SAE-30 oil. NC contact opening pressure : 0.9 /0.6 bar
ENGINE LUBRICATION COMPONENTS
MAINOIL
GALLERY
OILFILTER
OILPUMP
GASKET
OILSUMP
STRAINER
DRAINPLUG
Fig. 158
103
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ENGINE
104
Fig. 159
COOLING CIRCUIT
INDEX
RADIATOR VENT HOSE
AUXILIARY WATER TANK
ENGINE 475 SI MPFI
INTEGRAL HOSE
RADIATOR
GROUP INDEX
WATER INLET ELBOW
HEATER RETURN HOSE
CYLINDER HEAD VENT LINE
BYPASSLINE
UPPERCOOLINGLINE CAB HEATER FEEDER HOSE
NEXT
THERMOSTATCOVER
WATER TEMP. SENSOR
PREVIOUS
THERMOSTATHOUSING
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 Fig. 160
5000 5250 100

THEMOSTATE OPEN
5500 5775 110
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
Fig. 161
Thermostat is installed in cooling system between cyl.
head & radiator inlet tank.
3. As the engine cooling temperature reaches
The working principle of thermostat : thermostat full open temperature, thermostat valve
1. For cold engine (immediately after starting) : opens fully and thermostat by-pass valve closes
Thermostat does not allow coolant to flow to radiator completely.Under such condition maximum quantity
(Thermostat valve in closed position) instead coolant of engine coolant flows to radiator Fig. 161.
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.
105
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ENGINE 475 SI MPFI
Satisfactory operation of thermostat is very much essential

for :
l Efficient engine operation
ENGINE
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 Fig. 162
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 Fig. 163
thermostat element.
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
Fig. 164
106
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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
107
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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 Fig. 168
piston with piston rings can slide inside it. Fig. 169
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 VALVE POCKETS
same side Fig. 170.
JET
LUGS
Fig. 170
108
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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 ENGINE
manner.
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
109
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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
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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
111
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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
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AIR INTAKE SYSTEM
Fig. 182
AIRTEMPRATURESENSOR
INDEX
SNORKEL
ENGINE 475 SI MPFI
T - HOSE
AIR FILTER
GROUP INDEX
RESONATOR BOX
INTAKEMANIFOLD
CYLINDERHEAD
NEXT
PREVIOUS
113
ENGINE
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.
Fig. 183
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
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ENGINE 475 SI MPFI
ACCELERATOR CABLE
ENGINE
9 11 10
1 ASSY.ACC.CABLE-RHD
2 CLIP
3 HOSE
4 GROMMET
6 CABLE TIE 4.7X110
7 BRACKET ACC. CABLE
8 TOP SIDE NUT
9 ACCELERATOR PEDAL
10 ACCELERATOR CABLE PLASTIC END
11 INNER CABLE END
Fig. 184
Removal : Installation :
1. Loosen the top side nut (8) from threaded end of 1. Insert accelerator cable plastic end (10) inside the
accelerator cable at throttle body end. firewall hole.
2. Remove Hex FL screws (5) & remove cable from clip 2. Insert inner cable end (11) in accelerator pedal.
(2).
3. Locate accelerator cable in clip (2). Ensure that rubber
3. Remove inner cable end from throttle body sector sleeve (3) on accelerator cable are located inside the
after disengaging the threaded end of the cable in clip.
throttle body bracket (7).
4. Loosen the top side nut (8) from threaded end of the
4. Remove inner cable end (11) from accelerator pedal cable. Engage the threaded end of the cable in body
(9). bracket (7). Insert inner cable end in throttle body
sector.
5. Remove accelerator cable plastic end (10) through
firewall hole. 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.
115
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ENGINE
116
ASSY. FOOT CONTROL
INDEX
4.0
ENGINE 475 SI MPFI

NO.
1 ASSY FOOT CONTROL MODULE -RHD
2 ASSY.CONTROL MOUNTING
BRACKET (WELDED)
GROUP INDEX
3 ASSY CLUTCH PEDAL LEVER COMPLETE.
4 ASSY ACC PEDAL (RHD)
5 SLEEVE (FOR BRAKE & CLUTCH)
6 CLUTCH PEDAL ASSISTANCE SPRING
7 BRIGHT WASHER 10.5
8 HEX BOLT M10X125
9 ASSY BRAKE PEDAL LEVER COMPLETE
10 TORSION SPRING (FOR BRAKE PEDAL RETURN)
11 NYLOC NUT M10
12 TORSION SPRING FOR ACC.PEDAL RETURN.
13 BUSH
14 CIRCLIP E9X1.1
NEXT
15 STOP LIGHT SWITCH
16 CLUTCH PEDAL STOPPER
17 HEX SCREW M8X45
PREVIOUS
18 HEX NUT M8 Fig. 185 ® -Non Reusable Part
19 RUBBER COVER (PEDAL PLATE)
20 RUBBER COVER (ACC.PEDAL)
ENGINE 475 SI MPFI
ENGINE TESTING Allow engine to cool down for about 3 hours.Then remove
cylinder head cover.
After assembly of the engine, mount engine on test bed,
prepare engine for starting and testing in the following Loosen cylinder head mounting bolt by quarter turn and ENGINE
manner. retighten immediately to 7 mkg torque in the correct

sequence.
Connect oil pressure gauge and temperature gauge.
Complete cylinder head tightening operation in the same
Connect coolant hose to and from radiator. Fill coolant in sequence and with the same torque.
the cooling system. Fit radiator cap. Start the engine and check for any fuel leakages. Rectify, if
necessary.
Fill required quantity of recommended running-in oil in
the oil sump.
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 Time (minutes) Torque (mkg)
(rpm)
800 5 0.0
2000 5 2.3
2500 5 4.6
3000 5 5.8
3500 5 4.9
2500 5 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.
117
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ENGINE 475 SI MPFI
EVAPORATIVE EMISSION CIRCUIT :

ENGINE
Fig. 186
118
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ENGINE 475 SI MPFI
8. TROUBLE SHOOTING
NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE WIRING HARNESS CAREFULLY.
ENGINE
Sr. Problem Observed Probable Cause Action to be taken
no.
1. Engine not cranking Low battery voltage Clean and tighten the connectors
Jump start using another battery
Get battery charged or changed
Faulty starter Rectify or replace
Worn out piston rings/seized pistons Overhaul & replace affected parts
Faulty immobiliser Check and rectify
2. Engine cranks but

doesnot start Clogged air filter Clean as per the instructions
Incorrect valve timing Set valve timing /check & reset
Faulty spark plugs Clean, check gap/replace if necessary
Faulty crank angle signal Check & correct the gap
Faulty water temperature sensor Check & replace if necessary
Faulty MAP signal Check & replace if necessary
Faulty throttle position signal Check & replace if necessary
Faulty ISC valve Check & replace if necessary
Clogged injectors Check & replace if necessary
Faulty fuel regulator Check & replace if necessary
Clogged fuel filter Replace
Faulty ignition coil Check and replace
Faulty firing order/ injector Check and replace
(connection) order
Faulty E C U Replace
Faulty inertia switch Reset if tripped off or replace
Faulty Fuel Pump Check and replace if necessary
3. Erratic idling Inlet manifold leakage/

vacuum connections Check and rectify
Valve timing incorrect Set valve timing /check & reset
Vehicle speed signal faulty Check & replace
ISC valve faulty Check & replace
Vacuum line to presure
regulator connections Check & tighten/replace
Faulty firing order/
injector(connection) order Check and rectify
4. Does not idle Faulty MAP signal Check & replace

Faulty ISC Valve Check & replace
Faulty fuel regulator Check & replace
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ENGINE 475 SI MPFI

no.
5. Maximum RPM low Battery voltage low Check and tighten connections
ENGINE
Jump start using good battery
Get battery charged/changed
Clogged air filter Clean as per instruction
Valve timing incorrect set valve timing /check & reset
Spark plugs defective Clean and check gap/replace if
necessary
Adulterated fuel Flush the system and refill
Faulty crank angle signal Check and rectify the gap 1.5 + 0.5 mm
Clogged injectors Check and Replace
Fuel pump faulty Check and Replace
injector (connection) order Check and rectify
6. Poor Low battery voltage Check and tighten connections

acceleration/Power
Clogged air filter Clean as per instructions
Inlet manifold leakage/
Faulty ISC valve Check & replace
Clogged injectors Check & replace
Faulty fuel regulator Check and replace
Faulty ignition coil Check and replace
Faulty firing order/ injector Check and replace
(connection) order
Incorrect tappet clearances Check and reset
Inlet manifold leakage/
Worn out piston rings/seized pistons Overhaul /replace affected parts
necessary
Adultrated fuel Flush the system and refill
Faulty fuel regulator Check and Replace
Fuel pump faulty Check and Replace
injector(connection) order Check and rectify
120
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ENGINE 475 SI MPFI

no.
7. Knocking Spark plugs defective Clean and check gap/replace if necessary ENGINE
regulator connections Check and tighten/replace
Incorrect valve timing Check and adjust.
8. Misfiring Inlet manifold leakage/ Check and Replace

necessary
Faulty crank angle signal Check and rectify the gap
injector(connection) order Check and Rectify
9. Whitish/Bluish smoke Clogged air filter Clean as per instructions

Worn out pistonirings/seized pistons Overhaul /replace affected parts
Valve guide seals leaking Check and Replace
Adultetated fuel Flush the system and refill
10. High fuel Low battery voltage Check and tighten connections
consumption
Inlet manifold leakage/ Set valve timing /check & reset
Worn out piston rings/seized pistons Overhaul /replace affected parts
necessary
Faulty lambada signal Check and Replace
Faulty fuel regulator Check and Replace
regulator connections Check and tighten/replacet
Faulty firing order/ injector Check and rectify
(connection) order
11. High oil consumption Clogged Air Filter Clean/replace

Worn out piston rings/siezed pistons Overhaul /replace affected parts
Valve guide seals leaking Check and Replace
121
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FUEL FEED SYSTEM
NEXT
GROUP INDEX
PREVIOUS
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).
NEXT i
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FUEL FEED SYSTEM
CONTENTS
FUEL
1. Technical Specification 1 FEED
SYSTEM
2. Exploded Views
a) Assembly Fuel Tank with Filler pipe 2
b) Schematic circuit for MPFI Fuel Lines Euro II 3
3. General operation of evaporative emission system 4
4. Fuel tank 5
5. Fuel tank purging procedure 8
6. Electric intank fuel pump 10
7. Fuel pressure regulator 11
8. Fuel level guage (tank unit) 12
9. Fuel level guage (dashboard) 13
10. Fuel filter 14
11. Fuel filler cap 16
12. Fuel hoses and lines 17
13. Fuel level warning light 18
14. Evaporative emission control system 19
a) Restrictor 19
b) Vapour separator 19
c) Tank pressure valve 20
d) Carbon canister 21
e) Canister purge valve 23
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FUEL FEED SYSTEM
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 FUEL
FEED
3. Fuel filter type : Inline (BOSCH) SYSTEM
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
1
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INDEX GROUP INDEX
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FUEL
FEED
SYSTEM
2
ASSEMBLY FUEL TANK WITH FILLER PIPE - Specified Torque in Kgm
INDEX
FUEL FEED SYSTEM
0.8 to 1.0
2.2
GROUP INDEX
NO. 13 ASSY FILLER NECK WITH BRACKET (22.7 DIA)
0.8 to 1.0
1 ASSY FUEL TANK COMPLETE (MPFI) 14 ASSY FUEL TANK CAP-NONVENTED
2 ASSY FUEL TANK WELDED (FOR MPFI VERSION) 15 ASSY.HOSE PIPE 26 ASSY NYLON LINE
3 SEALING PLUG AM18X1.5 16 HOSE CLAMP ( 53 DIA ) 27 PLUG (FOR VAPOUR LINE)
4 SEALING WASHER 18X22 IS3175 CU 17 ASSY BREATHER HOSE 28 SPRING CLIP (10)
5 ASSY INTANK FUEL PUMP 18 HOSE CLAMP ( 23 DIA ) 29 ASSY NYLON LINE (VAPOUR SEPARATOR TO TPV)
6 LOCKING RING 19 ASSY BRACKET (FUEL FILTER MOUNTING) 30 SPRING BAND CLAMP FORM A 12X14D
7 PUMP PACKING 20 RUBBER PACKING 31 SLEEVE ( VAPOUR SEPARATOR HOSE)
NEXT
8 HEX FLANGE SCREW M6X10 - 8.8 21 ASSY.FUEL FILTER (M/S BOSCH ) 32 CABLE TIE 8 0X300 BLACK
9 GASKET 22 HEX FLANGE SCREW M6X16 -8.8 33 WASHER A8 4 IS5370 - ST
10 ASSY TANK UNIT W/O LOW LEVEL SENSOR (INJ)-VDO 23 ASSY DELIEVERY LINE FROM PUMP TO FILTER 34 HEX FL BOLT M8X25 - 8.8
PREVIOUS
11 CR PAN HD SCREW M5X10 24 ASSY RETURN LINE ON TANK 35 CLAMP(PIPE 8X8)
12 SPRING WASHER B5 25 ASSY VAPOUR SEPERATOR 36 HEX FL SCREW M6X20 - 8.8
SCHEMATIC CIRCUIT FOR MPFI FUEL LINES EURO II - Specified Torque in Kgm
INDEX
NO.
1 ASSY DELIEVERY LINE FROM FILTER
2 ASSY CLUSTER ON ENGINE
(3 BUNDY TUBES) 0.8 0.8 0.8
3 SPRING BAND CLAMP FORM A 12X14D 0.8
4 ASSY RETURN LINE (FIREWALL
TO UNDERBODY)
5 ASSY PIPE
6 TANK PRESSURE CONTROL VALVE
7 RUBBER HOSE (TPV TO CANISTER)
FUEL FEED SYSTEM
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)
GROUP INDEX
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)
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0.8
3
FUEL
FEED
SYSTEM
FUEL FEED SYSTEM
The fuel system consists of : Warning :

1. Fuel tank assembly Before performing any operation on fuel system please
2. Electric intank fuel pump do following :
3. Fuel level gauge (tank unit)
4. Fuel level gauge (dashboard) Disconnect negative cable terminal at battery (you
FUEL 5. Fuel filter might have to connect the battery in some cases
FEED
SYSTEM 6. Fuel filler cap as explained in next pages).
7. Fuel hoses, fuel lines and fuel rail (i.e. delivery,
return and vapour lines) Always wear safety glasses.
8. Fuel Pressure regulator Release the fuel pressure from the fuel system to
The evaporative emission system consists of : reduce the possibility of injury or fire.
a) Tank pressure valve While removing the fuel tank from the vehicle, keep
b) Canister purge valve sparks, cigarettes and open flames away from it.
c) Carbon canister
d) Resistor Before repairing fuel tank assembly, clean it
e) Vapour separator 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.
4
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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 FUEL
removed from the vehicle. Fig 2. 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.
5
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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
A small amount of fuel may be released after fuel FEED
SYSTEM
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.
Fig 8.
9. Remove fuel filter from bracket.
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.
7
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FUEL FEED SYSTEM
FUEL TANK PURGING PROCEDURE :

Caution : The purging may not remove all fuel
vapours. Therefore any repair on fuel tank using
external heat or flame may result in explosion
FUEL
causing personal injury or damage.
FEED
SYSTEM 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. Fig 9.
Replace the fuel tank if it is rusty from inside.
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.
9
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FUEL FEED SYSTEM
ELECTRIC INTANK FUEL PUMP :

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
FUEL pressure fuel system from fuel tank.
FEED
SYSTEM
On Vehicle Inspection :
1. Check fuel pump for operation as follows :
a) Remove fuel filler cap.
Fig 13.
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 : Warning :
2 a) For fuel pump removal fold the rearseat and
Unless replacement is necessary, fuel pump, fuel level
open the plastic lid located under the floor
gauge should not be removed from the tank since the
carpet.
rubber parts i.e. gasket, seals etc. may get exposed
b) Disconnect electrical connectors. Release the to air, light and may become hard.
fuel system pressure as already explained in
fuel tank removal. Never apply an excessive force to the fuel pump nipple
or lead wire. This may result in bent or poor contact.
c) Disconnect the fuel lines (delivery and return).
d) Loosen fuel pump mountings screws. Take
the fuel pump out by pushing the ring aside.
Assembly :
e) Check fuel pump for evidence dirt and
contamination. If so, clean and check for Assemble the pump in reverse order of removal as
presence of dirt in fuel tank. 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
fuel rail and intake manifold. FEED
SYSTEM
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 Fig. 13aFuel pressure regulator
conditions.
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
VC PIPE AIR
CHAMBER
DIAPHRAGM FUEL IN
VALVE
TO FUEL OUTLET PIPE

TANK
Fig. 13c Fuel pressure regulator illustration
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FUEL FEED SYSTEM
FUEL LEVEL GAUGE (TANK UNIT) : 2PIN CONNECTOR
Removal : FULL
WIRE SEAL
Refer procedure as mentioned in Fuel tank removal. VIOLET
3/4
FUEL BROWN
FEED Inspection :
SYSTEM
1. Use an ohmmeter to confirm that the 1/2
resistance of the fuel level sensor changes BRAZED
with the level of float position.Fig 14,14a &15. SOLODERED 1/4
2. The specified resistance values of the fuel
gauge are given below : EMPTY HIGH
EMPTY LOW
Fig 14.
Tank fuel Capacity in lts. Position of Resistance Tolerance

level in mm float in tank value in Ohm value in Ohm
+8
9.5 1.1 Empty (low) 120
-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
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 14a. Fig 15.
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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 FUEL
FEED
a) Pullout the wiring harness connector on tank SYSTEM
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 :
Fig 16.
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
FUEL FILTER :
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
FUEL integral mount that holds a filter element with high
FEED
SYSTEM
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.
15
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FUEL FEED SYSTEM
FUEL FILLER CAP :

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
FUEL incorrect installation, which would prevent sealing fuel
FEED
SYSTEM
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 :
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.
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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 FUEL
with clamps at joints. 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 3. Add less than 5 litres of fuel and turn the ignition
SYSTEM 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 Level
fuel tank gauge. Warning Light
b) If light goes OFF, turn the key OFF.Test is Fig 20.
complete.
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FUEL FEED SYSTEM
EVAPORATIVE EMISSION CONTROL

SYSTEM :
RESTRICTOR ON
The car is fitted with an evaporative system to meet
TANK
all requirements of evaporative emission.
FUEL
The system is designed to prevent fuel vapours formed FEED
SYSTEM
within the tank and fuel system from escaping into
the atmosphere. The evaporative emission system
consists of :
a) Restrictor
b) Vapour Separator
c) Tank pressure valve FUEL TANK
d) Carbon canister ASSEMBLY
e) Canister Purge valve
a) Restrictor : Fig. 21 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
1 CAN
polypropylene and is mounted near to the filler
neck area on the rear wheel arch. A vapour liquid 2 TANK
separator allows only liquid free vapour to pass
from fuel tank restrictor to the carbon canister
through tank pressure valve. The vapours getting 3F
condensed / liquid fuel goes to the filler neck.
Removal :
1. To avoid damage to the vapour hoses while
disconnecting slideback the clamps and pull the
hoses. Fig 22.
2. Loosen vapour seperator mounting screws.
Inspection :
Check for crack or deformation of vapour separator.

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 Fig 23. Hose Clamp fitment
pressure valve.
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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
Unless replacement of vapour seperator is necessary,
SYSTEM 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 Fig 24.
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 VACCUM TUBE
by ECU.
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. TANK TUBE CANISTER TUBE
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. Fig 25.
Inspection :
1. Check tank pressure valve for crack or damage.
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
Assembly : FEED
SYSTEM
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:
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).
FUEL
FEED
3. If the operation differs from the above description,
SYSTEM canister must be replaced.
4. Connect hoses to canister.
5. Ensure that hoses are clamped securely.
Warning : Purge
Do not suck air through canister port. Fuel vapours
inside canister is harmful.
Inspection :
Fig 27.
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.
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 FUEL
manifold through canister purge valve operated by ECU. FEED
SYSTEM
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.
Fig 28a.
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 HOSE CONNECTION
Fig 39. NON RETURN VALVE
4. Verify that no air flows through the valve when the LEAF SPRING
engine is stopped with purge valve connectors
SEALING ELEMENT
disconnected.
SOLENOID ARMATURE
5. Air will pass through freely when the 12V battery
voltage is applied to valve connector. SEALING SEAT
It indicates that the valve is functioning properly. SOLENOID COIL
If no air flows, replace the valve.
6. Reinstall valve connector. HOSE CONNECTION
7. Reconnect vacuum hoses.
Warning :
Do not suck air through purge valve. Fuel vapours Fig 29.
inside valve is harmful.
Fig. 28 Location of purge valve Fig 30.
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EXHAUST
NEXT
GROUP INDEX
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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

1. Tightening Torque 1
2. Exploded View :
a. Exhaust System 2
3. General Precautions 3 EXHAUST
SYSTEM
4. Exhaust Pipe 4
5. Safety precautions for catalytic convertor 5
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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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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)
EXHAUST
SYSTEM
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
® -Non Reusable Part - Specified Torque in Kgm
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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
Check rubber mountings for damage, SYSTEM
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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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.
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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
EXHAUST
compatible with standard unleaded petrol SYSTEM
supply nozzle.
CARE AND MAINTENANCE : Switching OFF the ignition when driving

down the hill.(This will not save the fuel).
Use Unleaded petrol only, since use of
Leaded petrol will damage (poison) the Fuel tank getting almost empty.
Catalytic Convertor permanently. Idling the engine with any of the Spark Plug
Cable disconnected, manually, during
diagnostic test. (Use appropriate test
In the event of following symptoms, drive the equipment).
car at slow speed without rapid
acceleration: Pre- Coating/Painting of Catalytic Convertor.
a) Engine misfires or runs irregularly, following
a cold start. Parking Warning :
b) A significant loss of power is noticed. Avoid parking the vehicle over inflammable
c) In case Check Engine lamp remains ON materials,such as dry leaves, grass, etc. as the
even after engine has been started. 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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CLUTCH
NEXT
GROUP INDEX
PREVIOUS
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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CLUTCH
CONTENTS
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
CLUTCH
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
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
CLUTCH
1. Outside Diameter 190 mm
2. Inside Diameter 134 mm
3. Thickness of Clutch disc with new
lining under 320 kg load 7 + 0.3 mm
4. Max. Permissible out of Perpendicularity of each
lining surface of clutch disc 0.4 mm at 186 mm dia.
5. Max. Permissible imbalance of clutch disc 15 gm-cm
6. Cushioning of Clutch disc 0.6 to 0.85 mm
7. Total Friction Area (Both sides) 285 sq.cm
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CLUTCH
7+0.3
CLUTCH
TI ON
R EC
DI
N
TIO
OTA
R
DAMPENING
18.33 mm
[Minor dia]
18.2+0.5 O
SPRINGS *
25+0.5
190 O
134 O
DAMPENING SPRINGS
* THE CHARACTERISTICS OF DAMPENING SPRINGS FOR DIESEL AND PETROL CLUTCH DISCS ARE DIFFERENT.
Fig. 1 Clutch disc - Petrol Engine
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CLUTCH
34 O
TRAVEL
WEAR
27.1 O
HEIGHT
FINGER
6.51
8+1 18.7+3.02
CLUTCH
RELEASE
TRAVEL
132 +1 O
190 -1.5 O
Fig. 2
Clutch Pressure Plate : Fig. 2
1. Max. Height of Pressure plate housing

from mounting face 24 mm
2. Height of Diaphragm spring (finger)
from cover mounting surface 18.7 ± 3.02 mm
3. Max. Permissible imbalance of Pressure
plate assembly 150 gm-mm
4. Max. Permissible face run out of release
bearing contact surface of diaphragm 0.8 mm at 34 mm dia.
5. Clamp load (Minimum on unloading curve) 320 kg
6. Max. release load (New clutch) 95 kg
7. Release travel 8 +1 mm
8. Max. Wear travel 6.51 mm
9. Min. Pressure plate lift for release travel of 8 mm 1.4 mm
Tightening Torques :
Clutch Housing to Cylinder block - 4 to 5 mkg.
Clutch Pressure plate mounting bolts - 2.4 mkg.
List of Special Tools :

Mandrel for aligning clutch disc - 2702 5890 2501
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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
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CLUTCH
4
10
7
9
8 1) BACK COVER
6
2) ASSY. CLUTCH RELEASE YOKE
3) BUSH (LOWER)
4) TA65 MOUNTING BOLTS
5 5) COVER (INSPECTION WINDOW)
6) BUSH (UPPER)
7) CLUTCH RELEASE LEVER
8) HEX. FLANGED SCREW CLUTCH
11
1 4 9) HEX. FLANGED NUT
13 10) ASSY. BRACKET (ON TRANS AXLE)
11) CLUTCH RELEASE BEARING
12 12) CLUTCH DISC ASSEMBLY
13) COVER ASSEMBLY
2
14 14) FLANGED HEX SCREW
Fig. 4
1. CONSTRUCTIONAL DETAILS Fig. 4 i. Clutch riding
Clutch is the mechanism interposed between Using clutch pedal as foot rest by keeping foot
engine and the Transaxle which enables engine constantly on pedal while driving will cause
power as well as torque of the engine to be partial clutch disengagement. It will result in
transmitted at will to the transaxle through slipping of the clutch disc and premature failure
friction drive. When clutch pedal is depressed the of the clutch.
clutch is disengaged therefore motion and ii. Permitting the clutch to slip too long
power flow from engine to Transaxle and hence Half clutch driving and thereby permitting the
to road wheels is disconnected. clutch purposely to slip too long will have the
It is a single disc dry friction type clutch having same result as above.
190 mm dia. clutch disc. Clutch pressure plate iii. Permitting the clutch to jerk
assembly is diaphragm spring type. Clutch
actuation is through mechanical linkages (cable). Sudden clutch engagement at higher engine
speed specially while moving out the stuck car
2. FACTORS AFFECTING CLUTCH WEAR
will cause severe instantaneous clutch loading,
The clutch is designed to give maximum life resulting in clutch slippage and burning of the
under most severe conditions when handled lining locally. Starting the car in first gear under
carefully. However, while in operation, clutch such conditions will avoid such problem. Always
lining is subjected to wear. Apart from this the start the car in first gear.
extent of wear also depends on following.
iv. Restarting on gradient :
2a. DRIVING
While restarting the car on gradient, make use of
Following driving conditions will affect the parking brake. Half clutch driving while restarting
performance of the clutch. on the gradient will cause premature damage to
clutch.
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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
CLUTCH 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.
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.
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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
Centre of vehicle
50 Plastic straps
120
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 c) the boots are broken.
joint pin from inner cable. Fig. 5
4c Installation
2. Disconnect the cable from hook at clutch pedal top.
1 Grease the joint pin and cable end hook.
Fig. 5
2 Fix properly the clip for holding clutch cable on
3. Remove the clip holding clutch cable on firewall
firewall inside cabin.
inside cabin.
3 Hook the cable end with pedal from inside the
4. Remove cable holding clamp at LH side of fire
cabin.
wall in engine compartment.
4 Join the inner cable with joint pin in release arm.
5. Remove the plastic straps fitted on steering rack
housing and take out the cable. 5 Tie the clutch cable with plastic straps on steering
4b Inspection rack housing.
Replace the cable if 6 Ensure the heat resistant sleeve is in front of the
exhaust front pipe.
a) there are any bends or kinks.
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CLUTCH
4
10
7
9
6 8
1) BACK COVER
2) ASSY. CLUTCH RELEASE YOKE
3) BUSH (LOWER)
5 4) TA65 MOUNTING BOLTS
5) COVER (INSPECTION WINDOW)
6) BUSH (UPPER)
CLUTCH
7) CLUTCH RELEASE LEVER
11
1 4 8) HEX. FLANGED SCREW
13 9) HEX. FLANGED NUT
10) ASSY. BRACKET (ON TRANS AXLE)
12
11) CLUTCH RELEASE BEARING
12) CLUTCH DISC ASSEMBLY
2
14 13) COVER ASSEMBLY
14) FLANGED HEX SCREW
Fig. 6
7 Fix LH side cable holding clamp on firewall. Ensure l Unscrew the mounting bolts evenly (alternately and
that cable is free in the clamp. crosswise) in small steps Fig. 7
8 Adjust the pedal height according to specifications l Remove clutch pressure plate assembly and clutch
after the clutch cable nut is fastened on to the cable. 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 MANDREL
with mandrel. PART NO. 2702 5890 2501
Fig. 7
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CLUTCH
6 INSPECTION OF COMPONENTS clutch disc and centralize clutch disc on flywheel by

locating the mandrel at the flywheel end .
i. Check clutch disc hub splines for damage and wear.
NOTE :
ii. Check torsion damper mechanism springs for
distortion, damage etc. For this purpose, hold Do not mix clutch mounting bolts with other fasteners.
drive shaft in vice. Insert clutch disc and slide it Do not use longer or shorter screws. Longer screws
as far back as possible. Rotate disc by hand. may not tighten the clutch at all. Shorter screws will
Rattling noise and excessive play indicates not provide enough threads to achieve desired
damaged torsional damping mechanism and tightening.
such disc must be replaced. l While tightening the clutch mounting screws
check aligning mandrel for continuous free
iii. Check disc facing for wear, cracks, contact
sliding to ensure concentric installation of clutch
pattern, burning marks and oil contamination. CLUTCH
disc which will avoid trouble during the
Facings with any of the above defects or worn
installation of the transaxle.
out beyond permissible limits must be replaced.
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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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
Adjusting
Inner cable Nut
CLUTCH
Cable holding clamp

On fire wall stud
Steering rack housing
Cable ties
Fig. 8
Note : 4. It should be possible to lift the clutch pedal by
There is no free play in the system and hence no clutch hand easily without much force. The pedal should
pedal free play adjustment is required. However, for have movement of 40 to 50 mm. If pedal lifting
ensuring the proper functioning of the clutch the force is high, (more than 0.9 kg.) then shift the
following procedures should be used. position of tension spring hook on holes 1, 2 and
3 for reducing tension Fig. 8
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.
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CLUTCH
9 TROUBLE SHOOTING
SR. IN THE VEHICLE THE COMOPONENT CAUSE REMEDY
NO.
1. New Clutch : Difficulty in changing gear
Difficulty in changing Burrs thrown up around Due to poor alignment of the Care with the centering of
gear, following splines causing stiff gearbox on reassembly. driven plate; use an
replacement of clutch movement on input shaft. appropriate clutch aligning
tool.
The driven plate was Do not force the gearbox but
improperly aligned. rotate the flywheel or
Aggressive location of input gearbox shaft to line up with CLUTCH
shaft into hub. splines.
2. Loss of Drive : With recently fitted clutch
Loss of drive and loud The centre hub of the The weight of the gearbox has Ensure that the gearbox shaft
clatter, only covered driven plate has ripped been hung on the centre and gearbox are not hung on
a few hundred out and possibly one or plate. This has distorted the the clutch driven plate by
kilometres. more of the springs have driven plate resulting in failure
using a pit jack or trolley jack
been pushed out. within a short period of use. 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.
3. Slipping Clutch
Clutch slip. The control The clutch friction There is an oil leak from the Carefully check the engine
system is in good material is contaminated engine or gearbox. and gearbox oil seals.
condition and correctly with oil. Replace seals if oil is present
adjusted. in bell housing.
4. Juddering During Pulling Away
Clutch judder on initial Oil or grease found on Excess grease applied Only use the correct amount
take up of torque. the middle of the clutch to input shaft splines. and the correct type of
driven plate. grease.
5. Loss of Drive
Loss of drive 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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CLUTCH

NO.
6. 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 Signs of rubbing on the Incorrect clutch adjustment Systematically check the
CLUTCH
noise affected by diaphragm fingers, in the excess travel. Automatic condition of the cable,
engine speed with area of contact with the adjuster is faulty. linkage and automatic
pedal fully depressed release bearings. adjuster.
Always refer to vehicle
workshop manual for correct
adjustment.
8. Excessively Heavy Pedal
The pedal is hard to The tips of the diaphragm The pre-load on the release During clutch installation
depress. fingers are worn away bearing is too low or not thoroughly inspect all
This stiffness increases by the release bearing. existent.The pre-load spring linkages and joints. Ensure
over time. The bearing can appear is unhooked. that the clutch cable is smooth
to be in good condition. 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.
9. Noisy Clutch
The clutch is noisy and A location lug on the A lug has broken. An other Check the fork and the
the pedal can be slack. release bearing has fault in the mechanical guide sleeve and replace if
broken. operation of the clutch has signs of wear are present.
caused the lug to break. For Ensure components are
example, the fork is out of lubricated. Carefully check
shape or wrongly positioned at the clutch cable.
the time of assembly.
10. Horse Noise on Decltuching
A harsh whistling noise The movement of the The bearing has seized Systematically check the
can be heard either on release bearing is hard or was noisy from the start. clutch cable, linkages, joints
declutching or all the when rotated by hand. Or the bearing has overheated, fork bearings, pre-load
time. It varies according burning off the grease caused spring .
to the pressure applied by incorrect pre-load.
to the pedal.
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CLUTCH

NO.
11. Permanent Loud Noise
Permanent, loud The levers are badly Incorrect clutch adjustment Regularly check the clutch
noise. damaged and the release causing bearing failure. adjustment. Always refer to
bearing has seized. the vehicle workshop
manual for correct method
of clutch adjustment.
12. Slipping and Juddering
The clutch slips and The pressure plate shows Driver resting foot on pedals. Regularly correct clutch CLUTCH
eventually judders. burn marks. Incorrect clutch adjustment. adjustment. Always refer to
the vehicle workshop
manual for correct method
of clutch adjustment.
Educate the driver.
13. Juddering After Changing the Clutch
The clutch judders. Circular grooves can be The clutch has been replaced Systemically check the
seen on the friction when the flywheel has been condition of the flywheel.
material on the flywheel previously scored. Skim flywheel if necessary.
side.
14. Pedal Stiff
Stiff pedal with the risk The guide tube is The release bearing jams If there are any signs of
of prolonged slipping corroded and worn. on the guide. irregular wear replace guide
after pulling away. Clutch wear is abnormal tube. Avoid excessive
taking into account the lubrication which could
amount of mileage. contaminate the friction
material.
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TRANSAXLE
NEXT
GROUP INDEX
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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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TRANSAXLE
CONTENTS
1. Technical Specifications 1
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 TRANSAXLE
9. Installation of Transaxle on the car 9

10. Disassembly of Transaxle 10
11. Assembly of Transaxle. 17
12. Sub-assemblies :
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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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 Indica 85PS

LEi & LSi LX & LXi
1st - 3.42 1st - 3.42
2nd - 1.95 2nd - 1.95 TRANSAXLE
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.
There is an interlock provided to prevent engagement of reverse gear directly

from fifth gear
1
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TRANSAXLE
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

TRANSAXLE
7. Fuel Line Clamps 1.5
8. Transaxle mounting bolt 4
9. Gearshift Linkage to transaxle end 2.5
10. Gearshift Linkage to body shell 2.5
11. Transaxle intermediate plate mounting bolt. 3.2 to 3.8
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 2.1 to 2.5
16. Drain plug & filler plug 3 to 4.1
2
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TRANSAXLE
LIST OF SPECIAL TOOLS :
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
TRANSAXLE
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 2641 5890 2601
b) Rear hub outer bearing seating on spindle
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
3
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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
SPACER ASSY GEAR SHIFT LEVER
PIN
ASSY EXTENSION ARM COLLAR BUSH
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
2.3 PIN
ASSY SHIFT LINK
ASSY YOKE (SHIFT LINK)

2.3
COLLAR BUSH
-- SPECIFIED TORQUE IN Kgm
4
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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
LOCK PLATE
1.6-1.9
DETENT SPRING AND BALL
NEEDLE BUSH (SKEWED) GASKET
REV. IDLER GEAR

DETENT PLATE
REV. IDLER SHAFT 1.8-1.15
3.2-3.8
INTERLOCK PIECE
DOWEL SLEEVE
STOPPER BKT (REV. IDLER)
TAPER ROLLER BRG
SPIDER
DIFFERENTIAL HOUSING
SPEEDO PINION EXT CIRCLIP
SPEEDO ADAPTOR
BEVEL PINION
O-RING
GEAR FINAL DRIVE
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)
5
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TRANSAXLE
INPUT SHAFT AND LAYSHAFT

LOCK PLATE (5th SPEED GEAR) 12.3-16.7
SHIFTER SLEEVE (5th SPEED)
ENGAGING GEAR
(5th SPEED)
SYNCHROCONE
SUB ASSY 5th GEAR LAYSHAFT (3rd/4th/5th)
BUSH (5th GEAR

NEEDLE CAGE (5th GEAR LAYSHAFT) LAYSHAFT)
BALL BRG WITH SNAP RING

SUB ASSY 4th GEAR LAYSHAFT
TRANSAXLE SHIFTER SLEEVE (3rd/4th) SYNCHROCONE (3rd/4th/5th)
ENGAGING GEAR (3rd/4th)
3rd GEAR LAYSHAFT SYNCHROCONE (3rd/4th/5th)
CIRCLIP
SYNCHROCONE (1st/2nd) 2nd GEAR LAYSHAFT
ENGAGING GEAR (1st/2nd) REV GEAR / SHIFTER SLEEVE

(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 NOTE : ALL CIRCLIPS TO BE USED IN SELECTION
6
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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
SPRING (1st/2nd) SPIRAL DOWEL
CUP (BKT SEL./SHIFT) SHIFTER DOG (5th/REV)
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
0.85-1.05
2.1-2.9
7
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TRANSAXLE
REMOVAL OF TRANSAXLE FROM THE

CAR :
1. Park the vehicle properly, and place chocks on
rear wheels. Disconnect the battery terminals and
remove the battery.
2. Drain the Transaxle oil.
3. Jack up and remove front wheels and support
the vehicle properly.
4. Remove the starter motor.
5. Remove the air filter assembly.
7. Remove tie member front suspension. Fig. 1
8. Disconnect power steering pressure line.
9. Remove ball joint (steering rack) from steering
knuckle from both sides.
10. Disassemble ball joint assembly from steering
TRANSAXLE
knuckle by loosening clamping bolt. Fig. 1
11. Disconnect gear shifter linkage.
Remove dust cover of flywheel (on lowerside of
engine)
12. Remove clutch housing cover and remove stifner
bracket bolts.
13. Loosen mounting bolts of clutch housing. Fig.2
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
Fig. 3
8
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TRANSAXLE
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.
21. Loosen and remove B Mount nut.
22. Remove Bmount rubber pad.
23. Lower the assembly (engine and transaxle).
24. Remove B mount bracket from transaxle housing.
25. Remove clutch housing mounting bolts and take
out the transaxle.
26. Remove clutch release bearing from input shaft.
Fig.4
27. Lift and support the engine assembly properly.
INSTALLATION OF TRANSAXLE ON THE
Fig. 4 TRANSAXLE
CAR
1. 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 Fig. 5
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 C
into transaxle carefully. MOUNT
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.
11. Assemble ball joints on lower link (both RH &
LH). FRONT
12. Connect ball joint (steering rack) on steering

A MOUNT B MOUNT
knuckle.
Fig. 6
9
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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.
TRANSAXLE
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. Fig. 8
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
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 TRANSAXLE
9. 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
11
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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
TRANSAXLE Fig. 13
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
13
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TRANSAXLE
25. Remove double dowel pins of shifter fork (1st and

2nd) Fig.19
26. Remove spiral pin of shifter dog (Rev) Fig. 20.
TRANSAXLE Fig. 19
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
15
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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.
TRANSAXLE Fig. 25
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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NOTE :
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.
C
5. Use sealing anaerobic compound for all oil seals
outer diameter.
6. For oil seals of input drive shaft & bellows use
anabond 112.
ASSEMBLY
1. Fit clutch release fork shaft. Fit plastic bushes. TRANSAXLE
Fit lever on clutch release shaft and lock it by
grooved pin.
2. Fix delrin bush and rubber bush into assembly
shaft (selector/shifting). Ensure that delrin bush
B
is at the centre of the hole of the selector shifter

shaft boss.
3. Fit rubber bellow on assembly shaft (selector/
shifting).
A
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 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 to (A+B)-C + 0.05
and install the shims against front half taper
roller bearing outer race.
17
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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
TRANSAXLE Fig. 29
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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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
19
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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
TRANSAXLE keeping its dog slot downward and lock it on Fig. 35
shifter shaft by spiral pin.
17. Assemble shifter shaft 3/4 through shifter fork B A - 1/2 SHIFTER
and shifter dog below it with its dog slot and lock SHAFT
it with shifter fork and shifter dog by spiral pins.
B - 3/4 SHIFTER
18. Locate the reverse shifter dog slot into pin on SHAFT
bkt. and place shifter shaft 5/R, locate and C - 5/R SHIFTER
lock, the shifter dog on shifter shaft with spiral SHAFT
A
pin.
19. Assemble reverse idler shaft with assembly
reverse idler gear, and new spring & spacer.
CAUTION :
C
THE SLOT IN REVERSE IDLER SHAFT IS TO BE
LOCKED IN GROOVE IN FRONT GEAR BOX
HOUSING.
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 C
and uniformly so that it gets located on lay shaft
and input shaft bearing.
B A
NOTE :
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
21
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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.
é
34. Assemble speedo pinion with speedo adaptor.
Fix assembly speedo pinion. Fix assembly hex.
é
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.).
CAUTION : ENSURE THAT TUBULAR PORTION OF
THE RUBBER SEAL IS SEATED PROPERLY
(WITHOUT ANY PINCHING ONTO THE CHANNEL IN
THE REAR COVER). Fig. 41
TRANSAXLE 36. Tighten the screws to specified torque. Fig.41a Fig. 41
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 Fig. 41a
2654 5890 3508 Fig. 42
Fig. 40 Fig. 42
22 NEXT
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TRANSAXLE
2. Remove spacer Fig. 43
Fig. 43 TRANSAXLE
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 - Shifter sleeve, engaging gear,
synchrocone, spring, ball, carrier
(sleeve in case of 1st gear).
5. Pry out circlip from lay shaft Fig. 46

Fig. 44
Fig. 46 Fig. 45
23
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TRANSAXLE
6. Remove 3rd gear lay shaft Fig. 47
TRANSAXLE Fig. 47
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
Fig. 51
11. Remove 1st gear lay shaft Fig. 52
Fig. 52
25
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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
TRANSAXLE Fig. 53
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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5. Install preselected circlip. Fig. 56 Circlip

thickness should be so selected that there is no
axial play of gear.
Fig. 56 TRANSAXLE
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.
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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TRANSAXLE
10. Place 2nd gear with its dog teeth downward.

Fig. 59
TRANSAXLE Fig. 59
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
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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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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
TRANSAXLE Fig. 65
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
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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 TRANSAXLE
3. 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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TRANSAXLE
8. Mount differential housing on fixture part no. 2702

5890 2609 and lock it. Fig. 71
TRANSAXLE Fig. 71
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
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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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10. Fix speedo gear with recess inside using drift

part No. 2654 5890 3507 Fig. 77
TRANSAXLE Fig. 77
11. Press taper roller bearings using drift part no.

2702 5890 2608 on either side of differential
housing Fig. 78
Fig. 78
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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) 5th gear shifter fork has three prominent ribs
and dowel hole is approx. in the centre of Fig. 79 TRANSAXLE
the boss. Fig. 79

ii) 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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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.
TRANSAXLE Fig. 82
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
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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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TRANSAXLE
3. 1st/2nd synchropack Assembly

i) Place the engaging gear 1st/2nd such that
the groove for circlip is downwards.Fig. 89
TRANSAXLE Fig. 88
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
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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
TRANSAXLE
iv) 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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DRIVESHAFT
NEXT
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DRIVESHAFT
INTRODUCTION :
Driveshaft assemblies are flexible assemblies, which DRIVE

transmit engine power to independently suspended SHAFT
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.
1
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DRIVESHAFT
CONTENTS
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
3
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DRIVESHAFT
SPECIAL TOOL : SWAGE TOOL : 2779 5890 2001
DRIVESHAFTS PARTS
INBOARD JOINT
OUTBOARD JOINT SMALL SEAL
RETAINING
CLAMP
AXLE SHAFT
DRIVE
LARGE SEAL TRIPOT SEAL LARGE SEAL
SHAFT
CV BOOT SEAL
RETAINING (INBOARD RETAINING
(OUTBOARD SEAL)
CLAMP(CV SIDE) SEAL) CLAMP
(TRIPOT SIDE)
Fig.1 LH Driveshaft assembly (NON ABS TYPE)
CV JOINT
RETAINER RING BALL SPIDER TRIPOT OUTER
CV BOOT SEAL
ASSEMBLY HOUSING
AXLE SHAFT
RUBBER DAMPER
C.V. DEFLECTOR
RING LARGE SEAL TRIPOT
RETAINER TRIPOT
RETAINING CLAMP SMALL SEAL SEAL
RING RETAINER
(CV SIDE) RETAINING
RING
CLAMP
A = 418+50
LARGE SEAL
RETAINING
CLAMP
Fig.2 RH Driveshaft assembly (NON ABS TYPE)
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DRIVESHAFT
EXPLODED VIEW
ABS RING CV JOINT INNER
DEFLECTOR RING CV OUTER RACE
CV JOINT CAGE RETAINING RING
CV BIG CLAMP
CV BALLS
CV JOINT BOOT
CLAMP
DRIVE CV SMALL CLAMP
SHAFT
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)
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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 Fig.6 View of Toner and Deflector ring
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DRIVESHAFT
DRIVESHAFT PARTS : treatment. The main function of the inboard joint is to

allow the halfshaft assembly to compensate for
SEALS : suspension movement in the vehicle by allowing the
Driveshaft assemblies use inboard and outboard joint shaft to move axially or stroke in the inboard housing.
seals. The inboard and outboard seals are made of AXLE SHAFT :
thermoplastic material. The thermoplastic material
performs well against normal handling and operational The axle shaft simply connects the inboard joint and
wear conditions. However, it is not strong enough to the outboard joint. It is made out of special steel heat
withstand abusive handling or damage due to objects treated to give optimum strength and fatigue
such as sharp tools or the sharp edges of any other performance. The function of the axle shaft is to
surrounding component in the vehicle. transmit torque and rotation to the wheel from the
transmission.
The functions of the seal are as below :
Note :
To protect the internal parts of the inboard and
outboard joint by protecting the grease from The rubber damper is fitted on RH driveshaft only
surrounding detrimental atmospheric conditions for petrol versions.
DRIVE such as stones, dirt, water, salt, etc.
SHAFT
Facilitate angular and axial movement as

applicable for inboard and outboard joints.
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 cold-
formed surfaces give superior wear resistance and
increased joint life. The main function of the outboard
joint is to allow the vehicles 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
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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 DRIVE
SHAFT
clamp ear junction by screw-driver with rounded
edge as shown in the Fig.8. Discard the small
retaining clamp.
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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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
5. Remove the spider assembly retainer ring by

DRIVE
SHAFT 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
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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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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. Place the tripot spider assembly on to the drive

DRIVE
SHAFT
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
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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 DRIVE
SHAFT
as shown in Fig. 18. Insert the swage tool part
no: 2779 5890 2001 over the clamp as shown in SWAGE
Fig. 18. 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. dont tighten
one bolt alone completely at a time).
Fig. 19
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DRIVESHAFT
DISASSEMBLY PROCEDURE :
1. Clean the shaft thoroughly using cleaning sol-
vent and hold the shaft at the middle of the axle
shaft in the vice as shown in Fig.20
Fig. 20
2. Remove the large seal retaining clamp from the

DRIVE
SHAFT 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
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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 This ring
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.
Fig. 23
7. Clamp the CV assembly on a vice and place a

brass drift/screw-driver against the CV joint cage DRIVE
SHAFT
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.
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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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
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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
DRIVE
SHAFT
the lands of the outer race.
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/screw-
driver 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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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
8. Align the inner race spline and the axle spline in

DRIVE
SHAFT 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
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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
DRIVE
SHAFT
the seal with the larger seal retaining clamp in
place over the outside of CV joint as shown in
Fig. 33
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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DRIVESHAFT
CV JOINT SPIDER
RETAINER RING ASSEMBLY
BALL TRIPOT OUTER
CV BOOT SEAL
HOUSING
AXLE SHAFT
RUBBER
DAMPER
C.V. DEFLECTOR
RING LARGE SEAL TRIPOT TRIPOT
RETAINING CLAMP SMALL SEAL SEAL RETAINER RETAINER
(CV SIDE) RETAINING RING RING
CLAMP
DRIVE
SHAFT ‘A’ = 418 +50
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
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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
Note: If Out board joint must be may reduce the performance of the
angulated to fit the half shaft assembly mating seal.
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
Note : Take all precautions to avoid any dented/Damaged deflector ring may
contact between the inboard and result in an interference condition and
outboard seals and any surface which affect the seal
may cause a cut, nick or abrasion. The DRIVE
SHAFT
seals are extremely delicate and
critical to the performance to the Note : Eared clamp must be in
halfshaft. Do not allow the seals to position and crimped. Take precaution
contact other halfshafts, workbenches, to avoid any contact between the ear
the vehicle frame, lower control arm, of the clamp and any object, which
or any other chassis component. If may bend/crush, the ear. A damaged
grease leakage is observed from either ear will decrease the clamping load,
seal, the halfshaft should be removed which may cause grease leakage and/
from the vehicle, handled with care, and or intrusion of water/debris.
returned to authorised dealer for
analysis
Note : Clamps should be in position

and tight. If clamps are loose, dont Note : Take precaution to avoid any
install into vehicle. 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
Note : To prevent damage to the may reduce the life of the seal and
internal components of the inboard lead to dissatisfied customer.
joint, take all precautions to avoid over
extending the joints.
CROSS SECTION SHOWN IS NON ABS TYPE LH DRIVERSHAFT
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DRIVESHAFT
GENERAL GUIDELINES FOR TESTING

DRIVE SHAFT NOISE : Extreme
RIGHT
Ensure that the DRIVER is alone in the vehicle Turn
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). Extreme
LEFT Turn
It should be noted here that the driver may
encounter difficulty in distinguishing between Fig. 36
similar sounding noises resulting from either the
DRIVE drive shaft or the under-body (for example noise
SHAFT
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.
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.
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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 DIAGNOSIS
DRIVE
SHAFT
Noise accompanied by vibration of the brake pedal A. Vibration could be from the calipers and
& not from the drive shaft.
B. If there is NO vibration on the pedal, the
noise could be from the drive shaft.
23
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INDEX GROUP INDEX
PREVIOUS
SUSPENSION
LEi & LSi
LX & LXi
NEXT
GROUP INDEX
PREVIOUS
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 SUSPENSION
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.
i
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INDEX GROUP INDEX
PREVIOUS
CONTENTS
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
6) a) Removal & Installation of wheel hub 10
b) Sub-assembly of knuckle/Hub 13
7) a) Removal & Installation of lower link assembly 14
b) Removal & Fitment of Rubber bushes 14
8) Procedure for checking the ball joint play on front suspension lower arm ball joints 15 SUSPENSION
II) REAR SUSPENSION :

1) Repairs/Adjustment data 16
3) Lubricants Specification 16
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) Removal & Installation of shock absorber assembly 26
a) Disassembly & Assembly of shock absorber 26
8) Disassembly/Assembly of Trailing Arm 28
9) Inspection of shock absorber / strut on the car 29
iii
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INDEX GROUP INDEX
PREVIOUS
FRONT SUSPENSION (LEi & LSi - 75 PS)
TIGHTENING TORQUE (kg-m)

1. Strut assembly upper mounting nuts 2.3
2. Strut mounting bolts on knuckle 8
3. Knuckle bottom ball joint clamping hex bolt 5.5
4. Drive shaft nut 26 +2
5. Lower link mounting on body hex bolt 8
6. Clamp hex screw on antiroll bar 4.5
7. Lower link front mounting pin with tie member 10
8. Strut top nut 4 to 6
9. Ball joint to lower link 4.6
SUSPENSION
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
1
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INDEX GROUP INDEX
PREVIOUS
ASSY. FRONT STRUT

NO.
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
® 2.3
7 ASSY SPRING SEAT TOP

8 SPACER
9 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
SUSPENSION 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
22 HEX FLANGE BOLT
23 HEX FLANGE NUT AM10
®
24 HEAT SHIELD (LOWER BALL JOINT)
25 NYLOC NUT M12
8.0
4.5 8.0

2
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INDEX GROUP INDEX
PREVIOUS
ASSY. LOWER LINK
8.0
INDEX
®
8.0
4.6 8.0
GROUP INDEX
1.2

NO.
1 ASSY LOWER LINK COMPLETE - (P/STG) 7 HEX FL BOLT M10X30 TS17130-8.8-SS8451-8C 14 Tie Member
NEXT
2 LOWER LINK,FRONT 8 HEX NUT M10 IS1364P3-8-SS8451-8C
3 ASSY.PIVOT BUSH (INNER) 9 WASHER
10 MOUNTING PIN
PREVIOUS
4 ASSY. RUBBER BUSH (REAR)
5 ASSY. CLAMP (LOWER LINK REAR MTG. BKT.) 11 SPRING WASHER B14 IS3063 SS8451-8C ® -Non Reusable Part
6 ASSY. LOWER BALL JOINT 12 HEX NUT M14X1.5 IS13722-8-SS8451-8C
13 HEX FL SCREW M12
3
SUSPENSION
SUSPENSION
4
FRONT ANTI ROOL BAR MOUNTING
8.0
INDEX
®
4.5
GROUP INDEX
®

NO.
1 FRONT HOLLOW ANTIROLL BAR(TC SPRING) 7 HEX BOLT M10X130
2 NYLOC NUT M10 8 SLEEVE (ANTI ROLL BAR)
3 ASSY RUBBER MOUNTING. 9 BEARING BLOCK (ANTI ROLL BAR)
4 CUP (FRONT ANTIROLL BAR)
NEXT
10 CLAMP
® -Non Reusable Part 5 RUBBER BUSH (ANTIROLL BAR MTG) 11 SPECIAL HEX.FL.SCREW
- Specified Torque in Kgm 6 CUP (FRONT ANTIROLL BAR) 12 WASHER A10.5
PREVIOUS
FRONT AXLE
SUSPENSION

NO.
1 STEERING KNUCKLE
26.0
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
7 WASHER
8 LOCK NUT
Fig. 15
5
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INDEX GROUP INDEX
PREVIOUS
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
SUSPENSION 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.
Fig. 2
BEARING BLOCK AND

MOUNTING BRACKET
ANTI ROLL BAR
CRANK
Fig. 3
6
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INDEX GROUP INDEX
PREVIOUS
3. Tighten rubber cushion bolt assembly on lower link,
maintaining bolt projection above the nyloc nut 9 +1mm
between 9-10 mm Fig. 4. ANTI ROLL BAR
4. Apply silicon grease molycoate-33 (medium) on anti

roll bar over bearing width before fitment.
Fig. 4
REMOVAL & INSTALLATION OF STRUT

ASSEMBLY
REMOVAL
SUSPENSION
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.
Fig. 5
5. Unscrew mounting bolts on strut bottom bracket

Fig.6.
Fig. 6
7
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INDEX GROUP INDEX
PREVIOUS
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 OFFSET SPANNER
DOWEL PIN PART NO. 2702 5890 3201
mounting bolt no. 2.
3. Tighten all bolts and nuts to specified torque. Fig. 7
4. Apply ADH thread locker wicking grade ANABOND
124 at nut end & bolt thread. Ensure that the threads
are free from oil/grease. FRONT OF VEHICLE
CAUTION :
SUSPENSION
1. Ensure that brake hose does not twist during
installation.
TOP ECCENTRIC BOLT
2. Strut colour having the same colour code mark
on the spring should be assembled on the left
hand and right hand side.
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 Fig. 8
seating place). Unscrew nut (1) and dismantle the
parts Fig.9.
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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INDEX GROUP INDEX
PREVIOUS
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
9
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INDEX GROUP INDEX
PREVIOUS
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. SPRING SEAT SPRING SEAT
4. Insert bump stopper. LOWER UPPER
5. Fit spring rubber seat and assembled spring seat

LUG
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)
LUG
8. Grease the thrust bearing with recommended grease
and fit the bearing over the locater.
9. Fit bottom plate. Fig. 12
10. Fit assembly top cup.
11. Fit spacer.
12. Fit top stopper.
13. Fit spring washer & tighten hex nut to 4-6 mkg torque.
SUSPENSION
Fig 13
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. Fig. 13
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. 14
10
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PREVIOUS
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. 17
Fig. 19
SUSPENSION
Fig. 18
Fig. 16 Fig. 19
11
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INDEX GROUP INDEX
PREVIOUS
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.
Fig. 21
18. Remove circlip from knuckle Fig. 23.
19. Pull out knuckle bearing using puller part No.
2702 5890 3306. Fig. 24
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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INDEX GROUP INDEX
PREVIOUS
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.
Fig. 24
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. SUSPENSION
4. Fill transaxle with recommended oil if you have

removed dry shaft during disassembly.
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. Fig. 25
1. With the help of drift part No 2779 5890 3301 and
2640 5890 3511 fit bearing in the knuckle. Fig. 26
PRESS
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. 26
13
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INDEX GROUP INDEX
PREVIOUS
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. Fig. 28
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
SUSPENSION flange i.e towards front of the vehicle (Fig. 28a).
5. Ensure that heat shield is assembled properly on
ball joint.
REMOVAL AND FITMENT OF RUBBER
BUSHES
1. Remove front bracket and bush from the lower link.
2. Remove rear rubber bush from Lower link.
3. 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.
4. 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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INDEX GROUP INDEX
PREVIOUS
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 Fig. 29a
b) 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. SUSPENSION
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
15
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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 0.05, 0.10, 0.15, 0.20, 0.25, 0.30,
available in steps of 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 4.5
flange nuts on the shell
4. Shock absorber bottom nyloc nut 6
5. Assembly inner bracket to cab hex screw 8
(Semi trailing arm)
6. Semi trailing arm mounting nut (inner and outer pivots) 8
7. Castle nut on hub 10-12
SUSPENSION
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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INDEX GROUP INDEX
PREVIOUS
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
17
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INDEX GROUP INDEX
PREVIOUS
SUSPENSION
18
③ -Non Reusable Part
REAR SUSPENSION
4.5
③
8.0
4.5
INDEX
③
③
③
8.0
③
8.0
8.0
③ ③
③
GROUP INDEX
③
NO.
6.0
1 ASSY.SEMI TRAILING ARM WITH BUSHES
2 ASSY. SEMI TRILING ARM- (WITH ABS)
2 ASSY.SEMI TRAILING ARM - LH/RH
3 SPINDLE
4 SPACER (FOR OIL SEAL) 12 REAR SPRING (SHOCK ABSORBER TOP MOUNTING)
5 ASSY.PIVOT BUSH (INNER) 13 DUST COVER (REAR SHOCK ABSORBER) 20 LOCK WASHER
6 ASSY PIVOT BUSH (SEMITRAILING ARM) 14 REAR BUMP STOPPER 21 NYLOC NUT M10
7 ASSY.INNER BRACKET- SEMI TRAILING ARM (POLYURETHANE) / (POLYURETHANE FOAM) 22 HEX FL NUT AM10
8 ASSY.OUTER BRACKET SEMI TRAILING ARM 15 ASSY.BUMP STOPPER CUP 23 RUBBER COVER (REAR SHOCK ABSORBER)
NEXT
9 HEX FLANGE BOLT M12x1.25x33 16 SPRING TOP RUBBER 24 HEX FL BOLT M10X70
10 ASSY REAR S/A COMP 17 BOTTOM RUBBER(SHOCK ABSORBER TOP MTG.) 25 NYLOC NUT M10
11 ASSY REAR SHOCK ABSORBER 18 ASSY.STRUT MOUNTING BRACKET_TOP 26 HEX BOLT M12 X 1.5 X 90
PREVIOUS
12 SPRING REAR SUSPENSION 19 TOP RUBBER 27 NYLOC NUT M12 X 1.5
ASSEMBLY REAR HUB
INDEX
® ®
4.5
®
10-12 ®
GROUP INDEX
4.5

NO.
1 ASSY.REAR HUB COMPLETE 6 SHIM (0.30 THK)
NEXT
2 HUB CUM BRAKE DRUM (REAR) (180 DIA.) 6 SHIM (0.25 THK) 9 THIN CASTLE NUT M16X1.5
3 TAPER ROLLER BEARING-OUTER 6 SHIM (0.20 THK) 10 SPLIT PIN 4X32 IS549 SS8451-8C
4 OUTER BEARING 6 SHIM (0.15 THK) 11 HUB COVER
5 SPACER TUBE (BETWEEN BRGS OF REAR HUB) 6 SHIM (0.100 THK) 12 SPACER PLATE
PREVIOUS
6 SHIM (1.00 THK) 6 SHIM (0.05 THK) 13 HEX SCREW M10X28
6 SHIM (0.50 THK) 7 DOUBLE-LIP OIL SEAL 14 SPRING WASHER B10
6 SHIM (0.40 THK) 8 THRUST WASHER 15 HEX NUT M10
19
SUSPENSION
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. Fig. 31
9. 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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INDEX GROUP INDEX
PREVIOUS
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 REMOVAL OF OUTER BEARING OUTER RACE
PULLER PART NO. PULLER PART NO.

2702 5890 3502 2702 5890 3503
Fig. 34 Fig. 35
21
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PREVIOUS
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. Fig. 36
5. Bearings should not be cleaned with kerosene /

cotton waste.
ASSEMBLY
SUSPENSION 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. Fig. 37
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. 37a
22
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PREVIOUS
15 1. Assembly Brake Drum

3 2. Spacer plate
3. Inner Taper Roller Bearing
4. Spacer Tube
5. Outer Taper Roller Bearing
4 14 6. Shims
5 7. Castle Nut
11 8. Hub Cap
12 9. Split Pin
7 13
10. Thrust Washer
6
11. Spacer for Oil Seal
8
12. Oil Seal
9 13. Spindle
14. Semi Trailing arm
15. Anchor Plate SUSPENSION
2
10
Fig. 38
ASSEMBLY OF REAR HUB ON STUB AXLE SPINDLE may result in loss of lubricating power. Insufficient
Fig. 38. grease may prevent perfect lubrication of
bearings.
1. If removed, fit anchor plate assembly, connect
Parking brake cable, connect hoses. 5. Insert a shim of 1.5 mm thickness over the spacer
tube. For shim selection see page no. 20.
2. Fit hub assembly on the spindle. Make sure that
oil seal lip is not getting damaged during 6. Pack roller cage of outer bearing race with
assembly. recommended wheel bearing grease. Grease
quantity 5gm.
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
23
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PREVIOUS
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 - Fig. 40
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
SUSPENSION
released condition.
Fig. 41
Fig. 39 Fig. 41a
24
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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 follows-
1.5 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. SUSPENSION
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.
13. Fit the wheel and tighten the wheel mounting
bolts to recommended torque.
25
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REMOVAL OF SHOCK ABSORBER ASSEMBLY
2. Loosen rear wheel mounting bolts.
3. Jack up the car, allowing rear suspension to hang
freely.
4. Support the trailing arm.
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 Fig. 42
absorber assembly Fig. 43.
INSTALLATION OF SHOCK ABSORBER ASSEMBLY
2. Tighten upper mounting flange nut to 4.5 kg-m
SUSPENSION
torque.
3. Tighten bottom mounting bolt to 6 kg-m torque.
DIS-ASSEMBLY AND ASSEMBLY OF SHOCK

ABSORBER
DIS-ASSEMBLY :-
length is reduced such that load on upper and
lower cups is released. Unscrew nut(1) and Fig. 43
dismantle the parts Fig. 44.
Fig. 44
26
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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
1. LOCK WASHER
2. ASSEMBLY BUMP STOPPER CUP
2 6
3. ASSEMBLY STRUT TOP BRACKET
4. BOTTOM RUBBER (SHOCK ABSORBER MOUNTING)
9 5. TOP RUBBER (SHOCK ABSORBER MOUNTING)
6. RUBBER SEAT
7 7. OUTER COIL SPRING
8. BUMP STOPPER
9. DUST COVER
8
Fig. 46
27
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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
SUSPENSION assembly from the brackets.
3. Remove the rubber bushes from the trailing arm
Fig. 50.
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 Fig. 49
torque.
DOLLY
PART. NO.
2702 5890 0108 /
2702 5890 0109
RUBBER BUSH
TRAILING ARM
Fig. 50
28
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INSPECTION OF SHOCK ABSORBER / STRUT Checks to be carried out after removal of
ON THE CAR 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
1. Ensure that the brake hose is tightened fully, results of accident or abuse of suspension parts.
loose brake hose will give noise.
2. Discoloration & light scratch marks on working
Noise due to fouling parts : area of piston rod is normal and doesnot need
1. Ensure that the Strut components are not fouling replacement, unless leakage is noticed &
with any other parts near by. confirmed.
2. Ensure that the spring end is sitting securely on 3. Look for signs of suspected oil leakage such as
the spring seat at the correct place Fig. 51. oil patches or wet mud cakes on the damper
body. The presence of oil patch or mud cake can
3. Ensure the correct torque on the two bolts is also be result of oily sprayfrom road or
correct : 8 kgf-m of the strut mounting at the accidental spillage of oil during servicing.
bottom bracket. It may be noisy if there is any
play in the bolts. 4. Examine damper area near the seal. Presence of
oil here is sign of oil leakage.
INDICA rear suspension
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.
SPRING SEAT SPRING SEAT
LOWER UPPER
LUG
LUG
Fig. 51
29
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SUSPENSION (LX & LXi)
INTRODUCTION :
The front and Rear suspension of Indica are Independent
SUSPENSION
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.
i
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CONTENTS
I) FRONT SUSPENSION (LX & LXi) :

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 SUSPENSION
9) a) Removal & Installation of lower link assembly 14

b) Removal & Fitment of Rubber bushes 15
10) Procedure for checking the ball joint play on front suspension lower arm ball joints 17
II) REAR SUSPENSION (LX & LXi) :
1) Repairs/Adjustment data 18
3) Lubricants Specification 18
5) Exploded view
a) Rear Suspension 20
b) Assembly Rear Hub - ABS 21
6) Removal of Rear Hub 22
a) Rear Hub-dismantling & Assembly 23
b) Assembly of Rear Hub on semi-trailing arm Spindle 25
7) Removal & Installation of shock absorber assembly 27
a) Disassembly & Assembly of shock absorber 27
8) Disassembly/Assembly of Trailing Arm 30
9) Inspection of shock absorber / strut on the car 31
iii
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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 8
3. Knuckle bottom ball joint clamping flange bolt 5.5
4. Drive shaft nut 26 +3
5. Lower link mounting on body hex bolt 8
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

SUSPENSION
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
1
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SUSPENSION LX & LXi

NO.
FRONT STRUT & LOWER LINK 1 ASSY FRONT STRUT COMP
2 ASSY FRT DAMPER
3 SPRING SEAT RUBBER (BOTTOM)
4 DUST COVER
5 FRONT BUMP STOPPER -POLYURETHANE
6 SPRING FRONT SUSPENSION
7 SPRING SEAT TOP (RUBBER)
4.0 - 6.0 8 ASSY SPRING SEAT
9 SPACER-FRONT STRUT TOP CUP-THRUST BRG.
10 THRUST BALL BEARING
2.5 11 ASSY TOP CUP (FORGED FOR THRUST BRG)
12 SHIM 0.1 THK
12 SHIM 0.15 THK
® 12
12
SHIM 0.2THK
SHIM 0.25 THK
12 SHIM 0.3 THK
12 SHIM 0.35 THK
2.5 12 SHIM 0.5 THK
12 SHIM 1.0 THK
13 SUPPORT-THRUST BRG
14 SPACER-(THRUST BRG)
15 TOP STOPPER
® 16 SPRING WASHER B12
17 HEX NUT M12X1.5
® 18
19
COVER STRUT TOP CUP
NYLOC NUT M8
20 STRUT MOUNTING PIN (ECCENTRIC)
21 SP HEX FL BOLT (M12 X 1.25 X 60)
22 HEX FL.NUT AM12X1.25
23 ASSY LOWER LINK COMPLETE LH
24 LOWER LINK
® 25 ASSY PIVOT BUSH (FRONT SUSPENSION)
26 ASSEMBLY RUBBER BUSH (REAR)
SUSPENSION
27 ASSY CLAMP
® 28
29
ASSY.LOWER BALL JOINT (FRT.SUSP.)-RANE
HEX FL BOLT M10X35
30 SPRING WASHER B10
31 HEX NUT M10
32 WASHER 35 SPRING WASHER B16
33 MOUNTING PIN 36 HEX NUT M16X1.5
34 WASHER 37 HEX FL SCREW M12
38 HEX FL SCREW M12
39 HEAT SHIELD (LOWER BALL JOINT)
40 HEX FLANGE BOLT
41 NYLOC NUT M10
42 TIE MEMBER FRONT SUSPENSION
®
8.0 4.6 ®
5.5
8.0 8.0
®
8.0
12.0
- Specified Torque in Kgm ® - Non Reusable Part
2
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ANTI ROLL BAR MOUNTING
INDEX
®
4.5
SUSPENSION LX & LXi
8.0
GROUP INDEX
®
® NO.
1 ANTI ROLL BAR (FRONT SUSPENSION)
4.6 2 BALL JOINT ASSY,FRONT ARB
3 ASSY RUBBER MOUNTING.
NEXT
5 RUBBER BUSH (ANTIROLL BAR MTG)
7 NYLOC NUT M12X1.5
PREVIOUS
- Specified Torque in Kgm 8 NYLOC NUT M10
9 BEARING BLOCK (ANTI ROLL BAR-28 DIA.)
10 CLAMP (ANTIROLL BAR MTG BRACKET)
® - Non Reusable Part 11 SPECIAL HEX.FL.SCREW
3
SUSPENSION
SUSPENSION LX & LXi
FRONT SUSPENSION
SUSPENSION
4
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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) SUSPENSION
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).
Fig. 2
4. Assemble ball joint, rubber bush, cup and spacer

ARB FACE IN ASSEMBLED CONDITION
as shown in (Fig. 3). Ensure ball joint face is THIS FACE TO BE MAINTAINED
parallel to mounting face of ARB. Tighten ball PARALLEL TO
joint to ARB. ARB FACE
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). HEX ON THE SHANK
NYLOC NUT 6 to 7 mm
Fig. 3
5
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SUSPENSION LX & LXi

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

wheel.
5. Remove brake hose from the clamp on strut
bracket.
SUSPENSION
6. Remove ABS wheel speed sensor harness
mounting bolt (if equipped).
7. Unscrew mounting bolts on strut mounting
bracket (Fig. 5).
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
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SUSPENSION LX & LXi
INSTALLATION :
1. Install strut assembly in reverse order of removal. APPLY THREAD LOCKER FRONT OF VEHICLE
ANABOND - 124
2. Fit bolts and nuts only as shown in Fig. 7.
NOTE :
First tighten top eccentric bolt and then the bottom TOP ECCENTRIC
mounting bolt. 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 BOTTOM
that the threads are free from oil/grease. BOLT
CAUTION :
1. Ensure that brake hose does not twist during
installation. Fig. 7
2. Strut having the same colour code mark on the

spring should be assembled on the left hand and
right hand side.
DISASSEMBLY AND ASSEMBLY OF SUSPENSION
STRUT
DISASSEMBLY :
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
7
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SUSPENSION LX & LXi
15 14 13 12
11
10
9 1. FRONT STRUT DAMPER

2. DUST COVER
8
3. BUMP STOPPER
7 4. SPRING FRONT STRUT

5. SPRING SEAT RUBBER
6
6. ASSEMBLY SPRING SEAT
5 7. SPACER - FRT STRUT TOP
17 8. ASSEMBLY TOP CUP
4
9. THRUST BALL BEARING
10. SHIMS
3
11. SUPPORT THRUST BEARING
2 12. SPACER
13. TOP STOPPER
SUSPENSION
1 14. HEX NUT & SPRING WASHER
15. NYLOC NUT & BRIGHT
16 WASHER
16. SPRING SEAT BOTTOM
17. RUBBER SLEEVE
Fig. 9
ASSEMBLY (Fig. 9) :
Check the condition of the components and replace if
necessary.
tool part No. 2702 5890 3202 to reduce length
as done during dis-assembly as shown in
Fig. 10.
Fig. 10
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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. SPRING SEAT SPRING SEAT
LOWER UPPER
4. Insert bump stopper
5. Fit top spring rubber seat and assemble spring LUG
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. LUG
8. 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 SUSPENSION
0.05 to 0.1mm by selecting proper shims. Use
60 A/F spanner to hold top stopper during
tightening of nut (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.
12. Remove spring compressing special tool carefully.
Note :
It is a good practice to replace bump stopper at every
30000 km / 18750 miles. Fig. 12
9
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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
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SUSPENSION LX & LXi

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
11
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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
SUSPENSION
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
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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 :
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
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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
Fig. 23
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 /
SUSPENSION
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.
LOWER LINK ASSEMBLY : Fig. 24
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).
5a. Unscrew mounting bolt of rear bush clamp.
Fig. 25
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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. SUSPENSION
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.
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) PRESS
3. Fit rear bush on lower link, ensure bush

inclination/orientation as shown in fig.28,fig.28a. PIVOT
BUSH
Note :
ASSEMBLY LOWER LINK
It is a good practice to replace a ball joint and
suspension bushes at every 30000 km/18750 miles. Fig. 28
15
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SUSPENSION LX & LXi
PRESS
SUSPENSION
PIVOT BUSH
ASSEMBLY LOWER LINK
Fig. 28a
16
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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 :
Fig. 29a
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
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
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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 0.05, 0.10, 0.15, 0.20, 0.25, 0.30,
available in steps of 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 4.5
flange nuts on the shell
4. Shock absorber bottom nyloc nut 6
5. Assembly inner and outer bracket to cab hex screw 8
(Semi trailing arm)
6. Semi trailing arm mounting nut (inner and outer pivots) 8
7. Castle nut on hub 10-12
SUSPENSION
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
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INDEX GROUP INDEX
PREVIOUS
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
19
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INDEX GROUP INDEX
PREVIOUS
SUSPENSION
20
REAR SUSPENSION
4.5
®
8.0
4.5
INDEX
®
®
®
8.0
®
8.0
8.0
® ®
®
GROUP INDEX
®
NO.
6.0
1 ASSY.SEMI TRAILING ARM WITH BUSHES
2 ASSY. SEMI TRILING ARM- (WITH ABS)
2 ASSY.SEMI TRAILING ARM - LH/RH
3 SPINDLE
4 SPACER (FOR OIL SEAL) 12 REAR SPRING (SHOCK ABSORBER TOP MOUNTING)
5 ASSY.PIVOT BUSH (INNER) 13 DUST COVER (REAR SHOCK ABSORBER) 20 LOCK WASHER
6 ASSY PIVOT BUSH (SEMITRAILING ARM) 14 REAR BUMP STOPPER 21 NYLOC NUT M10
7 ASSY.INNER BRACKET- SEMI TRAILING ARM (POLYURETHANE) / (POLYURETHANE FOAM) 22 HEX FL NUT AM10
8 ASSY.OUTER BRACKET SEMI TRAILING ARM 15 ASSY.BUMP STOPPER CUP 23 RUBBER COVER (REAR SHOCK ABSORBER)
NEXT
9 HEX FLANGE BOLT M12x1.25x33 16 SPRING TOP RUBBER 24 HEX FL BOLT M10X70
10 ASSY REAR S/A COMP 17 BOTTOM RUBBER(SHOCK ABSORBER TOP MTG.) 25 NYLOC NUT M10
11 ASSY REAR SHOCK ABSORBER 18 ASSY.STRUT MOUNTING BRACKET_TOP 26 HEX BOLT M12 X 1.5 X 90
PREVIOUS
12 SPRING REAR SUSPENSION 19 TOP RUBBER 27 NYLOC NUT M12 X 1.5
ASSEMBLY REAR HUB ABS
INDEX
®
®
4.5
®
10-12
®
4.5
GROUP INDEX
4.5

6 SHIM (0.30 THK)
NO.
6 SHIM (0.25 THK) 11 SPLIT PIN 4X32
1 ASSY.REAR HUB COMPLETE - ABS 6 SHIM (0.20 THK) 12 HUB COVER
NEXT
2 HUB CUM BRAKE DRUM (REAR)FOR ABS VERSION 6 SHIM (0.15 THK) 13 SPACER PLATE
3 TAPER ROLLER BEARING-OUTER 6 SHIM (0.100 THK) 14 ASSY. SENSOR MTG.PLATE & SENSOR LH/RH
4 OUTER BEARING 6 SHIM (0.05 THK) 15 HEX FL SCREW M6X12
PREVIOUS
5 SPACER TUBE (BETWEEN BRGS OF REAR HUB) 7 DOUBLE-LIP OIL SEAL 16 HEX SCREW M10X28
6 SHIM (1.00 THK) 8 TONER RING -REAR ON REAR BRAKE DRUM 16 HEX SCREW M10X25
6 SHIM (0.50 THK) 9 THRUST WASHER 17 SPRING WASHER B10
6 SHIM (0.40 THK) 10 THIN CASTLE NUT M16X1.5 18 HEX NUT M10
21
SUSPENSION
REMOVAL OF REAR HUB

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 Fig. 31
take out the hub assembly from the spindle.
Fig. 32
9. If required, Disconnect brake bundy tube from
wheel cylinder Fig. 33, disconnect parking brake
from anchor plate. Unscrew anchor plate mounting
SUSPENSION bolts and remove the anchor plate.
Fig. 32
Fig. 30 Fig. 33
22
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INDEX GROUP INDEX
PREVIOUS
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 REMOVAL OF OUTER BEARING OUTER RACE
PULLER PART NO. PULLER PART NO.

2702 5890 3502 2702 5890 3503
Fig. 34 Fig. 35
23
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INDEX GROUP INDEX
PREVIOUS
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
contaminations 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. Fig. 36
5. Bearings should not be cleaned with kerosene/

cotton waste.
SUSPENSION 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. Fig. 37a
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. 37
24
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INDEX GROUP INDEX
PREVIOUS
1
2
15 1. Assembly Brake Drum
3 2. Toner Ring
14 3. Inner Taper Roller Bearing
13 4. Spacer Tube
5. Outer Taper Roller Bearing
4 16 6. Shims
5 7. Castle Nut
11 8. Hub Cap
12 9. Split Pin
7 17
10. Thrust Washer
6
11. Spacer for Oil Seal
8
12. Oil Seal
9 13. Sensor Mounting Plate
14. Wheel Speed Sensor
15. Anchor Plate SUSPENSION
16. Semi Trailing arm

17. Spindle
18 18. Spacer plate
10
Fig.38.
ASSEMBLY OF REAR HUB ON SEMI-TRAILING 5. Insert a shim of suitable thickness (e.g.1.5 mm)
ARM SPINDLE Fig.38. over the spacer tube so that recommended axial
play is achieved. For shim selection see
1. If removed, fit anchor plate assembly, connect page no. 27.
Parking brake cable, connect brake pipe.
6. Pack roller cage of inner and outer bearing race
2. Fit hub assembly on the spindle. Make sure that with recommended wheel bearing grease. Grease
oil seal lip is not getting damaged during assembly. quantity 5gm.
3. Assemble the spacer tube on the spindle. 7. Fill the hub cap with 25gm of recommended wheel
4. Fill the space between two taper roller bearings bearing grease before fitment.
with 20 gm quantity of recommended grease. 8. Install inner race of outer bearing using drift part
Note: Recommended wheel bearing grease and its No. 2702 5890 26 02 Fig.No.39 & 40.
quantity must be maintained. If grease in excess,
9. Install thrust washer.
excessive heat can be generated and may result
in loss of lubricating power. Insufficient grease
may prevent perfect lubrication of bearings.
25
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INDEX GROUP INDEX
PREVIOUS
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 Fig. 40
play ensure that the parking brake lever is in
released condition.
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
SUSPENSION 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. 39 Fig. 41a
26
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INDEX GROUP INDEX
PREVIOUS
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
follows-
1.5 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)
Fig. 42
REMOVAL OF SHOCK ABSORBER
ASSEMBLY
2. Loosen rear wheel mounting bolts.
3. Jack up the car, allowing the rear suspension to SUSPENSION
hang freely.
4. Support the trailing arm.
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. 43
INSTALLATION OF SHOCK ABSORBER
ASSEMBLY
2. Tighten upper mounting flange nut to 4.5 kg-m
torque.
3. Tighten bottom mounting bolt to 6 kg-m torque.
DIS-ASSEMBLY AND ASSEMBLY OF
SHOCK ABSORBER
DIS-ASSEMBLY :-
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. 44
27
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INDEX GROUP INDEX
PREVIOUS
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.
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. Fig. 45
4. Insert rear bump stopper.
5. Fit dust cover on assembly bump stopper cup.
SUSPENSION
1
5
4
3
1. LOCK WASHER
2. ASSEMBLY BUMP STOPPER CUP
2 6
3. ASSEMBLY STRUT TOP BRACKET
4. BOTTOM RUBBER (SHOCK ABSORBER MOUNTING)
9 5. TOP RUBBER (SHOCK ABSORBER MOUNTING)
6. RUBBER SEAT
7 7. OUTER COIL SPRING
8. BUMP STOPPER
9. DUST COVER
8
Fig. 46
28
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INDEX GROUP INDEX
PREVIOUS
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 SUSPENSION
BUMP
STOPPER 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
29
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INDEX GROUP INDEX
PREVIOUS
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
SUSPENSION assembly from the brackets.
3. Remove the rubber bushes from the trailing arm
Fig. 49.
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 Fig. 48
torque.
PRESS
TRAILING ARM
ASSEMBLY PIVOT
BUSH
SLEEVE INNER
Fig. 49
30
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INDEX GROUP INDEX
PREVIOUS
INSPECTION OF SHOCK ABSORBER / Checks to be carried out after removal of

STRUT ON THE CAR shockabsorber & strut.
Front Suspension 1. Look for signs for breakage such as piston rod
bent or heavy dents on the body. These are
Noise due to loose brake hose results of accident or abuse of suspension parts.
1. Ensure that the brake hose is tightened fully, 2. Discoloration & light scratch marks on working
loose brake hose will give noise. area of piston rod is normal and doesnot need
replacement, unless leakage is noticed &
Noise due to fouling parts :
confirmed.
1. Ensure that the Strut components are not fouling
3. Look for signs of suspected oil leakage such as
with any other parts near by.
oil patches or wet mud cakes on the damper
2. Ensure that the spring end is sitting securely on body. The presence of oil patch or mud cake
the spring seat at the correct place Fig. 50. can also be result of oily sprayfrom road or
accidental spillage of oil during servicing.
3. Ensure the correct torque on the two bolts is
correct : 8 kgf-m of the strut mounting at the 4. Examine damper area near the seal. Presence
bottom bracket. It may be noisy if there is any of oil here is sign of oil leakage.
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 SPRING SEAT SPRING SEAT
rear shock. LOWER UPPER
LUG
LUG
Fig. 50
31
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INDEX GROUP INDEX
PREVIOUS
BRAKES
LEi & LSi
LX & LXi
NEXT
GROUP INDEX
PREVIOUS
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.
i
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INDEX GROUP INDEX
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BRAKES
CONTENTS
1. Technical Specification 1
3. Exploded Views :
a) Servo and tmc assembly (9 inch, ø22.22) 3
b) Caliper Assembly C - 54 4
c) Rear brake assembly (HASF ø200x30) 5
d) Parking brake system 6
e) Hydraulic lines - Non ABS Version - RHD 7
3. How does your car’s brake work 8
4. Front Brakes : 9
a) Salient Features 9
b) Caliper Operation 10
c) Front Brake Service 11
[Removal / Inspection / Installation of Pads, Calipers & Disc]
5. Rear Brakes :
a) Working of Hydraulic auto adjust service brake 21 BRAKE
b) Rear Brake Service 23
[Removal / Inspection / installation of Drum,
brake shoes, Back Plate, & wheel cylinder]
6. Bleeding of Hydraulic system 30
7. Tandem Master Cylinder(for Non - ABS version) 33
8. Vacuum Booster 36
a) Working Principle 37
b) Servicing 38
c) Check list for ensuring satisfactory functioning of vacuum booster 40
d) Vacuum Leak Test 41
9. Pressure Conscious Regulating Valve (PCRV) 42
10. Parking Brake 43
[Removal, Installation & Adjustment]
11. Troubleshooting of Brake system 46
iii
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INDEX GROUP INDEX
PREVIOUS
BRAKES
BRAKES FRONT REAR

Type 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 15 mm 2.6 mm
for pad /lining
Tandem Master Cylinder Type - AS/AS (BIL*)
Size - 22.22 mm dia (BIL*)
Material - Aluminium
BRAKE
Finish - Anodized
Stroke - 30 mm (Primary - 15 mm and Secondary -15 mm) (BIL*)
Stroke - 28.5mm (KBX*)
Circuit - Diagonal (Primary to Front Right / Rear and Left
Secondary to Front Left / Rear Right)
Vacuum Booster Type - LSC 65
Size - 9 Inch
Boost Ratio - 5:1
Pressure Conscious Valve Ratio : 3:7:1 (BIL*) & 4:1 (KBX*)
Regulating Valve (PCRV) Cut-in Pressure : 27 kg/cm2 (BIL*) & 25 kgcm2 (KBX*)
For non ABS version Location : Rear Circuit
Brake Pedal Free Play - 8 mm
Height - 200 mm
Stroke -140 mm (Available)
Brake Fluid Type - IS8654 / DOT 3 / DOT 4
Capacity - 0.270 Litres
1
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INDEX GROUP INDEX
PREVIOUS
BRAKES
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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INDEX GROUP INDEX
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BRAKES
EXPLODED VIEW OF SERVO AND TMC ASSEMBLY (9 INCH, Ø22.22)
FILLER CAP ASSEMBLY (WITH FLWI)
FLUID RESERVOIR SUB ASSEMBLY

○
(WITHOUT FLWI)
○
# * SEALING RING # * SEAL FLUID TANK

○
○
# * SEAL - RECUPERATING
# * SEAL GLAND PRIMARY
# * SEAL GLAND SECONDARY

1.0 to 1.6 # * CIRCLIP
SPRING WASHER
# STOP PIN # PLUNGER SECONDARY
# * WASHER
# PLUNGER ASSEMBLY
(STOP PIN)
PRIMARY
# STOP WASHER
# SPACER BRAKE
GROMMET 2.0 to 2.5 FILTER
NON RETURN VALVE ASSEMBLY DUST COVER

* - MAJOR REPAIR KIT # - MINOR REPAIR KIT - SPECIFIED TORQUE IN Kgm
3
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INDEX GROUP INDEX
PREVIOUS
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
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INDEX GROUP INDEX
PREVIOUS
BRAKES
EXPLODED VIEW OF REAR BRAKE ASSEMBLY (HASF Ø180X30)
1.0 to 1.3
BACK PLATE ASSEMBLY - LH/RH
GROMMET # DUST CAP WHEEL CYLINDER HOUSING
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
5
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INDEX GROUP INDEX
PREVIOUS
BRAKES
PARKING BRAKE SYSTEM
CENTRAL LOCATOR
EQUILISER
HAND BRAKE
SWITCH
ASSEMBLY PARKING 0.8 to 1
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 - SPECIFIED TORQUE IN Kgm
6
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INDEX GROUP INDEX
PREVIOUS
BRAKES
HYDRAULIC LINES - NON ABS VERSION - RHD

ASSEMBLY TUBE-TMC PRI.
PORT TO FRONT BRAKE RH VACUUM ASSEMBLY TUBE -
BOOSTER BRAKE HOSE REAR
AS/AS RH TO WH CYL. RH
REAR WH CYL RH
FRONT CALIPER RH ASSEMBLY

VACUUM PIPE - HOSE CLAMP 20
MPFI RHD
ASSEMBLY TUBE- ASSEMBLY TUBE- ASSEMBLY BRAKE
TMC SEC. PORT TO 3 REAR RH CONNECTOR HOSE REAR
WAY CONNECTOR TO PCRV RH SIDE
ASSEMBLY TUBE-
0.8 to1 TMC PRI. PORT - PCRV ASSEMBLY
CONNECTOR LH
ASSEMBLY TUBE- ASSEMBLY TUBE- ASSEMBLY TUBE-

T CONNECTOR TO 3 WAY CONNECTOR - PCRV RH TO REAR
FRONT BRAKE LH REAR RH CONNECTOR BRAKE HOSE RH
FRONT CALIPER LH
ASSEMBLY TUBE- ASSEMBLY TUBE-

3 WAY UNION
CONNECTOR LH PCRV LH TO REAR
(T CONNECTOR) BRAKE
TO PCRV LH BRAKE HOSE LH
REAR WH CYL LH
2.3 to 2.5 CONNECTOR

ASSEMBLY BRAKE (BRAKE CIRCUIT)
HOSE FRONT
SEALING
WASHER PCRV ASSEMBLY
0.8 to 1 CLIP (BRAKE HOSE)
SLEEVE CLAMP SLEEVE CLAMP 0.6 to 0.8
0.6 to 0.8 0.6 to 0.8

0.6 to 0.8
COATED SINGLE CLAMP CLAMP (PIPE 4.75X4.75) COATED DOUBLE CLAMP
NOTE : ALL COUPLING NUT TORQUE - 1.4 TO 1.6 Kgm - SPECIFIED TORQUE IN Kgm
7
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INDEX GROUP INDEX
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BRAKES
RIGHT SIDE REAR RIGHT SIDE
3 7
1
8 9
4
10
2
5
11
9
8
LEFT SIDE REAR LEFT SIDE

PRIMARY CIRCUIT
SECONDARY CIRCUIT
Fig. 1 - Schematic circuit diagram of brake system (Non ABS version).
1. VACUUM BOOSTER HOW DOES YOUR CAR’S BRAKE

2. TANDEM MASTER CYLINDER WORK : Fig. 1
3. PRIMARY PORTS When the brake pedal is depressed, hydraulic
pressure is developed in the Tandem Master
4. SECONDARY PORT
Cylinder, which is used to actuate the brake (two in
5. ‘3’ WAY CONNECTER front and two in rear).
6. STRAIGHT CONNECTER The brake pipes are connected from the tandem
master cylinder to the brakes. They make two
7. PRESSURE CONCIOUS REGULATING
independent circuits diagonally split. The primary
VALVE
circuit connects the Front Right and the Rear Left
8. BRAKE CALIPER brake while the secondary connects Front Left and
Rear Right brake through a 3-way connector.
9. REAR WHEEL CYLINDER
Pressure conscious regulating valve is provided at
10. PARKING BRAKE LEVER ASSY.
the rear brake to avoid rear brake locking and
11. PARKING BRAKE CABLE WITH GROMMET 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.
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Fig. 2
6
4
3
7
2
5
9 11
1 10
12
7
5
BRAKE
SR. NO. DESCRIPTION SR. NO. DESCRIPTION

1 CALIPER HOUSING 7 SLIDING PIN BOOT
2 SEALING RING 8 CARRIER 12
3 PISTON 9 ANTI RATTLING CLIP
4 DUST BOOT 10 BLEED SCREW
5 SLIDING PIN 11 DUST CAP
6 PAD ASSEMBLY 12 SLIDING PIN BOLT
Fig. 3 - Exploded view of caliper assembly
FRONT BRAKES When the brake pedal is pressed, the hydraulic

Ventilated disc brakes with Colette type single pot pressure from Tandem Master Cylinder pushes the
caliper of 54 mm piston diameter are provided for front piston in the caliper pot and with it the in-board pad on
brake. to the disc. The caliper body reacts and slides on the
sliding pins to bring the out-board pad into contact
SALIENT FEATURES OF DISC BRAKES (Fig.2&3) : with the disc. Thus the clamping forces on both sides
Colette type Caliper assy consists of a caliper carrier of the disc become equal.
bolted to the knuckle and the body assy slides on When the hydraulic pressure is released, upon release
two guide pins used in the carrier. The sliding pins are of the brake pedal the sealing ring fitted in the groove
sealed against water and dust by sliding pin boots of the caliper pot retracts the piston by a small amount
thereby avoiding possible unequal sliding loads caused which allows the moving parts to relax sufficiently for
by dirt, corrosion. Drag of the pads is taken directly the disc pads to retract and remain in close proximity
by the Carrier, consequently the pins are loaded only to disc, ready for the next brake application.
by the weight of the caliper body.
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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 PISTON SEAT
CYLINDER (RUBBER SEAL)
necessary to have the clearance adjusted to the
minimum. The clearance adjustment is done by means
of the piston (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 PISTON
pressure is released from the piston, a restoring force HYDRAULIC PRESSURE
is generated by the seal and it pushes the piston back ‘OFF’
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
PISTON SEAT
is fixed into the groove in the cylinder, the distortion is
(RUBBER
limited to the same amount as previously described. CYLINDER
SEAL)
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.
The caliper brake needs no adjustment.
PISTON
HYDRAULIC PRESSURE ‘ON’
Fig. 4
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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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INSPECTION OF PADS :
Measure pad thickness (with lining) with a Vernier and
if the thickness is found to be less than 6 mm any
CALIPER PAD ASSEMBLY
where in the pad, it is time to replace them Fig. 7
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 ANTIRATTLING
as given to recondition the disc. CLIPS
If there is no visible deterioration in piston dust boot SLIDING PIN BOOT

and sliding pin boot, new pads can be fitted.
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 PAD FRICTION
is towards the disc and ensure proper seating of the MATERIAL
anti rattling clips. TOWARDS DISC
Fig. 8
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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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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 DUST BOOT
hose from Caliper body. COMPRESSED AIR PISTON
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 WOODEN
PIECE
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 Fig. 12
with fingers. Fig. 13 Take out the piston from the
housing and remove the boot from the piston.
DUST BOOT
COMPRESSED
Fig. 13
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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 SEALING RING
air.
4. Care is to be taken not to damage inner bore of Fig. 14
the cylinder.
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
BOOT PISTON
paper on piston surface.
Fig. 15
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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 :
FITMENT OF SEALING RING
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
Smear fresh brake fluid to the piston surface.
Fit dust boot in to the caliper groove.
Fig. 18
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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 DUST BOOT
into the housing easily. COMPRESSED
AIR
Ensure that seal does not get damaged due to
excessive push. If required slightly swivel the piston
for the ease of entry. 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.
DUST BOOT
Smear sliding pins with special red rubber grease.
PISTON BRAKE
Insert the loose sliding pins into the holes of the carrier COMPRESSED
AIR
and fit the sliding pin boots.
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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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. SLIDING PIN
BOLT
DISC REMOVAL :
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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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
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. BRAKE
It will also help in extending pad life.

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 Fig. 24
hub.
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
SLIDING PIN
and torque the caliper carrier bolts to specification. BOLT
Fig. 25.
Fig. 25
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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
a. Depress brake pedal several times and

with pedal depressed, loosen bleed
screw a little.
b. With brake pedal depressed, retighten
b 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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REAR BRAKES :
27 26 24
25
16 15
21 22 23
7
65
4
20 2
14 9
8
18
19
11
12 13
10
BRAKE
17
3
SR. DESCRIPTION SR. DESCRIPTION SR. DESCRIPTION SR. DESCRIPTION

NO. NO. NO. NO.
1 BACK PLATE 9 SHOE RETURN 15 SPRING WASHER 23 GLAND SEAL
2 LINED SHOE TRAILING SPRING(CYLINDER END) 16 SET SCREW 24 WHEEL CYLINDER BODY
3 LINED SHOE LEADING 10 SHOE RETURN 17 SHOE HOLD DOWN CLIP 25 SPRING
4 HAND BRAKE LEVER SPRING(ABUTMENT END) 18 SHOE HOLD DOWN PIN 26 BLEED SCREW
5 WAVE WASHER 11 STRUT RETURN SPRING RH 19 GROMMET 27 DUST CAP
6 WASHER PLAIN 12 STRUT RETURN SPRING LH 20 GROMMET
7 SPLIT PIN 13 STRUT ASSY. 21 DUST COVER
8 HAND BRAKE LEVER PIN 14 WHEEL CYLINDER 22 PLUNGER
Fig. 27 : Exploded view of Rear Brake assembly
WORKING OF HYDRAULIC AUTO ADJUST To maintain the shoes square with the drum, both
SERVICE BRAKE (WITH FORWARD PULL HAND the rims rest on pads formed at suitable place on
BRAKE) Fig. 27 the back plate.
The hydraulic Auto adjust brake is simple in design, The shoe is held against the backplate by means
robust in construction with one trailing and leading of a shoe hold down clip. Mechanical lever
shoe with bonded linings. The brakes self adjust during mechanism is incorporated for normal hand brake
brake operation. operation, but the feature of the brake is that the
The shoe return spring are fitted from shoe to shoe to automatic adjustment of the lined shoes takes place
provide a positive shoe retraction thus avoiding any when the service brake is applied.
possibility of brake "hanging on".
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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
Release the parking brake lever and remove parking ADJUSTER
LINING
WINDOW
brake lever cover. Loosen parking brake cable INSPECTION
(slackness) adjustment nut. 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
BRAKE
3301 Fig. 29
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
Standard Service Limit

Brake Drum
Inside Fig. 29
Diameter 200 mm 202 mm
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
BRAKE DRUM
drum. It is unsafe and must be replaced.
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. Fig. 30
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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
INSPECT BRAKE SHOE / LINING : Fig. 31
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 Fig. 32
emery paper, hard particles of sandpaper will be
deposited in the lining resulting in damage of
drum surface.
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
Thickness 6 mm 2.6 mm
(Lining + Shoe Rim)
LINED SHOE ASSY.
Fig. 33
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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 Fig. 34
hydraulic parts.
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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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
Fig. 38
contamination and damaging the rubber parts.
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WHEEL CYLINDER
4
5 3
7
6
2
1
1. Dust cover
2. Plunger
3. Gland Seal
4. Dust Cap
5. Bleed Screw
6. Wheel Cyl. Body
7. Spring
BRAKE
Fig. 39
INSPECTION OF WHEEL CYLINDER : ASSEMBLING OF WHEEL CYLINDER :

Examine the wheel cylinder bore and the piston. If When properly inspected assemble as follows :
they are not scored, corroded or ridged and are smooth Absolute cleanliness has to be maintained and
to touch, then new seals can be fitted. clean brake fluid must be used. Never use brake
If there is any doubt about the condition of the bore, a fluid bled from the system as it may be certainly
new cylinder must be installed. aerated.
Inspect the wheel cylinder dust cover for cuts, cracks, Lubricate the wheel cylinder bore liberally with fresh
hardening or other signs of deterioration. If in doubt, brake fluid. Dip new seals and piston in fresh brake
the dust cover needs replacement. fluid.
If the system has been contaminated with mineral oil Fit the gland seal on to the plunger groove in one of
of any type, the system should be flushed out with the piston and insert the piston with seal into the bore,
fresh brake fluid or alcohol and all rubber parts including such that the smaller stem of the piston is facing
hoses should be replaced. outside.
For identification a contaminated seal can be compared Reverse the dust cover and fit the smaller dia of the
with a new seal (but do not allow them to touch). dust cover onto the neck of the piston and fit dust
If the old one is appreciably larger, seal contamination cover on the wheel cylinder.
is indicated. Insert the spring assy in to the bore.
Whenever wheel cylinders are serviced replace seals Insert the other plunger with seal (Assemble as said
and dust covers from appropriate wheel cylinder kit. 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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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.
1
The quadrant side of the strut should be located in the
leading shoe slot. Fit the spring. Fig. 41 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 3
2
side.
Connect the hand brake cable to the hand brake lever 1
in the reverse order of removal.
Do not handle linings more then it is necessary
and be sure that they are completely free from 1. BRAKE SHOE
oil or grease. 2. SHOE HOLD DOWN SPRING
3. PARKING BRAKE SHOE LEVER
Centralise the brake shoe relative to the back plate
before fitting the drum by lightly tapping in the required
direction.
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
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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BRAKES
BLEEDING OF HYDRAULIC SYSTEM :

The process of removing air from the hydraulic pipelines RIGHT
RIGHT
and cylinder is known as "Bleeding". BRAKE WHEEL
CALIPER CYLINDER
The brake hydraulic lines are based on diagonal split 3 2
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 FRONT REAR
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.) 1 4
LEFT LEFT
When any joint part of the Master Cylinder, other joint BRAKE WHEEL
CALIPER CYLINDER
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 Fig. 42
brake system must be bled at all 4 wheel brakes.
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 Fig. 43
immediately and clean the surface.
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 bleeding
end in to a clean glass container containing nipple
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 Fig. 44
only.
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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 a. Depress brake pedal several times and
until bubbles of air cease to appear at the end of the with pedal depressed, loosen bleed
bleed tube. Fig. 45. screw a little.
Close the bleed screw immediately after the last b the bleed screw.
downward stroke of the pedal. Whilst the pedal is
thus held, securely tighten the bleed screw to Fig. 45
recommended tightening torque and remove the
tube. Replace the dust cap on the bleed screw. bleeding
Ensure that the fluid level in the master cylinder nipple
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 BRAKE
assembly followed by the rear left wheel cylinder.
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 re-
Fig. 46
opening.
Tighten the bleed screw finally after the last downward
stroke of the pedal. Replace the dust cap on the bleed
screw.
After completion of bleeding, apply the brake pedal Lock Nut
hard and check for any leak at the joints and bleed
Brake Light Switch
screws.
Also check the brake pedal for "Sponginess" if found 3+0.5 Set Brake
Light
Sw itc h
spongy repeat the complete procedure of bleeding. As shown
Set brake light switch dimension 3 + 0.5 mm and
tighten the lock nut Fig. 46a
Brake
Pedal
Fig. 46a
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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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TANDEM MASTER CYLINDER (FOR NON ABS VERSION)
FILLER CAP
FLUID RESERVOIR
SEAL
O-RING
BACK SEAL
SPRING
BRAKE
ASSEMBLY PRIMARY
ASSEMBLY SECONDARY PLUNGER
PLUNGER
Fig. 49 Tandem Master Cylinder - Sectional view (AS/AS)
DESCRIPTION Under normal conditions when the brake pedal is

depressed, the servo output rod pushes the primary
The simultaneous cut off (AS/AS) tandem master
plunger of the cylinder. At the same time, the force of
cylinder is designed for finer control of the fluid cut off
the primary spring moves the secondary plunger
point. The AS/AS master cylinder consists of two
forward.
independent chambers in a single casting housing,
primary and secondary plungers are fitted with seals Simultaneously the recuperating pressure seals on
having minimum friction. both the plungers cover the cut off holes, developing
pressure in both the chambers. The pressurized fluid
Each hydraulic system is so designed that any failure
from primary chamber is transmitted to front left and
of a pressure seal in anyone of the chamber would not
rear right brakes and from secondary chamber to the
result in total failure of braking system, since the other
front right and rear left brakes.
chamber remains completely operational and ensures
minimum safe braking performance. The fluid reservoir comprises of two separate chambers
serving each system with a common topping up
The specific design feature of this master cylinder is
connection at the upper portion. The Filler cap
that pressure is developed in both the chambers
comprises of a Fluid Level Warning Indicator (FLWI).
simultaneously without any time lag.
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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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Clean the cylinder bore in fresh brake fluid or alcohol round-ended rod. Press it down fully and whilst
and blow with compressed air. Be sure that the Three holding, screw in the stop pin with a new gasket and
holes visible through the primary and secondary inlet tighten to the specified torque. Slowly let the
ports) in the cylinder body are clean, by blowing dry secondary plunger back till it touches the stop screw.
compressed air.
Now insert the new primary plunger assembly as
Do not poke the holes with sharp instrument. shown in Figure (3) into the bore.
CAUTION : First fit the stop washer on to the primary plunger
Do not use kerosene (or) petrol (or) any other shaft. Fit the washer primary back seal followed by
mineral oils to clean the cylinder and its internal spacer and back seal on to the primary plunger shaft.
parts. As it will lead to contamination and Now fit the circlip by using circlip plier.
damage of rubber part wash all disassembled NOTE
parts with brake fluid only.
While fitting the primary back seal, make sure
INSPECTION OF TANDEM MASTER CYLINDER : that the lip of the seal is facing forward.
Examine the bore of the master cylinder. If it is not Actuate the primary plunger assembly for couple of
scored, ridged or corroded and is smooth to touch, times and check for the quick return of the plungers.
the master cylinder assembly can be rebuilt using the
Fit a new 'O' ring into the groove on the spigot of the
appropriate parts from the genuine repair kit.
body. Fit new grommet into both the inlet ports by
If there is a slight doubt about the condition of the liberally lubricating the same with fresh brake fluid.
bore like having deep grooves or pit marks etc., fit a
Fit the fluid reservoir by positioning the same into the
new master cylinder assembly.
grommets and by slightly rocking them on to either
If contamination is observed on the removed seals side, press it home. Fit the locking pin as shown in
(Normally they would have swollen and can be Figure.
compared with new seals from the kit, which will show
NOTE BRAKE
clearly that the size is enlarged). The entire rubber
parts in the system including both front and rear hoses It is essential that the reservoir filler cap must be
must be discarded and the entire system should be removed.
flushed with fresh brake fluid. Clean the filter. Refit the filler cap. Clean the filter.
ASSEMBLING THE TANDEM MASTER CYLINDER : Replace the sealing ring the filter cap during overhaul.
Refit the filler cap.
Absolute cleanliness has to be maintained and clean
fresh brake fluid must be used. Never use the brake Now the master cylinder is ready for fitment on to the
fluid bled from the system as it is aerated. Servo. Fit the master cylinder to servo using nuts
along with spring washer and tighten to the specified
To facilitate easy assembly, smear the cylinder bore
torque.
with fresh brake fluid liberally. Dip the plungers and
all seals in fresh brake fluid. Fit the secondary back Connect the outlet pipes to the master cylinder.
seal in the secondary plunger groove such that the Tighten the coupling nut to the specified torque. Fill
seal lip faces the primary plunger assembly. the reservoir with recommended brake fluid and bled
the system. Check for brake fluid leakage.
Fit the seal shim and recuperating seal on the stem
side of the secondary plunger in such a way that the NOTE
lip of the seal faces towards the secondary spring. Do not alter the stand out of the output rod of the
Fit the seal retainer in correct position as shown in servo unit.
figure and fit the secondary spring with the smaller dia Make sure that Vaccum Booster output rod is correctly
coil coming on to the plunger stem. assembled into the primary plunger bore.
Clamp the cylinder body with its mouth pointing Make sure that the primary outlet is connected to the
upwards in a vice fitted with soft jaws. Insert secondary front left and rear right and secondary outlet to the
plunger assembly into the bore with the secondary rear left and front right brakes.
spring leading into the bore.
Do not polish bore of the tandem master cylinder.
Then slowly push the plunger down the bore with a Never use cloth to clean or dry the master cylinder.
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VACCUM BOOSTER

SR. DESCRIPTION
NO. NO. NO. NO.
NO.
7 SHIM 13 SPACER 19 CLEVIS 25 RESERVOIR
1 BODY
2 GASKET 8 SECONDARY PLUNGER 14 CIRCLIP 20 GROMMET (NRV) 26 FILLER CAP
3 STOP PIN 9 GLAND SEAL 15 BOOSTER 21 NON RETURN VALVE 27 PIN
4 SPRING 10 PRIMARY PLUNGER ASSY. ASSY. 22 SPRING WASHER 28 ‘O’ RING
5 SPRING RETAINER 11 WASHER 16 FILTER 23 NUT
6 RECUPERATING SEAL 12 PRIMARY BACK SEAL 17 BOOT 24 GROMMET
18 NUT
Fig. 53 Exploded view of TMC assembly & Vaccum Booster Assembly (LSC65 + ø22.22AS/AS)
There is a mechanical vaccum booster unit fitted on operates the master cylinder. Should a vacuum failure
the car. The above unit is designed to provide controlled occur, the two push rods act as a single rod and the
power assistance to the effort applied by the driver's brakes will work in the conventional manner, but more
foot to the brake pedal. pedal effort will be required and the fatigue of the driver
Vacuum supplied to the booster unit is obtained from will increase.
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.
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
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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 Fig. 54
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.
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 Fig. 55
depending on whether the brake pedal is released or
depressed.
Fig. 56
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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.
Fig. 57
Unscrew the booster mounting nuts from the firewall
end (2 Nos.) and remove the booster from the vehicle.
Fig. 58
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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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 115 +0.5
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 Booster Push Rod Length
table Page 2) From Mtg. Face to Hole Center Brake Pedal
Connect the vacuum hose to the booster and fill the

Fig. 61
master cylinder reservoir with recommended brake
fluid.
Bleed the system - refer brake bleeding procedure.
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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 non- If vaccum booster is operative, do the vacuum
return valve. Then with engine running, check leak test as given.
the vacuum supply with a vacuum gauge. There
should be atleast 20” of vacuum.
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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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 not vaccum booster

If the applications are vaccum booster assisted, assisted disconnect the vacuum hose from the
there is no vacuum leak. 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 If the non return valve is OK, the vaccum booster
non-return valve and repeat the vacuum leak is leaking. Replace the vaccum booster with a
test. new kit.
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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.
INLET OUT-
• It is necessary to regulate hydraulic pressure to LET
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 PCRV

as an assembly only.
Fig. 62
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PARKING BRAKE
PARKING BRAKE LEVER
PARKING BRAKE ADJUSTMENT

EQUALISER
PARKING BRAKE PARKING BRAKE

CABLE CABLE
BRAKE
BRAKE DRUM
BRAKE DRUM SEMITRAILING ARM LH
SEMITRAILING ARM RH
Fig. 63
PARKING BRAKE
The parking brake arrangement is cable operated This is a safety device so designed that the parking
console mounted mechanical type brake acting on rear brake does not get released accidentally.
wheels.
To release parking brake, lift the handle slightly and
The hand brake lever situated in the cab operates it. keeping release button pressed, push down the lever
When the hand brake lever is pulled up, the parking fully.
brake lever arrangement in the rear brake assembly
When release button is pushed as above, pawl rod
inside the rear brake drum brake is also pulled through
also gets pushed, disengaging pawl from ratchet, thus
the cable system.
releasing the parking brake.
This action expands the rear brake shoes against the
REMOVAL OF PARKING BRAKE LEVER
drum, thus applying the rear brakes. Fig. 63
Place wheels chocks at the rear wheels.
PARKING BRAKE HANDLE CONSTRUCTION
Fig. 64
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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.
Fig. 64
Disconnect the parking brake cable from the shoe lever
- refer Brake shoe removal.
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 cable-
mounting 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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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
Adjust the parking brake cable slackness as per the ADJUSTMENT NUT
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
Confirm pedal travel by depressing the brake pedal for APPLIED
few times.
Check the lining condition of the rear brake it should
not have been worn out beyond limit.
RELEASE
After confirming all the above points start adjusting BUTTON PARKING BRAKE BRAKE
the parking brake lever stroke by either loosening or LIGHT SWITCH
tightening the self locking slackness adjustment nut.
Parking Brake Lever Stroke
When a force of 20 kg is Travel should be within

applied to pull up the lever. 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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TROUBLE SHOOTING OF BRAKE SYSTEM
HEADING CAUSE REMEDY
SPONGY BRAKE PEDAL1. Air in hydraulic system 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 4. Replace
in Rear
BRAKE ROUGH OR 1. Excessive lateral run out in disc or 1. Repair if possible or replace the
CHATTER ON parallelism disc. not within specification.
APPLICATION
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 4. Check and adjust as per
adjustment specifications.
5. Seized caliper pistons 5. Overhaul Calipers
6. Damaged or loose wheel bearing 6. Replace wheel bearing
7. Distorted steering knuckle or rear 7. Replace knuckle or rear wheel
wheel spindle spindle
EXCESSIVE BRAKE 1.Lining soiled with brake fluid, oil 1. Replace

PEDAL EFFORT or grease.
(HARD PEDAL) 2. Brake pad worn below 2. Replace
recommended thickness.
3. Malfunctioning of Servo. 3. Identify the trouble in Servo and
rectify
4. Partial system failure (in tandem 4. Check both front and rear circuits
master cylinder). and rectify.
5. Piston in calipers stuck or sluggish 5. Remove caliper and rebuild
6. Fading brake due to non 6. Replace with approve grade of
recommended grade of brake brake pads.
pads.
7. Kinked, dented or clogged bundy 7. Identify and Replace
pipes, hoses or 'T' connections.
8. Binding pedal linkage 8. Lubricate and free up the system.
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BRAKE NOISE 1. Glazed shoe linings or foreign 1. Repair or replace shoe linings.
matters stuck on 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 4. Replace or retighten
mounting bolts.
EXCESSIVE PEDAL
TRAVEL 1. Incorrect pedal free play 1. Adjust as per specification.
2. Partial brake system failure either 2. Identify and repair by replacing
in dual circuit or in Master Cylinder necessary parts.
3. Air in system (pedal soft / spongy) 3. Bleed and top up with
recommended brake fluid.
4. Soft or bulging hose 4. Replace
5. Excessive clearance between 5. Check auto adjuster mechanism
lining and drum in rear brakes due
to malfunctioning of auto adjusters.
6. Lining pad knock back caused by 6. Adjust or replace faulty parts as
loose or worn wheel bearing or necessary. BRAKE
other related parts.

7. Insufficient fluid in master 7. Fill reservoir with approved brake
cylinder reservoir fluid check for leak and air in brake
system.
Check warning light, bleed system
if required.
8. Ben brake shoes or shoes worn 8. Replace brake shoes.
out.
GRABBING OR
PULLING OF CAR 1. Incorrect type pressure (or) 1. Inflate both front tyres to the
inflated unequally. 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 4. Check and adjust to correct
adjustment on rear brake. specification.
Note : If the above problems are not there then proceed further
with the checking of brakes for grabbing.
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BRAKES
5. Drum to shoe clearance out of 5. Check for auto adjusting

adjustment (malfunctioning auto mechanism.
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 9. Replace
soiled with brake fluid, oil or
grease
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 12.Replace
springs in the brake.
13.Sluggish parking - brake cable or 13.Repair or replace
linkage
14.Master cylinder piston not 14.Repair master cylinder.
returning correctly.
BRAKE WARNING LIGHT 1.Parking brake lever in applied 1. Release parking brake and check
LIGHTS AFTER ENGINE condition. that brake warning light turns off.
START
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. 1. Investigate and correct leaky point.
TURNS ON WHEN BRAKE Add brake fluid.
IS APPLIED
2. Brake fluid level very low. 2. Add brake fluid.
BRAKE WARNING LIGHT 1. Brake warning light circuit faulty 1. Repair circuit or Replace bulb.
FAILS TO TURN ON EVEN
WHEN PARKING BRAKE
IS APPLIED.
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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CONTENTS
3. Exploded Views :
a) Servo and tmc assembly (9 inch, ø22.22) 3
b) Caliper Assembly C - 54 4
c) Rear brake assembly (HASF ø200x30) 5
d) Parking brake system 6
e) Hydraulic lines - Non ABS Version - RHD 7
3. How does your car’s brake work 8
4. Front Brakes : 9
a) Salient Features 9
b) Caliper Operation 10
c) Front Brake Service 11
[Removal / Inspection / Installation of Pads, Calipers & Disc]
5. Rear Brakes :
a) Working of Hydraulic auto adjust service brake 21 BRAKE
b) Rear Brake Service 23
[Removal / Inspection / installation of Drum,
brake shoes, Back Plate, & wheel cylinder]
6. Bleeding of Hydraulic system 30
7. Tandem Master Cylinder(for Non - ABS version) 33
8. Vacuum Booster 36
a) Working Principle 37
b) Servicing 38
c) Check list for ensuring satisfactory functioning of vacuum booster 40
d) Vacuum Leak Test 41
9. Pressure Conscious Regulating Valve (PCRV) 42
10. Parking Brake 43
[Removal, Installation & Adjustment]
11. Troubleshooting of Brake system 46
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BRAKES
BRAKES FRONT REAR

Type 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 6 mm 2.6 mm
for pad /lining
Tandem Master Cylinder Type - AS/AS (for non ABS) & CV/CV (for ABS)
Size - 22.22 mm dia
Material - Aluminium
BRAKE
Finish - Anodized
Stroke - 30 mm (Primary - 15 mm and Secondary - 15 mm)
Circuit - Diagonal (Primary to Front Right / Rear and Left
Secondary to Front Left / Rear Right)
Vacuum Booster Type - LSC 65
Size - 9 Inch
Boost Ratio - 5:1
Pressure Conscious Valve Ratio : 3:7:1
Regulating Valve (PCRV) Cut-in Pressure : 20 kg/cm2
For non ABS version Location : Rear Circuit
Brake Pedal Free Play - 8 mm
Height - 200 mm
Stroke -140 mm (Available)
Brake Fluid Type - IS8654 / DOT 3 / DOT 4
Capacity - 0.270 Litres
1
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BRAKES
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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EXPLODED VIEW OF SERVO AND TMC ASSEMBLY (9 INCH, Ø22.22)
FLUID RESERVOIR SUB ASSEMBLY

○
(WITHOUT FLWI)
○
# * SEALING RING # * SEAL FLUID TANK

○
○
# * SEAL - RECUPERATING
# * SEAL GLAND PRIMARY
# * SEAL GLAND SECONDARY

1.0 to 1.6 # * CIRCLIP
SPRING WASHER
# STOP PIN # PLUNGER SECONDARY
# * WASHER
# PLUNGER ASSEMBLY
(STOP PIN)
PRIMARY
# STOP WASHER
# SPACER BRAKE
GROMMET 2.0 to 2.5 FILTER
NON RETURN VALVE ASSEMBLY DUST COVER

3
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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
GROMMET # DUST CAP WHEEL CYLINDER HOUSING
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
5
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BRAKES
CENTRAL LOCATOR
EQUILISER
HAND BRAKE
SWITCH
ASSEMBLY PARKING 0.8 to 1
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 - SPECIFIED TORQUE IN Kgm
6
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BRAKES
HYDRAULIC LINES - NON ABS VERSION - RHD

ASSEMBLY TUBE-TMC PRI.
PORT TO FRONT BRAKE RH VACUUM ASSEMBLY TUBE -
BOOSTER BRAKE HOSE REAR
AS/AS RH TO WH CYL. RH
REAR WH CYL RH
FRONT CALIPER RH ASSEMBLY

VACUUM PIPE - HOSE CLAMP 20
MPFI RHD
ASSEMBLY TUBE- ASSEMBLY TUBE- ASSEMBLY BRAKE
TMC SEC. PORT TO 3 REAR RH CONNECTOR HOSE REAR
WAY CONNECTOR TO PCRV RH SIDE
ASSEMBLY TUBE-
0.8 to1 TMC PRI. PORT - PCRV ASSEMBLY
CONNECTOR LH
ASSEMBLY TUBE- ASSEMBLY TUBE- ASSEMBLY TUBE-

T CONNECTOR TO 3 WAY CONNECTOR - PCRV RH TO REAR
FRONT BRAKE LH REAR RH CONNECTOR BRAKE HOSE RH
FRONT CALIPER LH
ASSEMBLY TUBE- ASSEMBLY TUBE-

3 WAY UNION
CONNECTOR LH PCRV LH TO REAR
(T CONNECTOR) BRAKE
TO PCRV LH BRAKE HOSE LH
REAR WH CYL LH
2.3 to 2.5 CONNECTOR

ASSEMBLY BRAKE (BRAKE CIRCUIT)
HOSE FRONT
SEALING
WASHER PCRV ASSEMBLY
0.8 to 1 CLIP (BRAKE HOSE)
SLEEVE CLAMP SLEEVE CLAMP 0.6 to 0.8
0.6 to 0.8 0.6 to 0.8

0.6 to 0.8
COATED SINGLE CLAMP CLAMP (PIPE 4.75X4.75) COATED DOUBLE CLAMP
NOTE : ALL COUPLING NUT TORQUE - 1.4 TO 1.6 Kgm - SPECIFIED TORQUE IN Kgm
7
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BRAKES
RIGHT SIDE REAR RIGHT SIDE
3 7
1
8 9
4
10
2
5
11
9
8
LEFT SIDE REAR LEFT SIDE

PRIMARY CIRCUIT
SECONDARY CIRCUIT
Fig. 1 - Schematic circuit diagram of brake system (Non ABS version).
1. VACUUM BOOSTER HOW DOES YOUR CAR’S BRAKE

2. TANDEM MASTER CYLINDER WORK : Fig. 1
3. PRIMARY PORTS When the brake pedal is depressed, hydraulic
pressure is developed in the Tandem Master
4. SECONDARY PORT
Cylinder, which is used to actuate the brake (two in
5. ‘3’ WAY CONNECTER front and two in rear).
6. STRAIGHT CONNECTER The brake pipes are connected from the tandem
master cylinder to the brakes. They make two
7. PRESSURE CONCIOUS REGULATING
independent circuits diagonally split. The primary
VALVE
circuit connects the Front Right and the Rear Left
8. BRAKE CALIPER brake while the secondary connects Front Left and
Rear Right brake through a 3-way connector.
9. REAR WHEEL CYLINDER
Pressure conscious regulating valve is provided at
10. PARKING BRAKE LEVER ASSY.
the rear brake to avoid rear brake locking and
11. PARKING BRAKE CABLE WITH GROMMET 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.
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BRAKES
Fig. 2
6
4
3
7
2
5
9 11
1 10
12
7
5
BRAKE
SR. NO. DESCRIPTION SR. NO. DESCRIPTION

1 CALIPER HOUSING 7 SLIDING PIN BOOT
2 SEALING RING 8 CARRIER 12
3 PISTON 9 ANTI RATTLING CLIP
4 DUST BOOT 10 BLEED SCREW
5 SLIDING PIN 11 DUST CAP
6 PAD ASSEMBLY 12 SLIDING PIN BOLT
Fig. 3 - Exploded view of caliper assembly
FRONT BRAKES When the brake pedal is pressed, the hydraulic

Ventilated disc brakes with Colette type single pot pressure from Tandem Master Cylinder pushes the
caliper of 54 mm piston diameter are provided for front piston in the caliper pot and with it the in-board pad on
brake. to the disc. The caliper body reacts and slides on the
sliding pins to bring the out-board pad into contact
SALIENT FEATURES OF DISC BRAKES (Fig.2&3) : with the disc. Thus the clamping forces on both sides
Colette type Caliper assy consists of a caliper carrier of the disc become equal.
bolted to the knuckle and the body assy slides on When the hydraulic pressure is released, upon release
two guide pins used in the carrier. The sliding pins are of the brake pedal the sealing ring fitted in the groove
sealed against water and dust by sliding pin boots of the caliper pot retracts the piston by a small amount
thereby avoiding possible unequal sliding loads caused which allows the moving parts to relax sufficiently for
by dirt, corrosion. Drag of the pads is taken directly the disc pads to retract and remain in close proximity
by the Carrier, consequently the pins are loaded only to disc, ready for the next brake application.
by the weight of the caliper body.
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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 PISTON SEAT
CYLINDER (RUBBER SEAL)
necessary to have the clearance adjusted to the
minimum. The clearance adjustment is done by means
of the piston (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 PISTON
pressure is released from the piston, a restoring force HYDRAULIC PRESSURE
is generated by the seal and it pushes the piston back ‘OFF’
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
PISTON SEAT
is fixed into the groove in the cylinder, the distortion is
(RUBBER
limited to the same amount as previously described. CYLINDER
SEAL)
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.
The caliper brake needs no adjustment.
PISTON
HYDRAULIC PRESSURE ‘ON’
Fig. 4
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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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INSPECTION OF PADS :
Measure pad thickness (with lining) with a Vernier and
if the thickness is found to be less than 6 mm any
CALIPER PAD ASSEMBLY
where in the pad, it is time to replace them Fig. 7
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 ANTIRATTLING
as given to recondition the disc. CLIPS
If there is no visible deterioration in piston dust boot SLIDING PIN BOOT

and sliding pin boot, new pads can be fitted.
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 PAD FRICTION
is towards the disc and ensure proper seating of the MATERIAL
anti rattling clips. TOWARDS DISC
Fig. 8
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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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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 DUST BOOT
hose from Caliper body. COMPRESSED AIR PISTON
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 WOODEN
PIECE
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 Fig. 12
with fingers. Fig. 13 Take out the piston from the
housing and remove the boot from the piston.
DUST BOOT
COMPRESSED
Fig. 13
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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 SEALING RING
air.
4. Care is to be taken not to damage inner bore of Fig. 14
the cylinder.
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
BOOT PISTON
paper on piston surface.
Fig. 15
15
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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 :
FITMENT OF SEALING RING
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
Smear fresh brake fluid to the piston surface.
Fit dust boot in to the caliper groove.
Fig. 18
16
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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 DUST BOOT
into the housing easily. COMPRESSED
AIR
Ensure that seal does not get damaged due to
excessive push. If required slightly swivel the piston
for the ease of entry. 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.
DUST BOOT
Smear sliding pins with special red rubber grease.
PISTON BRAKE
Insert the loose sliding pins into the holes of the carrier COMPRESSED
AIR
and fit the sliding pin boots.
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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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 SLIDING PIN
BOLT
after removing the dust cap from the bundy tube fitted
earlier and tighten to specified torque.
DISC REMOVAL :
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
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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
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. BRAKE
It will also help in extending pad life.

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 Fig. 24
hub.
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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BRAKES
Fit the wheels and torque the wheel mounting bolts to

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
a. Depress brake pedal several times and

with pedal depressed, loosen bleed
screw a little.
b 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
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BRAKES
REAR BRAKES :
1
13
18
12 15
10
16
20
19
14
17 5
4
6
3
2
7
11 8
BRAKE

NO. NO. NO. NO.
1. BACK PLATE ASSY 7. SPRING SHOE RETURN 13. SCREW 19. BLEED SCREW
2. LINED SHOE ASSY 8. SPRING SHOE RETURN 20. DUST CAP
14. WHEEL CYLINDER BODY
3. STRUT AND QUADRANT 9. SPRING STRUT AND RETURN
15. PLUNGER
4. LEVER HAND BRAKE 10. PIN
16. GLAND SEAL
5. PIN - HAND BRAKE LEVER 11. CLIP
17. SPRING
6. CIRCLIP 12. GROMMET
18. DUST COVER
Fig. 27 : Exploded view of Rear Brake assembly
WORKING OF HYDRAULIC AUTO ADJUST To maintain the shoes square with the drum, both
SERVICE BRAKE (WITH FORWARD PULL HAND the rims rest on pads formed at suitable place on
BRAKE) Fig. 27 the back plate.
The hydraulic Auto adjust brake is simple in design, The shoe is held against the backplate by means
robust in construction with one trailing and leading of a shoe hold down clip. Mechanical lever
shoe with bonded linings. The brakes self adjust during mechanism is incorporated for normal hand brake
brake operation. operation, but the feature of the brake is that the
The shoe return spring are fitted from shoe to shoe to automatic adjustment of the lined shoes takes place
provide a positive shoe retraction thus avoiding any when the service brake is applied.
possibility of brake "hanging on".
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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
Release the parking brake lever and remove parking ADJUSTER
LINING
WINDOW
brake lever cover. Loosen parking brake cable INSPECTION
(slackness) adjustment nut. 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
BRAKE
3301 Fig. 29
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
Standard Service Limit

Brake Drum
Inside Fig. 29
Diameter 200 mm 202 mm
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
BRAKE DRUM
drum. It is unsafe and must be replaced.
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. Fig. 30
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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
INSPECT BRAKE SHOE / LINING : Fig. 31
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 Fig. 32
emery paper, hard particles of sandpaper will be
deposited in the lining resulting in damage of
drum surface.
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
Thickness 6 mm 2.6 mm
(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 Fig. 34
hydraulic parts.
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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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
Fig. 38
contamination and damaging the rubber parts.
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BRAKES
WHEEL CYLINDER
4
5 3
7
6
2
1
1. Dust cover
2. Plunger
3. Gland Seal
4. Dust Cap
5. Bleed Screw
6. Wheel Cyl. Body
7. Spring
BRAKE
Fig. 39
INSPECTION OF WHEEL CYLINDER : ASSEMBLING OF WHEEL CYLINDER :

Examine the wheel cylinder bore and the piston. If When properly inspected assemble as follows :
they are not scored, corroded or ridged and are smooth Absolute cleanliness has to be maintained and
to touch, then new seals can be fitted. clean brake fluid must be used. Never use brake
If there is any doubt about the condition of the bore, a fluid bled from the system as it may be certainly
new cylinder must be installed. aerated.
Inspect the wheel cylinder dust cover for cuts, cracks, Lubricate the wheel cylinder bore liberally with fresh
hardening or other signs of deterioration. If in doubt, brake fluid. Dip new seals and piston in fresh brake
the dust cover needs replacement. fluid.
If the system has been contaminated with mineral oil Fit the gland seal on to the plunger groove in one of
of any type, the system should be flushed out with the piston and insert the piston with seal into the bore,
fresh brake fluid or alcohol and all rubber parts including such that the smaller stem of the piston is facing
hoses should be replaced. outside.
For identification a contaminated seal can be compared Reverse the dust cover and fit the smaller dia of the
with a new seal (but do not allow them to touch). dust cover onto the neck of the piston and fit dust
If the old one is appreciably larger, seal contamination cover on the wheel cylinder.
is indicated. Insert the spring assy in to the bore.
Whenever wheel cylinders are serviced replace seals Insert the other plunger with seal (Assemble as said
and dust covers from appropriate wheel cylinder kit. 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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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.
1
The quadrant side of the strut should be located in the
leading shoe slot. Fit the spring. Fig. 41 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 3
2
side.
Connect the hand brake cable to the hand brake lever 1
in the reverse order of removal.
Do not handle linings more then it is necessary
and be sure that they are completely free from 1. BRAKE SHOE
oil or grease. 2. SHOE HOLD DOWN SPRING
3. PARKING BRAKE SHOE LEVER
Centralise the brake shoe relative to the back plate
before fitting the drum by lightly tapping in the required
direction.
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
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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BRAKES
BLEEDING OF HYDRAULIC SYSTEM :

The process of removing air from the hydraulic pipelines RIGHT
RIGHT
and cylinder is known as "Bleeding". BRAKE WHEEL
CALIPER CYLINDER
The brake hydraulic lines are based on diagonal split 3 2
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 FRONT REAR
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.) 1 4
LEFT LEFT
When any joint part of the Master Cylinder, other joint BRAKE WHEEL
CALIPER CYLINDER
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 Fig. 42
brake system must be bled at all 4 wheel brakes.
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 Fig. 43
immediately and clean the surface.
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 Fig. 44
only.
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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 a. Depress brake pedal several times and
until bubbles of air cease to appear at the end of the with pedal depressed, loosen bleed
bleed tube. Fig. 45. screw a little.
Close the bleed screw immediately after the last b the bleed screw.
downward stroke of the pedal. Whilst the pedal is
thus held, securely tighten the bleed screw to Fig. 45
recommended tightening torque and remove the
tube. Replace the dust cap on the bleed screw.
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 BRAKE
assembly followed by the rear left wheel cylinder.
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 re-
Fig. 46
opening.
Tighten the bleed screw finally after the last downward
stroke of the pedal. Replace the dust cap on the bleed
screw.
After completion of bleeding, apply the brake pedal Lock Nut
hard and check for any leak at the joints and bleed
Brake Light Switch
screws.
Also check the brake pedal for "Sponginess" if found 3+0.5 Set Brake
Light
Sw itc h
spongy repeat the complete procedure of bleeding. As shown
Set brake light switch dimension 3 + 0.5 mm and
tighten the lock nut Fig. 46a
Brake
Pedal
Fig. 46a
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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
ASSEMBLY SECONDARY PLUNGER
PLUNGER
Fig. 49 Tandem Master Cylinder - Sectional view (AS/AS)
DESCRIPTION Under normal conditions when the brake pedal is

depressed, the servo output rod pushes the primary
The simultaneous cut off (AS/AS) tandem master
plunger of the cylinder. At the same time, the force of
cylinder is designed for finer control of the fluid cut off
the primary spring moves the secondary plunger
point. The AS/AS master cylinder consists of two
forward.
independent chambers in a single casting housing,
primary and secondary plungers are fitted with seals Simultaneously the recuperating pressure seals on
having minimum friction. both the plungers cover the cut off holes, developing
pressure in both the chambers. The pressurized fluid
Each hydraulic system is so designed that any failure
from primary chamber is transmitted to front left and
of a pressure seal in anyone of the chamber would not
rear right brakes and from secondary chamber to the
result in total failure of braking system, since the other
front right and rear left brakes.
chamber remains completely operational and ensures
minimum safe braking performance. The fluid reservoir comprises of two separate chambers
serving each system with a common topping up
The specific design feature of this master cylinder is
connection at the upper portion. The Filler cap
that pressure is developed in both the chambers
comprises of a Fluid Level Warning Indicator (FLWI).
simultaneously without any time lag.
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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 round-ended rod. Press it down fully and whilst
and blow with compressed air. Be sure that the Three holding, screw in the stop pin with a new gasket and
holes visible through the primary and secondary inlet tighten to the specified torque. Slowly let the
ports) in the cylinder body are clean, by blowing dry secondary plunger back till it touches the stop screw.
compressed air.
Now insert the new primary plunger assembly as
Do not poke the holes with sharp instrument. shown in Figure (3) into the bore.
CAUTION : First fit the stop washer on to the primary plunger
Do not use kerosene (or) petrol (or) any other shaft. Fit the washer primary back seal followed by
mineral oils to clean the cylinder and its internal spacer and back seal on to the primary plunger shaft.
parts. As it will lead to contamination and Now fit the circlip by using circlip plier.
damage of rubber part wash all disassembled NOTE
parts with brake fluid only.
While fitting the primary back seal, make sure
INSPECTION OF TANDEM MASTER CYLINDER : that the lip of the seal is facing forward.
Examine the bore of the master cylinder. If it is not Actuate the primary plunger assembly for couple of
scored, ridged or corroded and is smooth to touch, times and check for the quick return of the plungers.
the master cylinder assembly can be rebuilt using the
Fit a new 'O' ring into the groove on the spigot of the
appropriate parts from the genuine repair kit.
body. Fit new grommet into both the inlet ports by
If there is a slight doubt about the condition of the liberally lubricating the same with fresh brake fluid.
bore like having deep grooves or pit marks etc., fit a
Fit the fluid reservoir by positioning the same into the
new master cylinder assembly.
grommets and by slightly rocking them on to either
If contamination is observed on the removed seals side, press it home. Fit the locking pin as shown in
(Normally they would have swollen and can be Figure.
compared with new seals from the kit, which will show
NOTE BRAKE
clearly that the size is enlarged). The entire rubber
parts in the system including both front and rear hoses It is essential that the reservoir filler cap must be
must be discarded and the entire system should be removed.
flushed with fresh brake fluid. Clean the filter. Refit the filler cap. Clean the filter.
ASSEMBLING THE TANDEM MASTER CYLINDER : Replace the sealing ring the filter cap during overhaul.
Refit the filler cap.
Absolute cleanliness has to be maintained and clean
fresh brake fluid must be used. Never use the brake Now the master cylinder is ready for fitment on to the
fluid bled from the system as it is aerated. Servo. Fit the master cylinder to servo using nuts
along with spring washer and tighten to the specified
To facilitate easy assembly, smear the cylinder bore
torque.
with fresh brake fluid liberally. Dip the plungers and
all seals in fresh brake fluid. Fit the secondary back Connect the outlet pipes to the master cylinder.
seal in the secondary plunger groove such that the Tighten the coupling nut to the specified torque. Fill
seal lip faces the primary plunger assembly. the reservoir with recommended brake fluid and bled
the system. Check for brake fluid leakage.
Fit the seal shim and recuperating seal on the stem
side of the secondary plunger in such a way that the NOTE
lip of the seal faces towards the secondary spring. Do not alter the stand out of the output rod of the
Fit the seal retainer in correct position as shown in servo unit.
figure and fit the secondary spring with the smaller dia Make sure that Vaccum Booster output rod is correctly
coil coming on to the plunger stem. assembled into the primary plunger bore.
Clamp the cylinder body with its mouth pointing Make sure that the primary outlet is connected to the
upwards in a vice fitted with soft jaws. Insert secondary front left and rear right and secondary outlet to the
plunger assembly into the bore with the secondary rear left and front right brakes.
spring leading into the bore.
Do not polish bore of the tandem master cylinder.
Then slowly push the plunger down the bore with a Never use cloth to clean or dry the master cylinder.
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BRAKES
VACCUM BOOSTER

SR. DESCRIPTION
NO. NO. NO. NO.
NO.
7 SHIM 13 SPACER 19 CLEVIS 25 RESERVOIR
1 BODY
2 GASKET 8 SECONDARY PLUNGER 14 CIRCLIP 20 GROMMET (NRV) 26 FILLER CAP
3 STOP PIN 9 GLAND SEAL 15 BOOSTER 21 NON RETURN VALVE 27 PIN
4 SPRING 10 PRIMARY PLUNGER ASSY. ASSY. 22 SPRING WASHER 28 ‘O’ RING
5 SPRING RETAINER 11 WASHER 16 FILTER 23 NUT
6 RECUPERATING SEAL 12 PRIMARY BACK SEAL 17 BOOT 24 GROMMET
18 NUT
Fig. 53 Exploded view of TMC assembly & Vaccum Booster Assembly (LSC65 + ø22.22AS/AS)
There is a mechanical vaccum booster unit fitted on operates the master cylinder. Should a vacuum failure
the car. The above unit is designed to provide controlled occur, the two push rods act as a single rod and the
power assistance to the effort applied by the driver's brakes will work in the conventional manner, but more
foot to the brake pedal. pedal effort will be required and the fatigue of the driver
Vacuum supplied to the booster unit is obtained from will increase.
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.
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
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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 Fig. 54
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.
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 Fig. 55
depending on whether the brake pedal is released or
depressed.
Fig. 56
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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.
Fig. 57
Unscrew the booster mounting nuts from the firewall
end (2 Nos.) and remove the booster from the vehicle.
Fig. 58
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 115 +0.5
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 Booster Push Rod Length
table Page 2) From Mtg. Face to Hole Center Brake Pedal
Connect the vacuum hose to the booster and fill the

Fig. 61
master cylinder reservoir with recommended brake
fluid.
Bleed the system - refer brake bleeding procedure.
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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 non- If vaccum booster is operative, do the vacuum
return valve. Then with engine running, check leak test as given.
the vacuum supply with a vacuum gauge. There
should be atleast 20” of vacuum.
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 not vaccum booster

If the applications are vaccum booster assisted, assisted disconnect the vacuum hose from the
there is no vacuum leak. 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 If the non return valve is OK, the vaccum booster
non-return valve and repeat the vacuum leak is leaking. Replace the vaccum booster with a
test. new kit.
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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.
INLET OUT-
• It is necessary to regulate hydraulic pressure to LET
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 PCRV

as an assembly only.
Fig. 62
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BRAKES
PARKING BRAKE
PARKING BRAKE LEVER
PARKING BRAKE ADJUSTMENT

EQUALISER
PARKING BRAKE PARKING BRAKE

CABLE CABLE
BRAKE
BRAKE DRUM
BRAKE DRUM SEMITRAILING ARM LH
SEMITRAILING ARM RH
Fig. 63
PARKING BRAKE
The parking brake arrangement is cable operated This is a safety device so designed that the parking
console mounted mechanical type brake acting on rear brake does not get released accidentally.
wheels.
To release parking brake, lift the handle slightly and
The hand brake lever situated in the cab operates it. keeping release button pressed, push down the lever
When the hand brake lever is pulled up, the parking fully.
brake lever arrangement in the rear brake assembly
When release button is pushed as above, pawl rod
inside the rear brake drum brake is also pulled through
also gets pushed, disengaging pawl from ratchet, thus
the cable system.
releasing the parking brake.
This action expands the rear brake shoes against the
REMOVAL OF PARKING BRAKE LEVER
drum, thus applying the rear brakes. Fig. 63
Place wheels chocks at the rear wheels.
PARKING BRAKE HANDLE CONSTRUCTION
Fig. 64
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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.
Fig. 64
Disconnect the parking brake cable from the shoe lever
- refer Brake shoe removal.
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 cable-
mounting 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
Adjust the parking brake cable slackness as per the ADJUSTMENT NUT
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
Confirm pedal travel by depressing the brake pedal for APPLIED
few times.
Check the lining condition of the rear brake it should
not have been worn out beyond limit. RELEASE PARKING BRAKE
BUTTON LIGHT SWITCH
After confirming all the above points start adjusting BRAKE
the parking brake lever stroke by either loosening or
tightening the self locking slackness adjustment nut.
Parking Brake Lever Stroke
When a force of 20 kg is Travel should be within

applied to pull up the lever. 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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BRAKES
TROUBLE SHOOTING OF BRAKE SYSTEM
SPONGY BRAKE PEDAL1. Air in hydraulic system 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 4. Replace
in Rear
BRAKE ROUGH OR 1. Excessive lateral run out in disc or 1. Repair if possible or replace the
CHATTER ON parallelism disc. not within specification.
APPLICATION
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 4. Check and adjust as per
adjustment specifications.
5. Seized caliper pistons 5. Overhaul Calipers
6. Damaged or loose wheel bearing 6. Replace wheel bearing
7. Distorted steering knuckle or rear 7. Replace knuckle or rear wheel
wheel spindle spindle
EXCESSIVE BRAKE 1.Lining soiled with brake fluid, oil 1. Replace

PEDAL EFFORT or grease.
(HARD PEDAL) 2. Brake pad worn below 2. Replace
recommended thickness.
3. Malfunctioning of Servo. 3. Identify the trouble in Servo and
rectify
4. Partial system failure (in tandem 4. Check both front and rear circuits
master cylinder). and rectify.
5. Piston in calipers stuck or sluggish 5. Remove caliper and rebuild
6. Fading brake due to non 6. Replace with approve grade of
recommended grade of brake brake pads.
pads.
7. Kinked, dented or clogged bundy 7. Identify and Replace
pipes, hoses or 'T' connections.
8. Binding pedal linkage 8. Lubricate and free up the system.
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BRAKES
BRAKE NOISE 1. Glazed shoe linings or foreign 1. Repair or replace shoe linings.
matters stuck on 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 4. Replace or retighten
mounting bolts.
EXCESSIVE PEDAL
TRAVEL 1. Incorrect pedal free play 1. Adjust as per specification.
2. Partial brake system failure either 2. Identify and repair by replacing
in dual circuit or in Master Cylinder necessary parts.
3. Air in system (pedal soft / spongy) 3. Bleed and top up with
recommended brake fluid.
4. Soft or bulging hose 4. Replace
5. Excessive clearance between 5. Check auto adjuster mechanism
lining and drum in rear brakes due
to malfunctioning of auto adjusters.
6. Lining pad knock back caused by 6. Adjust or replace faulty parts as
loose or worn wheel bearing or necessary. BRAKE
other related parts.

7. Insufficient fluid in master 7. Fill reservoir with approved brake
cylinder reservoir fluid check for leak and air in brake
system.
Check warning light, bleed system
if required.
8. Ben brake shoes or shoes worn 8. Replace brake shoes.
out.
GRABBING OR
PULLING OF CAR 1. Incorrect type pressure (or) 1. Inflate both front tyres to the
inflated unequally. 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 4. Check and adjust to correct
adjustment on rear brake. specification.
Note : If the above problems are not there then proceed further
with the checking of brakes for grabbing.
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BRAKES
5. Drum to shoe clearance out of 5. Check for auto adjusting

adjustment (malfunctioning auto mechanism.
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 9. Replace
soiled with brake fluid, oil or
grease
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 12.Replace
springs in the brake.
13.Sluggish parking - brake cable or 13.Repair or replace
linkage
14.Master cylinder piston not 14.Repair master cylinder.
returning correctly.
BRAKE WARNING LIGHT 1.Parking brake lever in applied 1. Release parking brake and check
LIGHTS AFTER ENGINE condition. that brake warning light turns off.
START
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. 1. Investigate and correct leaky point.
TURNS ON WHEN BRAKE Add brake fluid.
IS APPLIED
2. Brake fluid level very low. 2. Add brake fluid.
BRAKE WARNING LIGHT 1. Brake warning light circuit faulty 1. Repair circuit or Replace bulb.
FAILS TO TURN ON EVEN
WHEN PARKING BRAKE
IS APPLIED.
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ABS
NEXT
GROUP INDEX
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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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ABS
CONTENTS
2. Wheel Slip 2
3. How ABS works 3
4. Braking without ABS 6
5. Braking with ABS:
a) Description of operation 6
- Pressure Maintaining phase 7
- Pressure Reduction phase 8
- Pressure Increase phase 9
6. ABS Components
a) Tandem Master Cylinder 10
b) Wheel speed sensor 11
d) Electronic Control Unit 12
- EBD control necessity 14
- Principle 15
- Action 16
- Effect 16
- Safety 16
7. Workshop Testing 18 ABS
a) Wheel speed sensor test 18

b) Dynamic test 18
8. Electronic Control Unit
[Removal, Installation] 18
9. Front wheel speed sensor
10. Rear wheel speed sensor
11. Inspection of front Toner Ring 23
12. Inspection of rear Toner Ring 23
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ABS
System Description Specification
General System ABS 5.3
Type 4-Sensor and 4-channel
Mode ABS + EBD4
Hydraulic control unit Type Diagonal (X) Split

(HCU)
Hydraulic Control Method 3 modes - Pressure
maintain /Reduction /
Increase
Type of Pump Two Piston Pump
Type of Motor DC
Electronic Control unit Operating Voltage 12 v

(ECU)
Operating Temperature -40º c to 120º c

ABS
ABS Sensors Type Passive Variable Reluctance
Resistance 1600 ohm ± 320 ohm
Front 0.3 to 1.2 mm

Air Gap
Rear 0.1 to 1.5 mm
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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
Wheel slip : Fig. 1 B : Unstable range
The vehicle can stop in relation to how well the tire 1: Dry Asphalt
contact surface grips the road.At 0% slip, the tyre 2: Wet Concrete
rotates freely and at 100% slip, the tire and wheel are 3. Snow
locked and the weight of the vehicle pushes the locked 4. Polished Ice
tires along the road surface. In this situation, vehicle
Fig 1.
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. vehicle stability and steerability. i.e. This system
prevents the wheel locking during emergency braking
This optimum slip (10 to 20 %) is required for situations and thereby helps the driver to maintain
achieving maximum braking Performance & for stability of the vehicle & also in bringing the vehicle to
stopping the wheel. a complete stop with a minimum possible stopping
distance in the safest possible way.
The theory behind ABS is simple. Whenever a driver
brakes, the wheels of the vehicle have to transfer this The purpose of ABS 5.3, 4-sensor 4-wheel, Diagonal
braking force to the ground surface for achieving split system is to provide
braking. As long as driver brakes gradually, the
braking force is transferred through the tyres to the 1. Enhanced steering control by enabling the vehicle
ground surface & optimum braking is achieved.But to move in a drivers intended direction, even during
when driver applies panic braking, the tyres will stop panic braking.
rotating instantaneously (locking condition). The 2. Enhanced braking stability by making the most of
vehicle drags all the 4 wheels in the same direction available traction on all surfaces.
(at the point of braking) & also driver cannot steer the 3. Its operational throughout the vehicles entire speed
vehicle so as to avoid any accident. 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
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ABS
Fig 2.
ABS
It is capable of rapid adaptation to changes in surface the Front Left and the Rear Right brake while the
traction. ( Dry road with patches of ice) and capable of secondary connects Front Right and Rear Left brake
slowing down the yaw effect on the vehicle when through connectors.
vehicle is driven on a µ split track, so that even an
average driver can initiate compensatory counter steer. Anti lock braking system ABS 5.3 is a 4-channel
diagonal (X) split system consists of an ECU attached
ECU continually monitors the operating status of ABS. to hydraulic unit and 4 wheels speed sensors (one at
Incase of ABS failure driver will be alerted and each wheel).The ECU controls the hydraulic unit. Each
conventional braking will still be operational without of the four wheels has one individual pair of inlet and
ABS. outlet solenoid valves to control each wheel speed
individually.
HOW ABS WORKS : Fig. 2 and Fig. 3
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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ABS
HYDRAULIC UNIT
MC2 MC1
D2 O1 D1
O2
RP2 M RP1
A2 A1
NRV1
LREV RFEV LFEV RREV

NRV3
NRV2
NRV4
LRAV RFAV LFAV RRAV
ABS
LR RF LF RR
REAR LEFT FRONT RIGHT FRONT LEFT REAR RIGHT
Fig 3.
MC1 & MC2 : Primary & Secondary brake M : Motor for driving recirculating
circuits pumps
D1 & D2 : Damping chambers.
RREV & RRAV : Inlet & outlet solenoid valves of O1 & O2 : Orifices
Rear Right wheel
LFEV & LFAV : Inlet & outlet solenoid valves of NRV1, NRV2, : Non return Valves of Rear left,
Front Left wheel NRV3 & NRV4 Front right, Front left & Rear
RFEV & RFAV : Inlet & outlet solenoid valves of right wheels respectively.
Front Right wheel
LREV & LRAV : Inlet & outlet solenoid valves of
Rear Left wheel
A1 & A2 : Accumulators of the circuits MC1

& MC2 respectively.
RP1 & RP2 : Recirculating pump of the circuits
MC1 & MC2 respectively.
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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 its 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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ABS
HYDRAULIC UNIT
MC2 MC1
D2 O1 D1
O2
RP2 M RP1
A2 A1
NRV1
LREV RFEV LFEV RREV

NRV3
NRV2
NRV4
LRAV RFAV LFAV RRAV
ABS
LR RF LF RR
Fig 4.
Braking without ABS : Braking with ABS :
Incase of brake operation without ABS, when driver DESCRIPTION OF OPERATION OF THE ANTI-LOCK
presses the brake pedal, brake pressure developed in BRAKING SYSTEM
the TMC reaches each wheel through HU. During this
phase, both inlet & outlet solenoid valves are not On the basis of the signals received from the rpm
switched ON (or excited) by ECU. Hence the inlet sensors located on the front and rear wheels, the
valve is open and outlet valve remains closed. electronic control unit instructs the hydraulic unit, so
as to vary the pressure of the brake fluid delivered to
When the driver releases the brake pedal, the brake the brake calipers, passing through the three stages
fluid flows back from the respective wheel, through described on next page:
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).
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ABS
Pressure Maintaining (Hold) Phase :

Fig. 5 DAMPING
CHAMBER
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
RECIRCULATION
the brake pressure coming from Master cylinder, so PUMP
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. ACCUMULATOR
During the pressure maintaining phase, ABS ECU
actuates only the inlet solenoid valve (EV) & there by
INLET VALVE
closes it. The outlet solenoid valve remains closed in OUTLET VALVE (CLOSED)
its default position. Since both the solenoid valves are (CLOSED)
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.
Fig 5.
Solenoid valve Electricity status Valve open-close Open-close channel
INLET ON CLOSE Master cylinder-

Wheel cylinder
ABS
OUTLET OFF CLOSE Wheel cylinder-

reservoir
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ABS
Pressure Reduction Phase : Fig. 6 DAMPING

CHAMBER
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 RECIRCULATION
ECU activates outlet solenoid valve and lets some PUMP
amount of brake fluid to reach the acumulator, which
serves the purpose of temporary storage.
ECU activates both Inlet & Outlet solenoid valves. The ACCUMULATOR
closed Inlet solenoid valve shuts the liquid channel
from master cylinder. The outlet valve opens and
connects the wheel circuit to the secondary circuit. OUTLET VALVE INLET VALVE
Brake fluid gets discharged into the accumulator. The (OPEN) (CLOSED)
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 Fig 6.
drivers foot. The pressure reduction is continued
till the wheel speed recovers to the vehicle
reference speed.
Solenoid valve Electricity status Valve open-close Open close channel

ABS
INLET ON CLOSE Master cylinder-Wheel

cylinder
OUTLET ON OPEN Wheel cylinder-reservoir
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ABS
DAMPING
Pressure increase Phase : Fig. 7 CHAMBER
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
RECIRCULATION
steps.
PUMP
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 ACCUMULATOR
master cylinder enters the wheel cylinder & increases
the brake pressure for that wheel.
OUTLET VALVE INLET VALVE
(CLOSED) (OPEN)
Fig 7.
Solenoid valve Electricity status Valve open-close Open-close channel
INLET OFF OPEN Master cylinder-Wheel

cylinder
ABS
OUTLET OFF CLOSE Wheel cylinder-reservoir
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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.
Electromagnetic pulse pick up with toothed wheels The ECU derives the wheel speeds from the signal
mounted directly to the rotating components of the sent by the wheel speed sensor. Inductive wheel speed
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

t Coil Resistance : 1600 ohm + 320 ohm
Inductivity : 800 mH to 1800 mH
Operating temp : -40oC to 115oC
TEETH
P1 P2 P1 P2 P1 P2 P1 P2
POLE PIECES
MAGNETIC DISPERSION
Vmin COIL
TIME t
TARGET WHEEL
V max
PERMANENT
MAGNET
VOLTAGE V
VELOCITY
USEFUL MAGNETIC FLUX
Fig 11.
11
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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
Solid state electronic device containing computer

functions, sensor signal processing circuits, output
ABS
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 Fig 12.
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.
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ABS
Brake Pressure / Hydraulic Modulator : Fig.12 and Fig.13
HYDRAULIC UNIT
MC2 MC1
D2 O1 D1
O2
RP2 M RP1
A2 A1
NRV1
LREV RFEV LFEV RREV

NRV3
NRV2
NRV4
LRAV RFAV LFAV RRAV
ABS
LR RF LF RR
Fig 13.
MC1 & MC2 : Primary & Secondary brake M : Motor for driving recirculating
circuits pumps
D1 & D2 : Damping chambers.
RREV & RRAV : Inlet & outlet solenoid valves of O1 & O2 : Orifices
Rear Right wheel
LFEV & LFAV : Inlet & outlet solenoid valves of NRV1, NRV2, : Non return Valves of Rear left,
Front Left wheel NRV3 & NRV4 Front right, Front left & Rear
RFEV & RFAV : Inlet & outlet solenoid valves of right wheels respectively.
Front Right wheel
LREV & LRAV : Inlet & outlet solenoid valves of
Rear Left wheel
A1 & A2 : Accumulators of the circuits MC1

& MC2 respectively.
RP1 & RP2 : Recirculating pump of the circuits
MC1 & MC2 respectively.
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ABS
Brake Pressure / Hydraulic Modulator : operational. EBD warning lamp is turned on in case
of error in the EBD system. EBD failure does not
This is an Electro-hydraulic device for reducing, necessarily mean ABS failure.
holding & restoring pressure to one or more wheel
cylinders, independent of the brake pedal effort EBD (Electronic Brake-force Distribution) Con-
applied by the driver. It consists of a Return Pumps, trol Necessity
Solenoid Valves, Damping Chamber, Accumulator,
Non-Return Valve and Motor. It forms the link between 1. During braking, whenever the rear axle wheels
the TMC and the foundation brakes. It implements the lock before the front axle wheels, the vehicle
commands issued by the ECU by using solenoid valves will loose its control & it may start to spin.
to control the pressure at the foundation brakes. This is because, braking is always associ-
ated with a certain weight transfer from rear
There are four pairs (4-channel system) of Inlet and axle onto the front axle wheels. Due to this
Outlet valves and are located in the upper section of drift of the vehicle weight, there will be lesser
the modulator. Solenoid valves are responsible for normal force acting on the rear axle when
modulating the pressure in the brake cylinder during compared to the front axle. Due to lesser
active ABS control. normal force, rear axle wheels can support
lesser brake pressure. In a passenger car,
The Return Pump element is installed in the center of as a counter measure to this problem, the
the modulator and is driven by an electric Motor. The brake circuit for the rear axle will be fitted
pump transfers the brake fluid emerging from the wheel with PCRV (Pressure conscious regulating
brakes through the accumulator on its way back to valve). This PCRV allows only the predeter-
the TMC through damping chamber. The pump mined max. pressure to the rear axle wheels
actuation can be felt on the foot pedal as pulsations. & hence avoids the locking of rear axle wheels
In order to prevent damage to the TMC primary seals before the front axle wheels.
from the compensating port, the design of TMC is
changed to central valve type (CV/CV)
2. But PCRV is a mechanical vehicle component
ABS Accumulator and Damping Chambers are Located in and it cannot result in ideal brake force
the lower section of the hydraulic modulator. The distribution for the rear axle wheels.
accumulator absorbs the surge in brake fluid that
accompanies the pressure reduction phase. The
Damping Chamber suppresses pressure oscillations 3. PCRV because of its design limitation, can-
within the hydraulic system, preventing them from being not allow higher brake pressure onto the
propagated back to the brake pedal and reduces noise rear axle wheels, when the vehicle is driven
levels in the system. in full load condition on a high friction sur-
face like Asphalt. This results in lesser brake
ELECTRONIC BRAKE FORCE force onto the rear axle wheels than the ideal
brake force & hence less efficient braking.
DISTRIBUTION (EBD) : This is viewed as a problem.
EBD substitutes Pressure conscious reducing valves
(PCRV). Its function is not determined by the brake 4. The brake force required for optimum braking
pressure or the weight transfer but by the amount of maybe different for each wheel. This is
wheel slip. EBD function is an additional program to depending on the road surface, the condition
the conventional ABS program. It reduces the of the friction material of brake lining/ pad &
pressure at the rear depending upon the wheel slip also the condition of the tyres (old/ new). With
and pressure reduction is carried out after certain PCRV, when the same brake force reaches
pressure-maintaining phase. It maintains the brake both the rear axle wheels, ideal braking can-
pressure to both the rear wheels same. If any of the not be achieved by the rear axle wheels.
rear wheels is still over braked, ABS becomes
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ABS
5. When the PCRV fails in any car, the driver has no

chance of knowing about this failure. Under this Laden
condition, when braked, the vehicle may Ideal Distribution
Outlet Pressurev
deviate/spin (depending on the brake force lines
applied by the driver) from the intended driving
direction.
Unladen
6. In this vehicle with ABS system, the ECU
incorporates a special function by name EBD Cut-in point
(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 Inlet Pressure
axle wheels. With EBD, the rear axle wheels either
lock along with front axle wheels during partial Fig 14. With PCRV
braking OR the rear axle wheels may lock after the
front axle wheels. EBD never allows the rear axle
Laden
wheels to lock before the front axle wheels.
Unladen
Principle : Fig.14 and Fig.15
Outlet Pressure
1. The principle is precise control of the rear axle

brake pressure such that it follows the ideal brake Cut-in point
pressure distribution curve closely. This is
achieved by the inclusion of a special control logic
to the ABS ECU (instead of PCRV).
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 Inlet Pressure
braking is calculated by means of the wheel Fig 15. With EBD
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.
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ABS
Action : Effect :
1. Just before rear wheel tends to lock preceding to 1. Braking distance is decreased as rear brake force
front wheel, the EBD function of ABS ECU is enhanced in comparison with existing PCRV
actuates the inlet solenoid valve & closes it, so
2. Stability is secured at time of partial braking,
that the brake oil pressure from TMC is blocked
since the right and left rear wheel liquid
at HU only instead of reaching that particular
pressures are controlled independently from each
wheel cylinder & hence the locking is prevented.
other.
Some times, EBD also actuates outlet solenoid
valve & opens it for very short intervals of time, 3. Stable braking effect can be achieved because
so that locking of the rear wheels is avoided. front brake pad abrasion and temperature rise
etc. are decreased as braking effect of rear brake
2. Soon after the rear wheels recover from locking
is increased at braking time.
phase, the inlet & outlet solenoid valves are
switched OFF, so that the brake pressure 4. PCRV can be eliminated.
applied at MC be transmitted to the rear wheel
cylinder / caliper.
3. Motor pump does not act at this time.
Category Vehicle equipped with EBD system
At time of failure 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 beha-
vior 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 lamp which is nothing but the parking brake lamp
in the following situations : will glow indicating the driver about the failure. Now
the driver should drive carefully till the authorized
1) One wheel speed sensor failure. workshop to set right the problem.
2) Motor pump failure.
3) Failure by low voltage of battery (Minimum voltage
for EBD functioning 6.5 V)
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
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ABS
III. EBD fail-safe
System Warning lamp

Cause of system failure
ABS EBD ABS EBD
None operate 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
Failure of 2 or more sensors,

Valve failure
ECU failure does not operate does not ON ON
Other failures operate
ABS
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ABS
WORKSHOP TESTING : Removal of Electronic Control Unit (ECU) :

Fig16-18
Any malfunction in the ABS is signaled by the
warning lamp in the instrument cluster,which can be 1.Turn OFF the ignition.
later on diagnosed at the workshop using a 2.Disconnect ECU wiring harness connector from
diagnostic tool. Malfunction code retrieval serves as Electronic Control Unit (ECU) assembly.
the basis for detecting and evaluating defects and
inconsistent performance. Data are analyzed using 3.Never apply a 12V-power source to any
special diagnostic tool. Following are some of the terminal of the ECU connector when its
common errors that occur disconnected.
a. Electrical circuit problem such as intermittent 4.Identify the brake pipes going into and out of the
contact. Hydraulic Unit (HU) with tags so that reinstallation
b. Component and sensor failure of the brake lines will be easy.
c. Sensor signal that deviates from specified levels 5. Proper care should be taken before removing
d. Unusual response and malfunction in the actuators the brake pipes from HU; the HU must be
thoroughly cleaned to prevent dirt Particles
Some of the common test which needs to be done from falling into the ports of HU or entering the
before drive test. This involves a check for the brake pipes.
following: 6. Remove the brake pipes from the HU and plug the
ports with suitable grommet.
Correct functioning of all input and output signals
5.Remove the Nuts attaching ECU / HU to the
of the ECU mounting bracket and then take out the ECU/HU
Correct functioning of wheel speed sensors from ECU / HU mounting bracket.
Correct functioning of all valves and hydraulic 6. Clean the top of the HU with a clean, dry cloth.
components
7. Visually inspect the ECU ports, grommets etc. If
Communication set up grommet is found damaged replace it with new one.
ABS
ECU identification
Clear and read fault code memory Installation of Electronic Control Unit (ECU):
Wheel speed sensor test Fig. 16-18
Dynamic ABS test
1.Put the grommets and the mounting studs at
WHEEL SPEED SENSOR TEST appropriate places as shown
2. Align the bottom ECU grommet to the dowel in
This is conducted to check the correlation of the mounting bracket and insert ECU so that both the
sensors ,signal quality by running individual wheels mounting studs get aligned onto the bracket slot.
one after the other. The tester picks up the wheel speed 3. Tighten the nut to the ECU / HU stud with mounting
data of the ECU and verifies the signal. This data gives bracket to specified Torque (2.65N +/- 0.3 N).
insight about the correctness of tone wheel, air gap, 4. Reconnect six brake lines. Be certain that the four
right connection, eccentricities etc. outlet and two inlet lines have been connected to
the correct ports. Tighten the nuts to specification.
DYNAMIC TEST
5. When installing the brake pipelines on the HU
This is designed to check the correct correlation of
valve block, they must be located correctly in
the solenoid valves and the wheel speed sensor. The
the valve block to ensure proper ABS
pedal is held in constant position and the software
operation.
turns the valves into pressure release and pressure
increase cycles. This deceleration rates are measured 6. Connect the ECU harness connector.
by the ECU and transmitted to the tester for 7. Bleed the brake system.
comparison with given limits 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
Fig 18. Assembly ECU/HU (Brake Fluid Filled Unit)
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ABS
BELOW THE BRAKE HOSE

LOOP FROM STRUT INTO BIW HOLE
BRACKE TO BRACKET
ON BIW
Fig 19. 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.
2. Remove sensor bolt and remove the wheel speed

ABS
sensor and the sensor mounting plate from the SMALLER BRACKET
steering knuckle.
3. Remove the sensor cable anchorage on the front FROM STEERING KNUCKLE
strut & on suspension tower. 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.
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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. 6. Make sure that the sensor cable connector is fully
seated and locked into vehicle wiring harness
2. Check the sensor mounting plate for rusting, and connector.
damage. Replace it with new one if found damaged.
7. Insert the sensor into the sensor mounting plate
3. Anchor both the sensor grommets to the strut and and fit it to the front steering knuckle by butting it
single grommet to shell. Route the sensor cable against the face on the knuckle and tighten the
as shown in Fig. 20-22. bolt to the specified torque.
4. Insert the sensor cable connector through the hole 8. Check the air gap between the face of the wheel
in the suspension tower, ensure that the cable is speed sensor and the top surface of the toner
routed with a loop as shown in the Fig. 20. wheel.
5. Install the wiring harness connector with wheel Air gap: 0.3 to 1.2 mm
speed sensor cable.
9. Road test vehicle to ensure proper operation of the
basic and ABS brake system.
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ABS
Rear wheel speed sensor Removal :

SENSOR
Fig. 24-26
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. ASSEMBLY REAR BRAKE
3. Jack up the wheels and remove the brake drum.

Fig 24.
4. Unscrew the four anchor plate mounting bolts and
remove the sensor with the sensor mounting plate. BRAKE DRUM WITH
ASSEMBLY REAR BRAKE TONER RING
5. Remove the sensor bolt and remove the speed SENSOR

sensor from the sensor mounting plate.
6. Measure speed sensor resistance.

Resistance:1600 ohm ± 320 ohm
ABS
SENSOR
MOUNTING SEMI TRAILING ARM
PLATE MOUNTING PLATE
Fig 25.
Fig 26.
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ABS
Installation of Rear wheel speed sensor
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.
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 semi-

trailing 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.
Fig 28.
10.Road test vehicle to ensure proper operation of the
basic and ABS brake system. 4. Check for any damaged teeth. (Front tone ring has
got 42 teeth) Fig. 27
Inspection of Front Toner ring. 5. Replace tone ring if any teeth are missing or
damaged.
1. Jack the vehicle and properly support front of the
vehicle. Inspection of Rear Toner ring
2. Steer the wheel to extreme steering locks position 1. Jack the vehicle removes the wheels.
so that the Tone ring on the drive shaft is easily 2. Remove the brake drum.
seen.
3. Closely inspect the tone ring and remove the dust
and mud/iron particles in between teeth.
3. Closely inspect the tone ring by slowly rotating the 4. Check for any damaged teeth. (Rear tone ring has
wheel and remove the dust and mud/iron particles got 42 teeth) Fig. 28
in between teeth.
5. Replace tone ring if teeth are missing or damaged
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ABS
SERVO AND TMC ASSEMBLY (LSC 65 AND DIAMETER 22.22)
MC ASSEMBLY (DIAMETER 22.22 CV/CV)
ABS
SERVO ASSEMBLY (LSC 65)
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ABS
ASSEMBLY ECU/HU (BRAKE FLUID FILLED UNIT)
STUD FOR ABS

ECU/HU MOUNTING GROMMET FOR ABS
0.3 ECU/HU MOUNTING
THREADED HOLE
FOR POWER
STEERING ABS
RESERVOIR
MOUNTING
CENTRAL DOWEL
FOR LOCATING ECU
- SPECIFIED TORQUE IN Kgm
25
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ABS
26
HYDRAULIC LINES - ABS VERSION - RHD
ABS
ASSEMBLY TUBE - ASSEMBLY TUBE -

ASSEMBLY TUBE -
ECU/HU LR TO REAR FROM TMC TO ECU/HU
ECU/HU RF TO FRONT
CONNECTOR LH PORT MC2 ASSEMBLY TUBE -
RH CONNECTOR
SEALING WASHER FROM TMC TO ECU/HU
PORT MC1
INDEX
VACUUM BOOSTER CV/
CV TYPE
PRIMARY
LR
RF
ABS
MC2
ELECTRONIC/HYDRAULIC SECONDARY
ECU CONTROL UNIT
HU
ASSEMBLY VACUUM
LF
RR
MC1
REAR WHEEL CYL. RH
PIPE - MPFI - RHD
FRONT CALIPER LH
HOSE CLAMP 20
ASSEMBLY TUBE -
CONNECTOR RH TO
FRONT BR. HOSE RH
ASSEMBLY TUBE - REAR LH

ASSEMBLY TUBE - ECU/HU LF ASSEMBLY TUBE - BRAKE
CONNECTOR (1) TO REAR LH
TO FRT LH CONNECTOR HOSE REA RH TO WH CYL
CONNECTOR (2)
REAR RH
FRONT CALIPER LH
ASSEMBLY TUBE - REAR LH ASSEMBLY TUBE - BRAKE
CONNECTOR (1) TO REAR LH HOSE REAR LH TO WH CYL
CONNECTOR (2) REAR LH
GROUP INDEX
2.3 to 2.5
REAR WHEEL CYL. LH

ASSEMBLY TUBE - REAR ASSEMBLY BRAKE
ASSEMBLY BRAKE ASSEMBLY TUBE - ASSEMBLY TUBE - CONNECTOR
LH CONNECTOR (2) TO HOSE REAR
HOSE FRONT CONNECTOR LH TO ECU/HU RR TO REAR (BRAKE CIRCUIT)
BRAKE HOSE REAR LH
FRONT BRAKE HOSE LH CONNECTOR RH
NEXT
NOTE : ALL COUPLING NUT TORQUE - 1.4 TO 1.6 Kgm
PREVIOUS
MECHANICAL STEERING
LEi & LSi
LX & LXi
NEXT
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
i
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MECHANICAL STEERING
CONTENTS
1. Specifications 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
MECHANICAL
STEERING
iii
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MECHANICAL STEERING
SPECIFICATIONS
1. No. of turns (lock to lock) : 4.27
2. Free pinion rotation torque : 8-15 kg-cm .
Lubrication : Pinion to be lubricated with sterak grease.
Lubrication
Sterak Grease @ Rack, Pinion, Bearing & Rack Bush : 20 grams
Silicon Grease @ Bellow lip Inner Ball Joint : Smear
TIGHTENING TORQUES
Sr. Description Torque

No. (mkg)
1) Steering Gear box mounting screw on firewall 5

2) Steering column mounting bolts 2.5
3) Steering wheel nut 4
4) Steering lock cum ignition switch mounting screws 1.5
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

MECHANICAL
Sr. No. Description Part No. STEERING
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
NEXT 1
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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
2
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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 STEERING COLUMN
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.
MECHANICAL
STEERING
COMBI SWITCH
ASSEMBLY
RACK & PINION

STEERING GEAR
ASSEMBLY
Fig.1 Mechanical Steering Assembly
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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
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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.
REMOVAL : Fig. 2
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.
MECHANICAL
STEERING
8 Remove steering wheel using puller Fig. 3.
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 :
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, Fig. 4
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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 :
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
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. Fig. 6
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.
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.
Fig. 7
6
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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

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 MECHANICAL
still fitted in the car. STEERING
Fig. 9
INSTALLATION :
2 Use new mounting screws.
3 Tighten mounting screws to 1.5 mkg torque. Fig.10
Fig. 10
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MECHANICAL STEERING
REMOVAL AND INSTALLATION OF

RACK AND PINION ASSEMBLY
REMOVAL
(Steering wheel, combi. switch and steering column
already removed)
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 : Cable
1 Proceed in reverse order of removal Mounting
PRECAUTIONS :
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
1266 + 1
tie. 5 mm.
PROCEDURE FOR WHEEL ALIGNMENT

Wheel alignment on Indica MPFI involves adjusting
MECHANICAL
camber and toe on front wheels. The caster is in built STEERING
on Indica MPFI .
Fig.15
Following precautions are to be taken before
commencing wheel alignment.
• Ensure no tyre wear on any wheels. If so replace
• Car should be unladen and parked on level surface.
the tyres.
• Front and rear tyres should be inflated to correct
1. Bring the tyre in straight ahead position.
pressure (30 and 28 psi respectively).
2. Lock the steering wheel in straight ahead position
• Ensure that the silent bushes in the front/rear
with suitable fixture, so that it does not disturb
suspension are in satisfactory condition.
the tie rod location.
• Ensure that the front rear & suspension fasteners
3. Check the camber and toe out, if not found within
are tightened to the specified torque.
the specification then adjust it as per the following
• Also ensure that there is no visible damage to sequence and procedure.
any of the suspension parts like lower link bushes
and struts.
• Ensure that there is no play in steering linkages
and suspension ball joints.
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MECHANICAL STEERING
First adjust the camber While removal & re-fitment of steering rack and pinion
1. Loosen the two strut mounting bolts. assembly or replacing the tie rods on the vehicle,
the following procedure should be followed before
2. Rotate the eccentric pin on Top of the strut till going in for the actual wheel alignment as given
required camber value is achieved (For the values, above.
see next page)
If not check eccentric pin for excessive wear. If 1. Steering rack & pinion gear comes with 1266 mm
so, replace with new one. (nominal) length between centres of the ball joints
at the end. Ensure that number of threads of outer
3. First tighten the eccentric pin flanged nut to 8
ball joint exposed out of the tie rod tube are equal
mkg torque & then tighten the bottom bolt to 8
on both sides of the tube.
mkg torque.
2. Fix the steering rack & pinion gear on the fire
4. Apply 2 drops of Anabond 124 at nut end.
wall. Assemble the steering column with steering
Now adjust the toe out wheel. (Do not tighten the steering wheel to full
torque.)
1. Loosen the tie rod end check nuts.
3. Bring the front tyre in straight ahead position.
2. Adjust the toe out values by rotating the tie rod
ends. While adjusting toe out, adjust the length of 4. Rotate steering gear from lock to lock. Measure
both the tie rods by rotating them in the opposite 4.27 number of turns approx (Mech.stg.) Bring
direction such that their lengths remain equal at the steering gear to the centre by rotating through
all times (For the values, see next page). half of the total number of turns (measured).
NOTE : 5. Fix the outer ball joints into the steering arm of
steering knuckle.
If toe is excessively out of limit, first adjust toe, then
the camber and then adjust toe again. Step 3,4,5 are particularly useful in centralisation of
Not following the sequence i.e. first camber and then steering linkages and could be even adopted during
toe out will lead to incorrect wheel alignment even normal wheel alignment process in case values are
though individual adjustments are done correctly. not achieved or excessive wheel lock angle is
observed.
WHEEL ALIGNMENT VALUES
(Unladen condition) 6. If steering wheel spokes are not centralised,
FRONT WHEELS: remove the steering wheel & refit, so that spokes
& mascot are correctly positioned. Tighten the
Parameter Power Steering steering wheel nut to specified torque.
Castor 10 30’ to20 30’ Further carry out the camber & toe in adjustments as
(Inbuilt) (Inbuilt) explained above.
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
OIL
BELLOW STRAP (PINION)
OUTER BALL JOINT SEAL
21 OUTER BALL JOINT 20
20 14
PINION BELLOW BELLOW CLIP
BELLOW CLIP COVER RETAINER STRAP 23
23 13 RING (SUPPORT)
9 22
PINION
BEARING
8
LOCK NUT
LOCK NUT BELLOW (SUPPORT)
BELLOW 18
NYLOC NUT (PINION)
DISASSEMBLY OF RACK & PINION
25 17 NYLOCK NUT
PINION
25
7
B HOUSING RACK TUBE RACK BUSH
MECHANICAL STEERING
A 1 2 15
C
Fig. 16 Exploded view of steering gear (Rack and Pinion)

RACK INNER BALL JOINT
10 C 19
INNER BALL JOINT A
B
GROUP INDEX
19
NEEDLE ROLLER BEARING

3
BUSHING, RUBBER
MOUNT RUBBER MOUNT YOKE
BRACKET (SUPPORT END) 6
4 11
24
YOKE COVER
12
SPRING
COLLAR GEAR 16
MOUNT
5 SECTION - CC SECTION - AA
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11
STEERING
MECHANICAL
MECHANICAL STEERING
DISASSEMBLY OF RACK AND PINION : (Fig 16) INSPECTION OF DISMANTLED PARTS
TO DISMANTLE : • Examine the Housing set which consists of Case

(Steering Gear (Rack & Pinion) assembly already Strg. Gear (1), Needle Roller Bearing (3) and
removed from the car). Rack Tube (2). If damage to any of the above
components is evident then Housing set must
• Hold the Steering Gear by the Rack tube on a be replaced as a set.
soft jaw vice.
• Examine the Rubber Mount (6). If damage is
• Remove the Bracket (24). evident, replace the part.
• Remove both the Outer Ball joints and Lock nuts • Examine the Rubber Bushing (4) and Collar gear
from the steering gear.(20) mount (5). If damage is evident, replace the parts.
• Remove the Bellow strapping parts (21/22) and • Examine the Rack-bush (15) for excessive wear
clips (23) on either sides using a plier via IBJ leading to loose fit with Rack. If any of the above
Rod and dispose them. is evident, remove the Rack Bush by knocking it
out of the Rack Tube using a mandrel gently.
• Remove the Bellows (17/18).
• Examine the Rack and Pinion set which consists
• Loosen the Inner Ball Joints (19) from the Rack of Rack, Pinion, Ball bearing and Retainer ring.
by arresting the Rack teeth with 21 mm double If damage to any of the above items is evident
end spanner. It is to be noted that gear should then the rack and Pinion set must be replaced
be free and not held / mounted on the housing / as a set.
rack tube while loosening the IBJ.
• Examine the Bellow (17 & 18) for crack and Torn
• Loosen the Yoke Cover (12) using tool and condition. If any of the above is observed, replace
dispose the Yoke cover. Remove the Spring (16) the bellows.
and Yoke (11) from the housing.
• Examine the Yoke for excessive wear and
• Loosen the Pinion Cover (13) using the Tool and damage. If fit between Yoke bore on Case
Remove the Pinion bearing Sub Assembly Steering Gear and Yoke is slack in either of
(7,8,9). Dispose the Pinion cover along with the designs, replace the Yoke by new one. If damage
oil seal (14). is evident, replace the Yoke.
• Remove the Rack (10) via Rack Tube or Via • Examine the Yoke Spring (16). If found to be
Housing side. damaged or found to be solid (Compressed Set)
NOTE : replace the part.
Dismantling of housing assembly for repair is not • Examine Inner Ball Joints and Outer Ball joints
recommended. 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.
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

COLLAR GEAR MOUNT
mounting as shown in Fig. 18. Press the Bushing
(5)
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.
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 ADAPTER (SEE DRAWING
"3 ears" of the Rack Bush is located well inside ATTACHED)
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.
3 SLOTS
RACK BUSH 3 EARS
(15)
GENTLE
BLOW
Fig. 19
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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 RACK
end spanner. It is to be noted that gear should (10)
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 STAKE HERE INNER BALL
JOINT (19)
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 Fig. 20
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.
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 YOKE COVER (12)
unscrew the Yoke cover by 30 0 to 45 0
approximately to achieve free Pinion torque of 8
to 15 kgf. cm.
Fig. 25
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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 BELLOW CLIP (23)
to rotate relative to IBJ.
BELLOW (17)
BELLOW WIRE (21)
Fig. 26
• Assemble Bellow Support End (18) over Rubber

mount (6) and secure with Bellow Strap (22) and
IBJ prior to Bellow assembly, to enable Bellow
• 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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TROUBLESHOOTING GUIDE
Sr. No Problem Causes
1. Abnormal Noise Some component is loose in the steering linkges

(A clicking noise heard during a turn, or and is shifting under load.
when changing directions)
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.
4. Shimmy Excessively worn or unevenly worn tyres

Improperly mounted tyre or wheel.
Wheel bearings improperly adjusted 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 MECHANICAL

STEERING
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.
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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
i
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MECHANICAL STEERING
CONTENTS
1. Specifications 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
MECHANICAL
STEERING
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MECHANICAL STEERING
SPECIFICATIONS
1. No. of turns (lock to lock) : 4.27
2. Free pinion rotation torque : 8-15 kg-cm .
Lubrication : Pinion to be lubricated with sterak grease.
Lubrication
Sterak Grease @ Rack, Pinion, Bearing & Rack Bush : 20 grams
Silicon Grease @ Bellow lip Inner Ball Joint : Smear
TIGHTENING TORQUES

No. (mkg)
1) Steering Gear box mounting screw on firewall 5

2) Steering column mounting bolts 2.5
3) Steering wheel nut 4
4) Steering lock cum ignition switch mounting screws 1.5
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

MECHANICAL
Sr. No. Description Part No. STEERING
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
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
2
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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 STEERING COLUMN
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.
MECHANICAL
STEERING
COMBI SWITCH
ASSEMBLY
RACK & PINION

STEERING GEAR
ASSEMBLY
Fig.1 Mechanical Steering Assembly
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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
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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.

WHEEL :
Caution: Please refer to Body Section safety

precautions of Airbag and it removal.
REMOVAL : Fig. 2
1 Park the car with front wheel in straight ahead

position.
rear wheels.
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.
MECHANICAL
STEERING
8 Remove steering wheel using puller Fig. 3.
Fig. 3
INSTALLATION :
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 :
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, Fig. 4
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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 :
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
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. Fig. 6
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.
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.
Fig. 7
6
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MECHANICAL STEERING
INSTALLATION :
2 Tighten all fasteners to specified torque Fig. 8 &
9
Fig. 8

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 MECHANICAL
still fitted in the car. STEERING
Fig. 9
INSTALLATION :
2 Use new mounting screws.
3 Tighten mounting screws to 1.5 mkg torque. Fig.10
Fig. 10
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MECHANICAL STEERING
REMOVAL AND INSTALLATION OF

RACK AND PINION ASSEMBLY
REMOVAL
(Steering wheel, combi. switch and steering column
already removed)
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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INDEX GROUP 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 : Cable
1 Proceed in reverse order of removal Mount- Tie
PRECAUTIONS :
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
1249 + 1
tie. 5 mm.
PROCEDURE FOR WHEEL ALIGNMENT

Wheel alignment on Indica MPFI involves adjusting
MECHANICAL
camber and toe on front wheels. The caster is in built STEERING
on Indica MPFI
Fig.15
Following precautions are to be taken before
commencing wheel alignment.
• Ensure no tyre wear on any wheels. If so replace
• Car should be unladen and parked on level surface.
the tyres.
• Front and rear tyres should be inflated to correct
1. Bring the tyre in straight ahead position.
pressure (28 and 24 psi respectively).
2. Lock the steering wheel in straight ahead position
• Ensure that the silent bushes in the front/rear
with suitable fixture, so that it does not disturb
suspension are in satisfactory condition.
the tie rod location.
• Ensure that the front rear & suspension fasteners
3. Check the camber and Toe in, if not found within
are tightened to the specified torque.
the specification then adjust it as per the following
• Also ensure that there is no visible damage to sequence and procedure.
any of the suspension parts like lower link bushes
and struts.
• Ensure that there is no play in steering linkages
and suspension ball joints.
NEXT 9
INDEX GROUP INDEX
PREVIOUS
MECHANICAL STEERING
First adjust the camber While removal & re-fitment of steering rack and pinion
1. Loosen the two strut mounting bolts. assembly or replacing the tie rods on the vehicle,
the following procedure should be followed before
2. Rotate the eccentric pin on Top of the strut till going in for the actual wheel alignment as given
required camber value is achieved (For the values, above.
see next page)
If not check eccentric pin for excessive wear. If 1. Steering rack & pinion gear comes with 1249 mm
so, replace with new one. (nominal) length between centres of the ball joints
at the end. Ensure that number of threads of outer
3. First tighten the eccentric pin flanged nut to 8
ball joint exposed out of the tie rod tube are equal
mkg torque & then tighten the bottom bolt to 8
on both sides of the tube.
mkg torque.
2. Fix the steering rack & pinion gear on the fire
4. Apply 2 drops of Anabond 124 at nut end.
wall. Assemble the steering column with steering
Now adjust the toe in wheel. (Do not tighten the steering wheel to full
torque.)
1. Loosen the tie rod end check nuts.
3. Bring the front tyre in straight ahead position.
2. Adjust the Toe in values by rotating the tie rod
ends. While adjusting Toe in, adjust the length of 4. Rotate steering gear from lock to lock. Measure
both the tie rods by rotating them in the opposite 4.27 number of turns approx (Mech. stg.) Bring
direction such that their lengths remain equal at the steering gear to the centre by rotating through
all times (For the values, see next page). half of the total number of turns (measured).
NOTE : 5. Fix the outer ball joints into the steering arm of
steering knuckle.
If toe is excessively out of limit, first adjust toe, then
the camber and then adjust toe again. Step 3,4,5 are particularly useful in centralisation of
Not following the sequence i.e. first camber and then steering linkages and could be even adopted during
Toe in will lead to incorrect wheel alignment even though normal wheel alignment process in case values are
individual adjustments are done correctly. not achieved or excessive wheel lock angle is
observed.
WHEEL ALIGNMENT VALUES
(Unladen condition) 6. If steering wheel spokes are not centralised,
FRONT WHEELS: remove the steering wheel & refit, so that spokes
& mascot are correctly positioned. Tighten the
Parameter Power Steering steering wheel nut to specified torque.
Caster 10 + 45’ Further carry out the camber & toe in adjustments as
(Inbuilt) explained above.
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) 00 + 30’
Toe in (per wheel) 00 to 30’ (+ve)
10
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INDEX
OIL
BELLOW STRAP (PINION)
OUTER BALL JOINT SEAL
21 OUTER BALL JOINT 20
20 14
PINION BELLOW BELLOW CLIP
BELLOW CLIP COVER RETAINER STRAP 23
23 13 RING (SUPPORT)
9 22
PINION
BEARING
8
LOCK NUT
LOCK NUT BELLOW (SUPPORT)
BELLOW 18
NYLOC NUT (PINION)
DISASSEMBLY OF RACK & PINION
25 17 NYLOCK NUT
PINION
25
7
B HOUSING RACK TUBE RACK BUSH
MECHANICAL STEERING
A 1 2 15
C
Fig. 16 Exploded view of steering gear (Rack and Pinion)

RACK INNER BALL JOINT
10 C 19
INNER BALL JOINT A
B
GROUP INDEX
19
NEEDLE ROLLER BEARING

3
BUSHING, RUBBER
MOUNT RUBBER MOUNT YOKE
BRACKET (SUPPORT END) 6
4 11
24
YOKE COVER
12
SPRING
COLLAR GEAR 16
MOUNT
5 SECTION - CC SECTION - AA
NEXT
SECTION - BB
PREVIOUS
11
STEERING
MECHANICAL
MECHANICAL STEERING
DISASSEMBLY OF RACK AND PINION : (Fig 16) INSPECTION OF DISMANTLED PARTS
TO DISMANTLE : • Examine the Housing set which consists of Case

(Steering Gear (Rack & Pinion) assembly already Strg. Gear (1), Needle Roller Bearing (3) and
removed from the car). Rack Tube (2). If damage to any of the above
components is evident then Housing set must
• Hold the Steering Gear by the Rack tube on a be replaced as a set.
soft jaw vice.
• Examine the Rubber Mount (6). If damage is
• Remove the Bracket (24). evident, replace the part.
• Remove both the Outer Ball joints and Lock nuts • Examine the Rubber Bushing (4) and Collar gear
from the steering gear.(20) mount (5). If damage is evident, replace the parts.
• Remove the Bellow strapping parts (21/22) and • Examine the Rack-bush (15) for excessive wear
clips (23) on either sides using a plier via IBJ leading to loose fit with Rack. If any of the above
Rod and dispose them. is evident, remove the Rack Bush by knocking it
out of the Rack Tube using a mandrel gently.
• Remove the Bellows (17/18).
• Examine the Rack and Pinion set which consists
• Loosen the Inner Ball Joints (19) from the Rack of Rack, Pinion, Ball bearing and Retainer ring.
by arresting the Rack teeth with 21 mm double If damage to any of the above items is evident
end spanner. It is to be noted that gear should then the rack and Pinion set must be replaced
be free and not held / mounted on the housing / as a set.
rack tube while loosening the IBJ.
• Examine the Bellow (17 & 18) for crack and Torn
• Loosen the Yoke Cover (12) using tool and condition. If any of the above is observed, replace
dispose the Yoke cover. Remove the Spring (16) the bellows.
and Yoke (11) from the housing.
• Examine the Yoke for excessive wear and
• Loosen the Pinion Cover (13) using the Tool and damage. If fit between Yoke bore on Case
Remove the Pinion bearing Sub Assembly Steering Gear and Yoke is slack in either of
(7,8,9). Dispose the Pinion cover along with the designs, replace the Yoke by new one. If damage
oil seal (14). is evident, replace the Yoke.
• Remove the Rack (10) via Rack Tube or Via • Examine the Yoke Spring (16). If found to be
Housing side. damaged or found to be solid (Compressed Set)
NOTE : replace the part.
Dismantling of housing assembly for repair is not • Examine Inner Ball Joints and Outer Ball joints
recommended. 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.
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

COLLAR GEAR MOUNT
mounting as shown in Fig. 18. Press the Bushing
(5)
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.
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 ADAPTER (SEE DRAWING
"3 ears" of the Rack Bush is located well inside ATTACHED)
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.
3 SLOTS
RACK BUSH 3 EARS
(15)
GENTLE
BLOW
Fig. 19
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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 RACK
end spanner. It is to be noted that gear should (10)
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 STAKE HERE INNER BALL
JOINT (19)
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 Fig. 20
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.
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 YOKE COVER (12)
unscrew the Yoke cover by 30 0 to 45 0
approximately to achieve free Pinion torque of 8
to 15 kgf. cm.
Fig. 25
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MECHANICAL STEERING
• Assemble the Bellow (17) on the Housing side

and secure the bellow with Bellow strap (21) and
IBJ prior to Bellow assembly, to enable Bellow 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
IBJ prior to Bellow assembly, to enable Bellow
• 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 Some component is loose in the steering linkges

(A clicking noise heard during a turn, or and is shifting under load.
when changing directions)
2. Road Wander Tyre pressure incorrect or unequal left to right

Wheel bearings improperly adjusted or wornout.
Front end alignment out of specification.
Steering gear mounting bolts loose on frame.
3. No Recovery Tyre pressure low

Front end alignment incorrect.
Steering column binding.
4. Shimmy Excessively worn or unevenly worn tyres

Improperly mounted tyre or wheel.
Wheel bearings improperly adjusted 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 MECHANICAL

STEERING
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.
NEXT 17
INDEX GROUP INDEX
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POWER STEERING
LEi & LSi
LX & LXi
NEXT
GROUP INDEX
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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
NEXT i
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POWER STEERING
CONTENTS
1) Technical Specifications 1
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 POWER
STEERING
12) Trouble shooting guide 22
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POWER STEERING
POWER STEERING GEAR
Type : End Take Off-Rack & Pinion Steering Gear

Rack travel : 134 mm
No. of steering wheel turns : 3.27
lock to lock
Flow rate : 7 lpm to 5 lpm
Maximum operating pressure : 70 bar
Free Pinion Rotation Torque : 8 -15 kgf - cm
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 Max. level- 320 ml (for non ABS)
At Min. level - 300 ml At Min. level - 250 ml (for non ABS) POWER
STEERING
Hydraulic fluid : Automatic Transmission Fluid
Lubricants :
Sterak Grease @ Rack & Pinion & Rack Bush : 10 grams
Silicon Grease @ Bellow LIP-IBJ : Smear
1
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INDEX GROUP INDEX
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POWER STEERING
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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INDEX GROUP 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
3
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INDEX GROUP INDEX
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POWER STEERING
(FOR ABS) HYDRAULIC POWER STEERING LINES
22
1.0
21
0.8
1.0
16
14
17
15
2.5
6
18 12
12
19
15
3.5
16
11
10
18
1
3
1.0
4
2
LIST OF PARTS 9 ASSY. RETURN PIPE LINE
10 ASSY.HIGH PRESSURE HOSE (COMPLETE)-RHD
No. Description 11 SEALING WASHER 14X20 IS3175 - CU
1 RUBBER HOSE (SUCTION LINE) 12 PIPE UNION BOLT 10 M14X1.5
1 RUBBER HOSE (SUCTION)-(ABS) 14 O’ RING (HP LINE)
2 SPRING BAND CLAMP FORM-A 15X23D 15 SLEEVE
3 CLAMP 16 CLAMP (FOR 10 DIA PIPE)
4 HEX FL SCREW M6X10 - 8.8 17 HEX FL NUT AM6
5 ASSY.RETURN LINE (P/STG)-RHD (ABS) 18 HEX FL SCREW M6X12 - 8.8
5 ASSY RETURN LINE (POWER STG) 19 ASSY.BRACKET (HP LINE CLAMPING)
6 SPRING BAND CLAMP FORM A 15X19D 21 SPRING WASHER B8 IS3063 SS8451-8C
22 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

POWER
STEERING
5.0
5.0 OUTER BALL JOINT ASSEMBLY
BELLOW CLIP
Fig.(ii)
5
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INDEX GROUP INDEX
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6
Fig.(iii)
INDEX
POWER STEERING
GROUP INDEX
ITEM NO DESCRIPTION 10 DOWEL PIN (QTY/KIT - 2) 21 RETAINING WASHER
11 VANES (QTY/KIT - 10)
22 SHAFT
12 ROTOR (QTY/KIT - 1)
1 ASSY.POWER STEERING PUMP 13 CAM(QTY/KIT - 1) 23 BALL BEARING
2 HOUSING ASSY. 14 END COVER ASSY.(QTY/KIT - 1) 24 RETAINING RING
3 HOUSING SUB ASSY.(QTY/KIT - 1) 15 SEAL KIT
4 FLOW CONTROL SPRING (QTY/KIT - 1) 25 O’ RING 20 X 2 NITRILE
16 DOUBLE LIP SEAL (QTY/KIT - 1)
26 SUCTION HOUSE CONNECTOR
NEXT
17 O’ RING (FOR PR PLATE ID,QTY/KIT - 1)
5 VALVE ASSY.QTY/KIT - 1) 27 SPRING WASHER B8 IS3073
6 O’ RING (QTY/KIT - 1) 18 O’ RING (FOR PR PLATE ID,QTY/KIT - 1)
19 GASKET (QTY/KIT - 1) 28 THIN HD.CAP SCREW M8 X 16
7 PRESSURE PORT CONNECTOR (QTY/KIT - 1)
PREVIOUS
8 CARTRIDGE ASSY. 20 BOLT FOR END COVER
9 PRESSURE PLATE (QTY/KIT - 1)
Fig.(iv)
INDEX
POWER STEERING
GROUP INDEX
NEXT
PLASTIC RESERVOIR 7 SCREW METALLIC RESERVOIR FOR ABS
1 PLASTIC RESERVOIR & MOUNTING STRAP ASSY. 8 STAINER 1 RESERVOIR ASSY.
2 SHELL 9 ...O-RING 2 SHELL
PREVIOUS
3 FILTER AND END COVER ASSY. 10 ...RESERVOIR CAP 3 FILTER
4 VALVE SEAT 11 COVER TIE STRAP 4 CAP ASSY.
5 SPRING (FOR BY PASS VALVE) 12 MOUNTING STRAP
6 WASHER
7
POWER STEERING
ALTERNATOR
BELT
TENSIONER
BOLT
STEERING WHEEL 1
RESERVOIR
COLUMN ASSEMBLY JOINT 7
PRESSURE LINE 8 SUCTION LINE
8
PULLEY PUMP
INTERMEDIATE ENGINE
LINE
RETURN
JOINT
5
2
9
POWER RACK & LOCK
PINION STG. NUT
6
GEAR
BELLOW BELLOW BALL

4
CLIP STRAP FEED PIPE - SHORT PIN
BELLOW FEED PIPE - LONG NUT
3
Fig. 2 Schematic layout of a typical belt driven power steering system
POWER RACK & PINION STEERING RESERVOIR

SYSTEM Hydraulic oil for the Power steering system is stored
GENERAL DESCRIPTION Fig. 2 in the Reservoir. The Reservoir generally is located at
a higher level above Pump to ensure feed by
The Hydraulic Power Steering reduces the driver’s effort
gravitational flow.
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. 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
BELLOW CLIP PINION ASSEMBLY INNER BALL
BELLOW STRAP JOINT ASSY
PINION
BALL- BEARING RACK ASSY
SEAL PINION LOCK STOP ASSY

SHAFT
NEEDLE ROLLER BRG
RACK TUBE
(CYLINDER)
OUTER BALL JOINT
Fig. 3 Schematic sketch - power rack and pinion gear.
POWER RACK & PINION STEERING and pinned on housing and the Piston swaged
GEAR Fig. 3 to the Rack. The bore of the steel tube is honed
The Power Rack & Pinion Steering Gear comprise of : for smooth Piston movement.
Manual steering mechanism The two sides of the Cylinder (RH & LH) are
1. Manual steering mechanism is based on proven, connected to the Rotary Control Valve by external
reliable, smooth and lashfree Rack & Pinion feed pipes.
mechanism. OPERATION
The Pinion is supported on Ball & Needle Roller What happens during steering manoeuvre ?
POWER
STEERING
Bearings and the Rack on anti friction bush to
ensure high efficiency and smooth operation and When the driver turns the steering wheel, he transmits
the mechanism is designed to operate manually force from the wheel to steering gear input shaft.
in the event of hydraulic power failure. Input shaft rotation is transmitted to the Pinion through
Rotary control valve (Hydraulic control valve) Torsion bar which is pinned at one end to the Input
2. The Rotary Control Valve combines simplicity of shaft and pressed firmly into the Pinion at the other
construction with desirable performance end.
characteristics that provides responsive steering The Pinion tends to push the Rack linearly through
control. the Rack tube bore.
The input shaft and the valve sleeve constitute But the linear movement of the Rack which is connected
the two members of the Rotary Control Valve. to the steered road wheels through link mechanism is
Power cylinder (Rack Tube) all in a single resisted by the load on the steered wheels.
compact package.
3. Power Cylinder : The built in hydraulic cylinder
is constituted by the strong steel tube press fitted
9
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INDEX GROUP INDEX
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POWER STEERING
POWER RACK & PINION STEERING GEAR - OIL FLOW
OIL IN
LH ROTARY VALVE
CYLINDER RH POSITION
RH CYLINDER
CYLINDER INPUT SHAFT
TORSION BAR
OIL IN
VALVE SLEEVE NEUTRAL
LH
LH
CYLINDER
CYLINDER
RH CYLINDER SHORT FEED PIPE LONG FEED PIPE
OIL IN
TO RH CYLINDER TO LH CYLINDER
SECTION - M VALVE ASSY
(ENLARGED)
OIL IN A A
OIL OUT BELLOW
IBJ
RACK TUBE
RACK (CYLINDER)
Fig. 4
PRESSURE ROTARY VALVE

OIL IN POSITION
PRESSURE
OIL IN RIGHT TURN
PRESSURE
OIL IN
CW
ROTATION
PRESSURE
OIL IN
RETURN OIL
Fig. 5
10
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INDEX GROUP INDEX
PREVIOUS
POWER STEERING
PRESSURE
OIL IN ROTARY VALVE
POSITION
PRESSURE
OIL IN
LEFT TURN
PRESSURE
OIL IN
CCW
ROTATION
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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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.
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POWER STEERING
DISENGAGEMENT OF OBJ FROM STEERING ARM
OBJ LOCK NUT INNER BALL JOINT END
OUTER BALL JOINT
STEERING ARM
BALL PIN NUT
REMOVAL OF OBJ FROM IBJ END
SPANNER
LOCATION
Fig. 7
MINOR REPAIRS ON POWER RACK & REMOVAL OF OUTER BALL JOINTS Fig. 7
PINION & PINION STEERING GEAR Raise the front of the car and support it on a safety
STEERING GEAR stand in the proper location.
This section covers only minor repairs that do not Remove the front wheels
require complete dismantling of steering gear Unscrew the ball pin nut of the Outer ball joint (RH
assembly. side & LH side) and using puller part no. 2702 5890
CAUTION : 4602, remove the Outer ball joint from the steering
arm (knuckle arm). POWER
The minor repairs should be handled only by proper STEERING
trained personnel who have proper equipment, tools, Hold the Inner ball joint with 14mm spanner and loosen
instructions and know-how and authorised to perform the lock nut with 17mm spanner to free the ball joint.
the work properly and safely. Now unscrew the Outer ball joint out of the Inner ball
REPLACEMENT OF OUTER BALL JOINT (OBJ) joint (Tie rod) assembly
ASSEMBLY. Discard the Outer ball joint assembly.
NOTE : ASSEMBLY OF OUTER BALL JOINTS
The outer ball joint assemblies must be replaced if Screw in the new Outer ball joint assembly on the
either of the following conditions are detected. Inner ball joint (Tie rod)
1. Any binding in articulation of the ball pin. Align the steering gear in mid position to straight ahead
2. Any axial play between the ball and cup of Outer position (SAP) of the steered wheels.
ball joint Assy, more than 0.1 mm at + 100 gms. Connect the Outer ball joints with the steering arm
The replacement of Outer ball joint can be done on Tighten the ball nut to specified torque.
the vehicle itself without removing the steering gear Install the front wheels and lower the front of the car.
from the vehicle as explained below : Carry out wheel alignment. Now tighten the outer ball
joint lock nut to specified torque.
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POWER STEERING
ASSEMBLY OF BELLOW
BELLOW STRAP
BELLOW CLIP
GROOVE TO LOCATE SMALL BELLOW CLIP

END OF BELLOW
HOUSING
BELLOW
DOLLY
PULL OUT
Fig. 8
REPLACEMENT OF BELLOWS : Fig. 8 Pull out the bellows away from the ends of the steering
gear box along with clip.
For better access and convenience to replace the
bellows properly, remove the steering gear assembly Discard the bellow/strap & clip.
from the car as per procedure in the Mechanical
Clean the outer surface at the ends of the steering
Steering Group of this Manual.
gear and Inner ball joint assembly.
CAUTION :
ASSEMBLY OF BELLOWS
1. Plug the ports tight with protective caps in the
steering gear. Clean the outer surface of the dolly (Taper guide tool)
and insert it on the Inner ball joint Assy.
2. Use only Special Tools and do not hammer to
remove outer ball joints from steering arm Apply grease (dow corning) on the groove of both the
(knuckle arm) tie rods.
3. Take care to avoid damage to bellows, feed pipes Assemble the bellow clip on the small end of the
and input shaft when drawing out the steering bellow.
gear assembly from the car. Keeping the rack in mid gear position slide the bellows
Mount the steering gear on a mock up bracket. on the dolly big end first till the small end of bellow
locates on the greased groove.
REMOVAL OF BELLOWS
Assemble the big end of the bellows over the ends of
Remove the Outer ball joint assembly after loosening the steering gear (Housing & Rack tube) ensuring no
the lock nut. Unscrew out the lock nut (Refer twist to the bellows.
Replacement of Outer ball joint for removal procedure).
Using the strapping gun, strap the big end of the bellow
Remove the bellows straps and discard. 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

INNER BALL JOINT
STAKING
Fig. 9
CAUTION : REMOVAL OF INNER BALL JOINTS Fig. 9

If the strapping is not sound means possibility of rusty Remove the steering gear assembly from the car (Refer
gear/entry of dust/water ingress/lack of lubrication. Steering group of this Workshop Manual).
Slide the rack to right and left by turning the Input CAUTION :
shaft to be certain that the bellows are not deformed 1. Plug the ports tight with protective caps in the
or twisted. steering gear.
POWER
Screw in the lock nut and Outer ball joint assembly 2. Use only Special Tools and not hammer to remove STEERING
on the Inner ball joint. Dismount the steering gear Outer ball joints from steering arm (knuckle arm)
assembly from the mock up bracket.
3. Take care to avoid damage to bellows, feed pipes
Reinstall the steering gear on the car. and input shaft When drawing out the steering
REPLACEMENT OF INNER BALL JOINTS gear assembly from the car.
ASSEMBLY (IBJ’S). WARNING :
NOTE : Improper tightening of Inner ball joint assemblies will
The Inner ball joint assembly must be replaced if either cause accident.
of the following conditions is detected. Mount the steering gear assembly on a mock up
1. Any binding in articulation of the Ball rod (tie rod) bracket.
2. Any axial play between the ball and cup of Inner Remove the outer ball joints and bellows on the LH
ball joint assembly, more than 0.1 mm at + 100 side and RH side of the steering gear (Refer
gms. Replacement of Outer ball joint / Bellows for removal
procedure).
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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 same and replace with new ones only.
rack surface. Using sputnik wrench, unscrew the Inner
Remove the steering gear assembly from the car.
ball joint assembly from the ends of the rack.
CAUTION :
Discard the Inner ball joint assembly.
ASSEMBLY OF INNER BALL JOINT
steering gear.
Screw in the new Inner ball joint assembly to the ends
2. Use only Special Tools and not hammer to remove
of the rack by hand.
Outer ball joints from steering arm.
Hold the rack suitably taking care not to damage the
surface. Using Sputnik wrench, tighten the Inner ball
and Input shaft when drawing out the steering
joint assembly to 8 kg-m torque.
gear assembly from the car.
Stake the Inner ball joint (RHS & LHS) using a punch
Carefully unscrew the flare nuts at the ends of
against the notch on both the ends of the rack.
the short/long feed pipes connected to housing
Reassemble the bellows and Outer ball joint (Refer and rack tube ends using 11 mm spanner.
Replacement of Outer ball joint/Bellows).
Discard the feed pipes.
Dismount the steering gear from the mock up bracket.
Blow clean the inside of the new feed pipes (short/
Reinstall the steering gear on the car.
long) with compressed air.
REPLACEMENT OF FEED PIPES (SHORT/
Install the feed pipes (short/long) by screwing
LONG) Fig. 10
the flare nuts at the ends to housing and rack
CAUTION : tube by hand.
Do not attempt to repair any bent or damaged feed Now tighten the flare nuts to 1.7 kg-m torque.
pipes. Whenever feed pipes are removed discard the
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
INPUT SHAFT SEAL
4605.
INPUT SHAFT SEAL
SEAL GUIDE TOOL
PRESSURE PORT
RETURN PORT
Fig. 11
REPLACEMENT OF INPUT SHAFT SEAL Disconnect the air pressure supply as soon as the
Fig. 11 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. Determine by inspection that seal bore is in good
condition.
2. Use only Special Tools and not the hammer for
POWER
removing the outer ball joints from knuckle. Clean the seal guide tool and insert it on the input STEERING
shaft covering the serration.
3. Take care to avoid damage to bellows, feed pipe
and input shaft when taking out the steering gear Apply power steering fluid on the input shaft seal and
from the car. slide it down the seal guide tool into the housing bore
with lip facing down. Using seal pressing tool part no.
Mount the steering gear assy. on a mock up bracket 2702 5890 46 05, press the seal till it butts on the
with Input shaft facing upwards. bearing face.
Using circlip plier remove the input shaft seal retaining Using circlip plier compress and engage the circlip in
ring. the bore of the housing. Now remove the circlip plier
Unplug the return port and hold the clean cloth around and using a drift, press the circlip until it locates in the
the input shaft and apply air pressure to the return groove of the housing bore.
port. 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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POWER STEERING
ON - CAR SERVICE - INSPECTION & MAINTENANCE

STEERING WHEEL 1
8
RESERVOIR
COLUMN ASSEMBLY JOINT. 7
PRESSURE LINE SUCTION LINE
PUMP 8
RETURNLINE
PULLEY
INTERMEDIATE ENGINE
JOINT
5
LOCK 9
POWER RACK &
2 NUT
PINION STG. GEAR
BELLOW 4 BALL PIN

BELLOW 6
CLIP 3 STRAP FEED NUT
BELLOW PIPE - LONG FEED PIPE - SHORT
Fig. 12 Power rack & pinion steering system

1. STEERING WHEEL PLAY replace with new one. Ensure Feed pipes do not
With Engine off and front wheels in Straight Ahead foul with each other (or) on any part of the vehicle.
Position , check for any free play at steering wheel 5. PUMP/DRIVE BELT
without moving the front wheels.
Engine driven belt drive Pump. Never run the pump
There should be no free play but only the feel of dry. Check Pump belt condition and proper tension
the Torsion bar twist in the stg. gear. With hands atleast once in a fortnight.
off stg. wheel, the reaction of torsional twist will Adjust tension as recommended.
bring the stg. wheel back to the original position.
If any play is detected, check for 6. STG. GEAR MOUNTING
1. Looseness in Stg. Joints / Links Check for any interference (or) condition that may
cause the gear to distort due to improper mounting
2. Yoke adjustment in stg. gear. / tightness. Correct if required.
2. INNER BALL JOINT (TIE ROD) 7. POWER STEERING OIL

SWING RESISTANCE Use only genuine. Power Stg. oil. Never run the
After disconnecting Outer ball joint from stg. arm Engine without oil in the Reservior. Check oil level
give ten hard swings to Inner ball joint to feel swing with Engine running and maintain between Min. &
resistance, If swing is tight replace the Inner ball Max. mark.
joint. Use specified oil. Follow the oil and filter change
schedule.
If swing is smooth and there is no play between
8. HYDRAULIC LINES
the ball and cup of Inner ball joint, it may be used.
Check the Hydraulic lines (Hoses/Pipes) of the
3. BELLOW / STRAP / CLIP
system for damage, Correct as required. for leak
Check Bellow for Crack (or) Damage, Replace if proof connection and smooth flow without
any. Check for proper crimping of Bellow by Strap/ restriction.
Clip.
9. OUTER BALL JOINTS
CAUTION :
Defective Bellow and loose crimping means possibility Check the boot condition for crack/damage. Check
of rusty gear, entry of dust or lack of grease. for play in the ball joint. If any of the above exist,
replace with new one. Check Outer ball joint lock
4. FEED PIPES
nut & Ball pin nut tightness.
Check Feed pipes for damage (or) bend. If any,
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POWER STEERING GEAR - EXPLODED VIEW :
LIST OF PARTS 17 ROLLER BEARING

No. DESCRIPTION 18 SEAL - INPUT SHAFT
1 HOUSING & TUBE ASSY 19 CIRCLIP
2. SEAL - RACK (HOUSING) 20 YOKE POWER
3. BALL BEARING 21 YOKE SPRING STEERING
4. SEAL - PINION SHAFT 22 YOKE COVER

5. BEARINGNEEDLE ROLLER 23 INNER BALL JOINT
6. RACK & PISTON ASSY. 24 BELLOW
7. PISTON SEAL RING 25 BELLOW CLIP
8. ‘O’ RING 26 BELLOW STRAP
9. LOCK STOP 27 RUBBER MOUNT BUSH
10 RETAINING RING 28 REAR MOUNT COLLAR
11 LINER 29 RUBBER MOUNTING
12 ‘O’ RING 30 MOUNTING CLAMP
13 SEAL - RACK (L/S) 31 FEED PIPE ASSY. - LONG
14 PISTON & VALVE ASSY. 32 FEED PIPE ASSY - SHORT
14A VALVE SEAL RING 33 AFTER BALL JOINT ASSY.
NOTE : INSTALL NEW SEALS
15 NUT - PINION 33A OBJ LOCK NUT
WHENEVER THE GEAR IS
16 PINION COVER 33B NYLOC NUT (OBJ BALL PIN)
DISMANTLED FOR REPAIR.
Fig. 13
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POWER STEERING
POWER STEERING SYSTEM - HYDRAULIC TESTS USING DIAGNOSTIC GAUGE
Diagnostic Gauge
Power Stg. Pump
Column Assembly Pressure Line
Suction line
Intermediate Joint
Return Line
Engine
Rack & Pinion Power Stg. Gear
Fig. 14
GENERAL 2. Steering Gear - Internal leakage
The Diagnostic Gauge is designed to conduct on PREPARATION OF HYDRAULIC SYSTEM
vehicle hydraulic tests in Power Steering System for
a detailed trouble shooting when all other aspects Install Diagnostic Gauge in the pressure line (fluid
checked prove satisfactory. supply line from Pump to Steering Gear).
The Diagnostic Gauge comprises of a PRESSURE Check and top up oil in Reservoir. Bleed the system
GAUGE, FLOW METER, SHUT OFF VALVE AND as per procedure (Refer page 6).
HOSES provided with quick coupling for easy Place a thermometer in the Reservoir to record
connection. Fig. 14 temperature. With the shut off valve of Diagnostic
Using this Diagnostic Gauge, we can check the Gauge fully open, warm up the hydraulic system by
following and compare to specification of the system. partially closing the shut off valve until the pressure
gauge reads 100 PSI (7 bar). When the temperature
1. Pump Performance Check reads 51.70 C and 57.20 C open the valve.
a. Flow The system is now warmed up and ready for
b. Relief Pressure conducting the hydraulic test.
c. Pump response
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Test No. 1 Test No. 2

PUMP PERFORMANCE PUMP RESPONSE TEST
Keep an eye on the Pressure Gauge and slowly close Keeping an eye on the flow meter, look for instant
the Shut off valve of Diagnostic Gauge. System return of flow rate to recommended flow range from
pressure not to exceed the relief pressure specified zero when shut off valve is opened from the closed
(Refer vehicle manual) for the system. position both at idling and governed speed. Conduct
CAUTION : Do not keep the shut off valve closed for the test once at idling speed and three times at Engine
more than 5 seconds at a time to avoid damage to governed speed.
the pump. If the flow rate does not return immediately the Pump
Measure and record in table below the flow, pressure is malfunctioning and can result in momentary loss of
and temperature at idling and governed speed with power assist. The Pump needs to be repaired or
shut off valve in fully opened and closed condition (with replaced.
hands off the steering wheel). Test No. 3
STEERING GEAR INTERNAL LEAKAGE TEST
Engine Shut off PressureFlow Temperature Comment
Speed valve First conduct Pump performance test and confirm that
condition the Pump is working satisfactorily.
Idling Open A With shut off valve open and at steady idling speed of
Speed Closed B Engine, turn the steering wheel to any wheel lock end
Governed Open A and apply force at the rim of the steering wheel to be
sure that the control valve is fully closed.
Speed Closed B
The Pressure gauge should now read maximum
Compare minimum/maximum flow and maximum pressure (relief pressure) specified for the pump.
pressure (relief pressure) recorded with specification
If it reads appreciably less than the relief pressure, it
and refer appropriate comments below for corrective
indicates reduction in power assistance because of
action. If it meets the specification, proceed to Test
excessive internal leakage. Repair or replace the
No. 2.
Steering gear.
COMMENTS
Repeat this test at the opposite wheel lock.
A. (i)steady state fluid pressure (with hands off
CAUTION : Don’t hold the steering wheel in the full
steering wheel) should be equal to or less than that
turn position (lock end) for more than 5 sec. to avoid
specified for the system. POWER
damaging the Pump. STEERING
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 Note :
any clogging.
1) When hydraulic tests are completed and fluid lines
(ii) If the measured flow is less than the specification are reconnected check fluid lever and bleed the
the Pump needs to be repaired (or) replaced. system.
2) For power steering wheel alignment values refer
B. (i)If maximum system pressure (relief pressure)
page 9 of mechanical steering group.
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: With shut off valve closed, the flow drops
to zero and should not be closed for more than five
seconds.
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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 Wheel Noise / Direction

Steering kick/Shock/ Vibration Pull
Vibration
Road wander / Poor Reduced External

Lash in Steering Self Centering Wheel Turns leaks
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POWER STEERING
COMPLAINT AS MAY BE NARRATED BY THE CUSTOMER
• Won’t turn • Lock up/stuck up

HARD STEERING • Not enough Power assist • Won’t turn unless moving
• High effort to steer • Sticky/binding
CONDITION PROBABLE DEFECT CORRECTIVE ACTION

Present during cold Some power steering pumps have Increase engine speed briefly to
start only temporary state, when pump correct the problem
element vanes are sticky
Sensitive to steering Air drawn in due to insufficient fluid Add fluid and bleed the system
wheel speed. per filling and bleeding procedure
More prevalent when Air being sucked in through cracks Replace/correct the crack/
steering fast or loose fittings/hose / pipes in loose fitting , hoses, pipes in
suction line suction line fill and bleed the
system as per procedure
Flow From the pump is less than Repair (or) replace the Pump.
minimum recommended for
steering gear.
Steady state fluid pressure (with Clean/replace the clogged/

hands off steering wheel) at idling deformed hydraulic lines as
with shut off valve fully open, is required.
high, due to clogging/deformation
of feed and return hydraulic lines
Present only in one Unequal tyre pressure Inflate both steered wheels to
direction of turn equal specified pressure. POWER
STEERING
Feed pipe to concerned cylinder is Replace the deformed feed pipe
deformed
Excessive internal leakage in one Repair or replace the steering gear

direction of turn only (verify with
internal leakage test)
Present in both the Low tyre pressure Inflate both steered wheels to
direction of turn equal specified pressure.
Low hydraulic fluid Check and rectify external leak if
any. Top up the oil and
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POWER STEERING
bleed the system (if required)

Improper rotation or binding in Determine by Inspection what
column related parts interference or condition is causing
binding and correct the problem.
Low pressure or flow from Pump Check pump performance. Repair or

replace as required.
Faulty steering joints Replace the joints
Faulty steering link components Determine by inspection. Identify

like inner/outer ball joints etc. 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 Replace Steering gear assembly.

assembly
Feed pipes to both the cylinders Replace the Feed pipes

deformed
Excessive internal leakage Repair or replace the Steering

gear as required.
Restriction in return line or line too Clear restriction/kinks, if hoses

small in diameter are same as OE. If not replace the
return line with specified one. Fill
and bleed the system as per
procedure.
Oversize tyres Check specifications and replace with
recommended size tyres
Present as intermittent Pump drive belt slip or worn out Adjust belt tension or replace belt
loss of power belt and adjust as required
assistance
Pump malfunctioning as no Repair or replace the pump as

immediate return of flow rate on required
opening the load valve from closed
position.
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POWER STEERING
STEERING WHEEL • Kick back • Bump steer

KICK/ SHOCK/VIBRATION • Rough Steering • Vibration in steering wheel
Prevalent when Engine idling speed low/erratic Adjust the engine speed for steady
turning at low speeds, tending to stall when the steering idling rpm.
particularly at rough wheel is turned affecting steady
roads or turning at minimum flow from pump.
engine idle speed while
car is stationery. Air in the system or Power If oil level is too low, look for
Steering oil too low. external leak. If any, correct & fill
oil and bleed the system.
Looseness or lash in steering Determine by inspection from
system that may be drifting under steering wheel to steered wheels,
load when turning. links/joints/mountings for
looseness/wear/ crack. Renew/
replace the affected part (s).
Improperly adjusted Steering Gear. Adjust the Rack guide to
May be Rack guide (Yoke) has Specification. If problem is not
backed off excessively or worn. corrected, replace the Steering gear.
Front shock absorber/ Replace the defective shock
suspension strut malfunctioning. absorber/suspension strut.
Vibration / shock / kick Pump stops momentarily due to Adjust the belt tension to
felt when turning the belt slipping on drive pulley. specification.
steering wheel to lock.
POWER
COMPLAINT AS MAY BE NARRATED BY THE CUSTOMER STEERING
REDUCED WHEEL TURN • Very high turning • Not enough turn from centre to lock
radius required
• Wheel cut restricted • Unequal number of turns from centretolock

No. of turns not equal Steering Gear mid position not Allign the Steering Gear mid
from centre to lock aligned to straight ahead condition position to straight ahead condition
(with Power Off of steered wheels. of steered wheels. Do the wheel
condition). alignment to the specification.
Bend in steering links due to heavy Determine by inspection the
impact load/accidents. affected steering link and replace
with new one. Do not attempt to
straighten the bend on the links.
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POWER STEERING

DIRECTIONAL PULL • Vehicle pulls to one side • A constant force needed
to hold steering

Pulling felt while Unequal braking force on steered Check and adjust the brakes of
braking only wheels steered wheels. Replace the
brakes if necessary
Uneven or badly worn tyres Replace the tyre
Pulling prevalent Deflection in suspension or Determine by inspection the
while accelerating steering links suspension and steering links and
only replace affected parts
Wheel bearings improperly Check and adjust to specifications
adjusted
Unequal tyre pressure on front tyres Inflate the front tyres to equal
pressure
Improper wheel alignment Check and correct wheel
alignment
Constant force is Motoring (automatic steering) due Replace the Steering gear
required to hold to unbalanced control valve in
steering wheel Steering gear

ROAD WANDER / LASH • Lash in steering • Constant correction is
IN STEERING • Lost motion in steering needed at steering
wheel to keep the
vehicle from wandering

Vehicle wanders Uneven or extreme tread wear Replace tyres with new one
requiring constant
correction at steering Unequal tyre pressure on steered Correct tyre pressure to
wheel wheels specification
Lash in steering due to any Determine by inspection to identify
looseness or wear or cracked the cause for lash and tighten or
components from steering wheel to Replace the affected component as
road wheels (Steering wheel, necessary
steering column, joints, inner/
outer ball joints)
Steering gear rack guide Adjust rack guide to specification
adjustment improper/disturbed -
Backed off excessively.
Wheel alignment out of Correct wheel alignment to
specification specification
Wheel bearings not adjusted Adjust or replace the bearings as
properly or worn out necessary
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POOR SELF CENTERING • Steering does not return • Steered wheels don’t
smoothly return to straight ahead
• Poor self centering position
Resistance or binding Poor tyre condition/uneven tyre Replace with good recommended
felt preventing wear/mismatched tyres tyres, inflate to specified pressure
smooth/quick return
of steered wheels
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 Determine by inspection the cause
with any other part during steering for rubbing/interference and
movement. correct the same
Improper mounting causing Remove the Steering gear and
distortion to Steering gear. determine by inspection what
interference or condition is causing
the gear to distort and correct the
problem.
Deformed/damaged Feed pipes Replace the Feed pipes
on Steering Gear
Input torque high due to improper Remove the Steering gear. Check POWER
STEERING
adjustment of Steering gear. and adjust Rack guide adjustment
to specification. If the problem is not
corrected, replace the Steering gear.
Binding in Steering axle (Upper/ Determine by inspection and
lower links) renew/replace Steering axles/
links/bushes / ball joints
Insufficient oil flow to steering Repair or replace the Pump if flow
gear for adequate steering speed. is less.
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POWER STEERING

NOISE AND VIBRATION • Humming noise while • Clicking sound while
steering steering
• Squealing noise • Hissing noise
• Rattling noise
Humming noise that This is not a defect. The noise is -
increases with engine due to pulsation of fluid when the
speed pump is running which is normal
Hissing noise when This is not a defect. The noise is -
turning right or left due to actuation of Flow Control
Valve during steering operation
which is normal.
Noise evident when This is not a defect. This noise is Caution : Do not hold the wheels
wheels are held on from the relief valve in the Pump at full lock for more than 5 seconds
full lock.
Gratting noise from Cavitation caused by air bubbles in Check fluid level in reservoir. If
pump the fluid, due to low or insufficient low top up the oil. Correct external leaks,
oil in system 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 Low belt tension or worn out belt Tighten the belt or replace as
pump necessary
Abnormally loud Pump internals excessively worn out or Replace the pump
noise from pump damaged
Rattling or chattering Loose pump pulley Tighten or replace the pulley. If
noise shaft is found damaged, replace
the Pump
Loose or worn steering columns/ Tighten or replace the parts as
intermediate joints necessary
Loose inner or outer ball joints Tighten to replace the parts as
necessary
Rack guide adjustments improper Adjust to specification if not
or disturbed. corrected, replace the Steering
gear
Clicking noise heard Some component is loose and Determine by inspection, tighten or
during a turn or when shifting under load replace if necessary
changing direction
Vibrating Noise Unclamped/Rubbing/damaged/ Determine by inspection and
deformed pipe lines correct or replace if necessary
28
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POWER STEERING
EXTERNAL LEAKS • Loss of steering fluid • Oil puddle under vehicle

• Frequent adding of fluid after parking
is required • Leak at steering gear /
• Oil wetness pump/reservoir
Leak through fittings/ Improper tightness of fittings Tighten and clamp suitably to
sealing washers avoid loosening under vibration
End fitting/Sealing washer is Replace the end fittings/sealing
damaged or cracked due to washer & tighten properly
improper tightening
Leak through hoses Loose connection Tighten & clamp suitably
Heat or age cracks Replace the hose with new one
Twisting or Abrasion wear due to Replace the hose & route and
improper routing/fouling/kinking/ clamp suitably
twist
Leak through Foaming or oil throwing out due to Check proper connection of
Reservoir air in the system suction line. Fill and bleed the
system.
Reservoir is overfilled. Drain the oil in reservoir to proper
level
Broken or cracked bracket/cover/ Replace the reservoir assembly
shell of reservoir due to improper with new and clamp properly
clamping/vibration
Leak through Pump Through shaft seal, due to defective seal Remove the seal. If seal bore is OK,
hardened or cracked Fill and bleed the system. replace with new seal.
seal. If it still leaks, replace the pump.
Leak through Pump assembly Replace the seals/ “O” rings. If it
POWER
housing/ cover/ joint face seals/ still leaks, replace the pump. STEERING
“O” rings
Leak through Leak through Input shaft seal Remove input shaft seal. If seal
Steering Gear Assy. bore is OK, replace the seal with
new one.
Leak from Cylinder (Rack tube) Replace the Rack seal using
through Rack seal into right/ left special tools taking care not to
bellows. cause any damage/scorings to
inner walls of Cylinder (Rack tube)
Leak through pinion seal in valve Replace pinion seals using special
housing into RH bellows. tools.
Leak through feed pipes Tighten the connection properly.
connection to Rack tube at flare
nut.
Cracked/damaged feed pipes Replace feed pipes.
29
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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
NEXT i
INDEX GROUP INDEX
PREVIOUS
POWER STEERING
CONTENTS
1) Technical Specifications 1
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 POWER
STEERING
12) Trouble shooting guide 22
NEXT iii
INDEX GROUP INDEX
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POWER STEERING
POWER STEERING GEAR
Type : End Take Off-Rack & Pinion Steering Gear

Rack travel : 134 mm
No. of steering wheel turns : 3.27
lock to lock
Flow rate : 7 lpm to 5 lpm
Maximum operating pressure : 70 bar
Free Pinion Rotation Torque : 8 -15 kgf - cm
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 Max. level- 320 ml (for non ABS)
At Min. level - 300 ml At Min. level - 250 ml (for non ABS) POWER
STEERING
Hydraulic fluid : Automatic Transmission Fluid
Lubricants :
Sterak Grease @ Rack & Pinion & Rack Bush : 10 grams
Silicon Grease @ Bellow LIP-IBJ : Smear
1
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INDEX GROUP INDEX
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POWER STEERING
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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INDEX GROUP INDEX
PREVIOUS
POWER STEERING
STEERING
WHEEL
STEERING
COLUMN
COMBI SWITCH
ASSEMBLY
POWER
STEERING
POWER RACK & PINION

STEERING GEAR
ASSEMBLY
Fig.1 Layout of power steering assembly
3
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INDEX GROUP INDEX
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POWER STEERING
(FOR ABS) HYDRAULIC POWER STEERING LINES
22
1.0
21
0.8
1.0
16
14
17
15
2.5
6
18 12
12
19
15
3.5
16
11
10
18
1
3
1.0
4
2
LIST OF PARTS 9 ASSY. RETURN PIPE LINE
10 ASSY.HIGH PRESSURE HOSE (COMPLETE)-RHD
No. Description 11 SEALING WASHER 14X20 IS3175 - CU
1 RUBBER HOSE (SUCTION LINE) 12 PIPE UNION BOLT 10 M14X1.5
1 RUBBER HOSE (SUCTION)-(ABS) 14 O’ RING (HP LINE)
2 SPRING BAND CLAMP FORM-A 15X23D 15 SLEEVE
3 CLAMP 16 CLAMP (FOR 10 DIA PIPE)
4 HEX FL SCREW M6X10 - 8.8 17 HEX FL NUT AM6
5 ASSY.RETURN LINE (P/STG)-RHD (ABS) 18 HEX FL SCREW M6X12 - 8.8
5 ASSY RETURN LINE (POWER STG) 19 ASSY.BRACKET (HP LINE CLAMPING)
6 SPRING BAND CLAMP FORM A 15X19D 21 SPRING WASHER B8 IS3063 SS8451-8C
22 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
BELLOW STRAP OUTER BALL JOINT ASSEMBLY
BELLOW BELLOW CLIP

POWER
STEERING
5.0
5.0 OUTER BALL JOINT ASSEMBLY
BELLOW CLIP
5
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INDEX GROUP INDEX
PREVIOUS
6
Fig.(iii)
INDEX
POWER STEERING
GROUP INDEX
ITEM NO DESCRIPTION 10 DOWEL PIN (QTY/KIT - 2) 21 RETAINING WASHER
11 VANES (QTY/KIT - 10)
22 SHAFT
12 ROTOR (QTY/KIT - 1)
1 ASSY.POWER STEERING PUMP 13 CAM(QTY/KIT - 1) 23 BALL BEARING
2 HOUSING ASSY. 14 END COVER ASSY.(QTY/KIT - 1) 24 RETAINING RING
3 HOUSING SUB ASSY.(QTY/KIT - 1) 15 SEAL KIT
4 FLOW CONTROL SPRING (QTY/KIT - 1) 25 O’ RING 20 X 2 NITRILE
16 DOUBLE LIP SEAL (QTY/KIT - 1)
26 SUCTION HOUSE CONNECTOR
NEXT
17 O’ RING (FOR PR PLATE ID,QTY/KIT - 1)
5 VALVE ASSY.QTY/KIT - 1) 27 SPRING WASHER B8 IS3073
6 O’ RING (QTY/KIT - 1) 18 O’ RING (FOR PR PLATE ID,QTY/KIT - 1)
19 GASKET (QTY/KIT - 1) 28 THIN HD.CAP SCREW M8 X 16
7 PRESSURE PORT CONNECTOR (QTY/KIT - 1)
PREVIOUS
8 CARTRIDGE ASSY. 20 BOLT FOR END COVER
9 PRESSURE PLATE (QTY/KIT - 1)
POWER STEERING
7
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POWER STEERING
ALTERNATOR
BELT
TENSIONER
BOLT
STEERING WHEEL 1
RESERVOIR
COLUMN ASSEMBLY JOINT 7
PRESSURE LINE 8 SUCTION LINE
8
PULLEY PUMP
INTERMEDIATE ENGINE
LINE
RETURN
JOINT
5
2
9
POWER RACK & LOCK
PINION STG. NUT
6
GEAR
BELLOW BELLOW BALL

4
CLIP STRAP FEED PIPE - SHORT PIN
BELLOW FEED PIPE - LONG NUT
3
Fig. 2 Schematic layout of a typical belt driven power steering system
POWER RACK & PINION STEERING RESERVOIR

SYSTEM Hydraulic oil for the Power steering system is stored
GENERAL DESCRIPTION Fig. 2 in the Reservoir. The Reservoir generally is located at
a higher level above Pump to ensure feed by
The Hydraulic Power Steering reduces the driver’s effort
gravitational flow.
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. 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
BELLOW CLIP PINION ASSEMBLY INNER BALL
BELLOW STRAP JOINT ASSY
PINION
BALL- BEARING RACK ASSY
SEAL PINION LOCK STOP ASSY

SHAFT
NEEDLE ROLLER BRG
RACK TUBE
(CYLINDER)
OUTER BALL JOINT
Fig. 3 Schematic sketch - power rack and pinion gear.
POWER RACK & PINION STEERING and pinned on housing and the Piston swaged
GEAR Fig. 3 to the Rack. The bore of the steel tube is honed
The Power Rack & Pinion Steering Gear comprise of : for smooth Piston movement.
Manual steering mechanism The two sides of the Cylinder (RH & LH) are
1. Manual steering mechanism is based on proven, connected to the Rotary Control Valve by external
reliable, smooth and lashfree Rack & Pinion feed pipes.
mechanism. OPERATION
The Pinion is supported on Ball & Needle Roller What happens during steering manoeuvre ?
POWER
STEERING
Bearings and the Rack on anti friction bush to
ensure high efficiency and smooth operation and When the driver turns the steering wheel, he transmits
the mechanism is designed to operate manually force from the wheel to steering gear input shaft.
in the event of hydraulic power failure. Input shaft rotation is transmitted to the Pinion through
Rotary control valve (Hydraulic control valve) Torsion bar which is pinned at one end to the Input
2. The Rotary Control Valve combines simplicity of shaft and pressed firmly into the Pinion at the other
construction with desirable performance end.
characteristics that provides responsive steering The Pinion tends to push the Rack linearly through
control. the Rack tube bore.
The input shaft and the valve sleeve constitute But the linear movement of the Rack which is connected
the two members of the Rotary Control Valve. to the steered road wheels through link mechanism is
Power cylinder (Rack Tube) all in a single resisted by the load on the steered wheels.
compact package.
3. Power Cylinder : The built in hydraulic cylinder
is constituted by the strong steel tube press fitted
9
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POWER STEERING
POWER RACK & PINION STEERING GEAR - OIL FLOW
OIL IN
LH ROTARY VALVE
CYLINDER RH POSITION
RH CYLINDER
CYLINDER INPUT SHAFT
TORSION BAR
OIL IN
VALVE SLEEVE NEUTRAL
LH
LH
CYLINDER
CYLINDER
RH CYLINDER SHORT FEED PIPE LONG FEED PIPE
OIL IN
TO RH CYLINDER TO LH CYLINDER
SECTION - M VALVE ASSY
(ENLARGED)
OIL IN A A
OIL OUT BELLOW
IBJ
RACK TUBE
RACK (CYLINDER)
Fig. 4
PRESSURE ROTARY VALVE

OIL IN POSITION
PRESSURE
OIL IN RIGHT TURN
PRESSURE
OIL IN
CW
ROTATION
PRESSURE
OIL IN
RETURN OIL
Fig. 5
10
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INDEX GROUP INDEX
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POWER STEERING
PRESSURE
OIL IN ROTARY VALVE
POSITION
PRESSURE
OIL IN
LEFT TURN
PRESSURE
OIL IN
CCW
ROTATION
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.
11
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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
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POWER STEERING
DISENGAGEMENT OF OBJ FROM STEERING ARM
OBJ LOCK NUT INNER BALL JOINT END
OUTER BALL JOINT
STEERING ARM
BALL PIN NUT
REMOVAL OF OBJ FROM IBJ END
SPANNER
LOCATION
Fig. 7
MINOR REPAIRS ON POWER RACK & REMOVAL OF OUTER BALL JOINTS Fig. 7
PINION & PINION STEERING GEAR Raise the front of the car and support it on a safety
STEERING GEAR stand in the proper location.
This section covers only minor repairs that do not Remove the front wheels
require complete dismantling of steering gear Unscrew the ball pin nut of the Outer ball joint (RH
assembly. side & LH side) and using puller part no. 2702 5890
CAUTION : 4602, remove the Outer ball joint from the steering
arm (knuckle arm). POWER
The minor repairs should be handled only by proper STEERING
trained personnel who have proper equipment, tools, Hold the Inner ball joint with 14mm spanner and loosen
instructions and know-how and authorised to perform the lock nut with 17mm spanner to free the ball joint.
the work properly and safely. Now unscrew the Outer ball joint out of the Inner ball
REPLACEMENT OF OUTER BALL JOINT (OBJ) joint (Tie rod) assembly
ASSEMBLY. Discard the Outer ball joint assembly.
NOTE : ASSEMBLY OF OUTER BALL JOINTS
The outer ball joint assemblies must be replaced if Screw in the new Outer ball joint assembly on the
either of the following conditions are detected. Inner ball joint (Tie rod)
1. Any binding in articulation of the ball pin. Align the steering gear in mid position to straight ahead
2. Any axial play between the ball and cup of Outer position (SAP) of the steered wheels.
ball joint Assy, more than 0.1 mm at + 100 gms. Connect the Outer ball joints with the steering arm
The replacement of Outer ball joint can be done on Tighten the ball nut to specified torque.
the vehicle itself without removing the steering gear Install the front wheels and lower the front of the car.
from the vehicle as explained below : Carry out wheel alignment. Now tighten the outer ball
joint lock nut to specified torque.
13
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POWER STEERING
ASSEMBLY OF BELLOW
BELLOW STRAP
BELLOW CLIP
GROOVE TO LOCATE SMALL BELLOW CLIP

END OF BELLOW
HOUSING
BELLOW
DOLLY
PULL OUT
Fig. 8
REPLACEMENT OF BELLOWS : Fig. 8 Pull out the bellows away from the ends of the steering
gear box along with clip.
For better access and convenience to replace the
bellows properly, remove the steering gear assembly Discard the bellow/strap & clip.
from the car as per procedure in the Mechanical
Clean the outer surface at the ends of the steering
Steering Group of this Manual.
gear and Inner ball joint assembly.
CAUTION :
ASSEMBLY OF BELLOWS
steering gear. Clean the outer surface of the dolly (Taper guide tool)
and insert it on the Inner ball joint Assy.
2. Use only Special Tools and do not hammer to
remove outer ball joints from steering arm Apply grease (dow corning) on the groove of both the
(knuckle arm) tie rods.
3. Take care to avoid damage to bellows, feed pipes Assemble the bellow clip on the small end of the
and input shaft when drawing out the steering bellow.
gear assembly from the car. Keeping the rack in mid gear position slide the bellows
Mount the steering gear on a mock up bracket. on the dolly big end first till the small end of bellow
locates on the greased groove.
REMOVAL OF BELLOWS
Assemble the big end of the bellows over the ends of
Remove the Outer ball joint assembly after loosening the steering gear (Housing & Rack tube) ensuring no
the lock nut. Unscrew out the lock nut (Refer twist to the bellows.
Replacement of Outer ball joint for removal procedure).
Using the strapping gun, strap the big end of the bellow
Remove the bellows straps and discard. firmly to ensure proper sealing.
14
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POWER STEERING
REMOVAL OF INNER BALL JOINT ASSEMBLY
INNER BALL JOINT
RACK
SPUTNIC WRENCH
ASSEMBLY OF IBJ
NOTCH FOR IBJ

INNER BALL JOINT
STAKING
Fig. 9
CAUTION : REMOVAL OF INNER BALL JOINTS Fig. 9

If the strapping is not sound means possibility of rusty Remove the steering gear assembly from the car (Refer
gear/entry of dust/water ingress/lack of lubrication. Steering group of this Workshop Manual).
Slide the rack to right and left by turning the Input CAUTION :
shaft to be certain that the bellows are not deformed 1. Plug the ports tight with protective caps in the
or twisted. steering gear.
POWER
Screw in the lock nut and Outer ball joint assembly 2. Use only Special Tools and not hammer to STEERING
on the Inner ball joint. Dismount the steering gear remove Outer ball joints from steering arm
assembly from the mock up bracket. (knuckle arm)
Reinstall the steering gear on the car. 3. Take care to avoid damage to bellows, feed pipes
REPLACEMENT OF INNER BALL JOINTS and input shaft When drawing out the steering
ASSEMBLY (IBJ’S). gear assembly from the car.
NOTE : WARNING :
The Inner ball joint assembly must be replaced if either Improper tightening of Inner ball joint assemblies will
of the following conditions is detected. cause accident.
1. Any binding in articulation of the Ball rod (tie rod) Mount the steering gear assembly on a mock up
bracket.
2. Any axial play between the ball and cup of Inner
ball joint assembly, more than 0.1 mm at + 100 Remove the outer ball joints and bellows on the LH
gms. side and RH side of the steering gear (Refer
Replacement of Outer ball joint / Bellows for removal
procedure).
15
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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 same and replace with new ones only.
rack surface. Using sputnik wrench, unscrew the Inner
Remove the steering gear assembly from the car.
ball joint assembly from the ends of the rack.
CAUTION :
Discard the Inner ball joint assembly.
ASSEMBLY OF INNER BALL JOINT
steering gear.
Screw in the new Inner ball joint assembly to the ends
2. Use only Special Tools and not hammer to
of the rack by hand.
remove Outer ball joints from steering arm.
Hold the rack suitably taking care not to damage the
surface. Using Sputnik wrench, tighten the Inner ball
and Input shaft when drawing out the steering
joint assembly to 8 kg-m torque.
gear assembly from the car.
Stake the Inner ball joint (RHS & LHS) using a punch
Carefully unscrew the flare nuts at the ends of
against the notch on both the ends of the rack.
the short/long feed pipes connected to housing
Reassemble the bellows and Outer ball joint (Refer and rack tube ends using 11 mm spanner.
Replacement of Outer ball joint/Bellows).
Discard the feed pipes.
Dismount the steering gear from the mock up bracket.
Blow clean the inside of the new feed pipes (short/
Reinstall the steering gear on the car.
long) with compressed air.
REPLACEMENT OF FEED PIPES (SHORT/
Install the feed pipes (short/long) by screwing
LONG) Fig. 10
the flare nuts at the ends to housing and rack
CAUTION : tube by hand.
Do not attempt to repair any bent or damaged feed Now tighten the flare nuts to 1.7 kg-m torque.
pipes. Whenever feed pipes are removed discard the
Reinstall the steering gear assembly on the car.
16
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POWER STEERING
REMOVAL OF INPUT SHAFT SEAL ASSEMBLY OF INPUT SHAFT SEAL
CIRCLIP PRESSING TOOL

PART NO. 2702 5890
INPUT SHAFT SEAL
4605.
INPUT SHAFT SEAL
SEAL GUIDE TOOL
PRESSURE PORT
RETURN PORT
Fig. 11
REPLACEMENT OF INPUT SHAFT SEAL Disconnect the air pressure supply as soon as the
Fig. 11 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. Determine by inspection that seal bore is in good
condition.
2. Use only Special Tools and not the hammer for
POWER
removing the outer ball joints from knuckle. Clean the seal guide tool and insert it on the input STEERING
shaft covering the serration.
3. Take care to avoid damage to bellows, feed pipe
and input shaft when taking out the steering gear Apply power steering fluid on the input shaft seal and
from the car. slide it down the seal guide tool into the housing bore
with lip facing down. Using seal pressing tool part no.
Mount the steering gear assy. on a mock up bracket 2702 5890 46 05, press the seal till it butts on the
with Input shaft facing upwards. bearing face.
Using circlip plier remove the input shaft seal retaining Using circlip plier compress and engage the circlip in
ring. the bore of the housing. Now remove the circlip plier
Unplug the return port and hold the clean cloth around and using a drift, press the circlip until it locates in the
the input shaft and apply air pressure to the return groove of the housing bore.
port. 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.
17
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POWER STEERING
ON - CAR SERVICE - INSPECTION & MAINTENANCE

STEERING WHEEL 1
8
RESERVOIR
COLUMN ASSEMBLY JOINT. 7
PRESSURE LINE SUCTION LINE
PUMP 8
RETURNLINE
PULLEY
INTERMEDIATE ENGINE
JOINT
5
LOCK 9
POWER RACK &
2 NUT
PINION STG. GEAR
BELLOW 4 BALL PIN

BELLOW 6
CLIP 3 STRAP FEED NUT
BELLOW PIPE - LONG FEED PIPE - SHORT
Fig. 12 Power rack & pinion steering system

1. STEERING WHEEL PLAY replace with new one. Ensure Feed pipes do not
With Engine off and front wheels in Straight Ahead foul with each other (or) on any part of the vehicle.
Position , check for any free play at steering wheel 5. PUMP/DRIVE BELT
without moving the front wheels.
Engine driven belt drive Pump. Never run the pump
There should be no free play but only the feel of dry. Check Pump belt condition and proper tension
the Torsion bar twist in the stg. gear. With hands atleast once in a fortnight.
off stg. wheel, the reaction of torsional twist will Adjust tension as recommended.
bring the stg. wheel back to the original position.
If any play is detected, check for 6. STG. GEAR MOUNTING
1. Looseness in Stg. Joints / Links Check for any interference (or) condition that may
cause the gear to distort due to improper mounting
2. Yoke adjustment in stg. gear. / tightness. Correct if required.
2. INNER BALL JOINT (TIE ROD) 7. POWER STEERING OIL

SWING RESISTANCE Use only genuine. Power Stg. oil. Never run the
After disconnecting Outer ball joint from stg. arm Engine without oil in the Reservior. Check oil level
give ten hard swings to Inner ball joint to feel swing with Engine running and maintain between Min. &
resistance, If swing is tight replace the Inner ball Max. mark.
joint. Use specified oil. Follow the oil and filter change
schedule.
If swing is smooth and there is no play between
8. HYDRAULIC LINES
the ball and cup of Inner ball joint, it may be used.
Check the Hydraulic lines (Hoses/Pipes) of the
3. BELLOW / STRAP / CLIP
system for damage, Correct as required. for leak
Check Bellow for Crack (or) Damage, Replace if proof connection and smooth flow without
any. Check for proper crimping of Bellow by Strap/ restriction.
Clip.
9. OUTER BALL JOINTS
CAUTION :
Defective Bellow and loose crimping means possibility Check the boot condition for crack/damage. Check
of rusty gear, entry of dust or lack of grease. for play in the ball joint. If any of the above exist,
replace with new one. Check Outer ball joint lock
4. FEED PIPES
nut & Ball pin nut tightness.
Check Feed pipes for damage (or) bend. If any,
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POWER STEERING
POWER STEERING GEAR - EXPLODED VIEW :
LIST OF PARTS 17 ROLLER BEARING

No. DESCRIPTION 18 SEAL - INPUT SHAFT
1 HOUSING & TUBE ASSY 19 CIRCLIP
2. SEAL - RACK (HOUSING) 20 YOKE POWER
3. BALL BEARING 21 YOKE SPRING STEERING
4. SEAL - PINION SHAFT 22 YOKE COVER

5. BEARINGNEEDLE ROLLER 23 INNER BALL JOINT
6. RACK & PISTON ASSY. 24 BELLOW
7. PISTON SEAL RING 25 BELLOW CLIP
8. ‘O’ RING 26 BELLOW STRAP
9. LOCK STOP 27 RUBBER MOUNT BUSH
10 RETAINING RING 28 REAR MOUNT COLLAR
11 LINER 29 RUBBER MOUNTING
12 ‘O’ RING 30 MOUNTING CLAMP
13 SEAL - RACK (L/S) 31 FEED PIPE ASSY. - LONG
14 PISTON & VALVE ASSY. 32 FEED PIPE ASSY - SHORT
14A VALVE SEAL RING 33 AFTER BALL JOINT ASSY.
NOTE : INSTALL NEW SEALS
15 NUT - PINION 33A OBJ LOCK NUT
WHENEVER THE GEAR IS
16 PINION COVER 33B NYLOC NUT (OBJ BALL PIN)
DISMANTLED FOR REPAIR.
Fig. 13
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POWER STEERING
POWER STEERING SYSTEM - HYDRAULIC TESTS USING DIAGNOSTIC GAUGE
Diagnostic Gauge
Power Stg. Pump
Column Assembly Pressure Line
Suction line
Intermediate Joint
Return Line
Engine
Rack & Pinion Power Stg. Gear
Fig. 14
GENERAL 2. Steering Gear - Internal leakage
The Diagnostic Gauge is designed to conduct on PREPARATION OF HYDRAULIC SYSTEM
vehicle hydraulic tests in Power Steering System for
a detailed trouble shooting when all other aspects Install Diagnostic Gauge in the pressure line (fluid
checked prove satisfactory. supply line from Pump to Steering Gear).
The Diagnostic Gauge comprises of a PRESSURE Check and top up oil in Reservoir. Bleed the system
GAUGE, FLOW METER, SHUT OFF VALVE AND as per procedure (Refer page 6).
HOSES provided with quick coupling for easy Place a thermometer in the Reservoir to record
connection. Fig. 14 temperature. With the shut off valve of Diagnostic
Using this Diagnostic Gauge, we can check the Gauge fully open, warm up the hydraulic system by
following and compare to specification of the system. partially closing the shut off valve until the pressure
gauge reads 100 PSI (7 bar). When the temperature
1. Pump Performance Check reads 51.70 C and 57.20 C open the valve.
a. Flow The system is now warmed up and ready for
b. Relief Pressure conducting the hydraulic test.
c. Pump response
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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 Keeping an eye on the flow meter, look for instant
the Shut off valve of Diagnostic Gauge. System return of flow rate to recommended flow range from
pressure not to exceed the relief pressure specified zero when shut off valve is opened from the closed
(Refer vehicle manual) for the system. position both at idling and governed speed. Conduct
CAUTION : Do not keep the shut off valve closed for the test once at idling speed and three times at Engine
more than 5 seconds at a time to avoid damage to governed speed.
the pump. If the flow rate does not return immediately the Pump
Measure and record in table below the flow, pressure is malfunctioning and can result in momentary loss of
and temperature at idling and governed speed with power assist. The Pump needs to be repaired or
shut off valve in fully opened and closed condition (with replaced.
hands off the steering wheel). Test No. 3
STEERING GEAR INTERNAL LEAKAGE TEST
Engine Shut off PressureFlow Temperature Comment
Speed valve First conduct Pump performance test and confirm that
condition the Pump is working satisfactorily.
Idling Open A With shut off valve open and at steady idling speed of
Speed Closed B Engine, turn the steering wheel to any wheel lock end
Governed Open A and apply force at the rim of the steering wheel to be
sure that the control valve is fully closed.
Speed Closed B
The Pressure gauge should now read maximum
Compare minimum/maximum flow and maximum pressure (relief pressure) specified for the pump.
pressure (relief pressure) recorded with specification
If it reads appreciably less than the relief pressure, it
and refer appropriate comments below for corrective
indicates reduction in power assistance because of
action. If it meets the specification, proceed to Test
excessive internal leakage. Repair or replace the
No. 2.
Steering gear.
COMMENTS
Repeat this test at the opposite wheel lock.
A. (i)steady state fluid pressure (with hands off
CAUTION : Don’t hold the steering wheel in the full
steering wheel) should be equal to or less than that
turn position (lock end) for more than 5 sec. to avoid
specified for the system. POWER
damaging the Pump. STEERING
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 Note :
any clogging.
1) When hydraulic tests are completed and fluid lines
(ii) If the measured flow is less than the specification are reconnected check fluid lever and bleed the
the Pump needs to be repaired (or) replaced. system.
2) For power steering wheel alignment values refer
B. (i)If maximum system pressure (relief pressure)
page 9 of mechanical steering group.
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: With shut off valve closed, the flow drops
to zero and should not be closed for more than five
seconds.
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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 Wheel Noise / Direction

Steering kick/Shock/ Vibration Pull
Vibration
Road wander / Poor Reduced External

Lash in Self Centering Wheel Turns leaks
Steering
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POWER STEERING
• Won’t turn • Lock up/stuck up

HARD STEERING • Not enough Power assist • Won’t turn unless moving
• High effort to steer • Sticky/binding

Present during cold Some power steering pumps have Increase engine speed briefly to
start only temporary state, when pump correct the problem
element vanes are sticky
Sensitive to steering Air drawn in due to insufficient fluid Add fluid and bleed the system
wheel speed. per filling and bleeding procedure
More prevalent when Air being sucked in through cracks Replace/correct the crack/
steering fast or loose fittings/hose / pipes in loose fitting , hoses, pipes in
suction line suction line fill and bleed the
system as per procedure
Flow From the pump is less than Repair (or) replace the Pump.
minimum recommended for
steering gear.
Steady state fluid pressure (with Clean/replace the clogged/

hands off steering wheel) at idling deformed hydraulic lines as
with shut off valve fully open, is required.
high, due to clogging/deformation
of feed and return hydraulic lines
Present only in one Unequal tyre pressure Inflate both steered wheels to
direction of turn equal specified pressure. POWER
STEERING
Feed pipe to concerned cylinder is Replace the deformed feed pipe
deformed
Excessive internal leakage in one Repair or replace the steering gear

direction of turn only (verify with
internal leakage test)
Present in both the Low tyre pressure Inflate both steered wheels to
direction of turn equal specified pressure.
Low hydraulic fluid Check and rectify external leak if
any. Top up the oil and
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POWER STEERING
bleed the system (if required)

Improper rotation or binding in Determine by Inspection what
column related parts interference or condition is causing
binding and correct the problem.
Low pressure or flow from Pump Check pump performance. Repair or

replace as required.
Faulty steering joints Replace the joints
Faulty steering link components Determine by inspection. Identify

like inner/outer ball joints etc. 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 Replace Steering gear assembly.

assembly
Feed pipes to both the cylinders Replace the Feed pipes

deformed
Excessive internal leakage Repair or replace the Steering

gear as required.
Restriction in return line or line too Clear restriction/kinks, if hoses

small in diameter are same as OE. If not replace the
return line with specified one. Fill
and bleed the system as per
procedure.
Oversize tyres Check specifications and replace with
recommended size tyres
Present as intermittent Pump drive belt slip or worn out Adjust belt tension or replace belt
loss of power belt and adjust as required
assistance
Pump malfunctioning as no Repair or replace the pump as

immediate return of flow rate on required
opening the load valve from closed
position.
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POWER STEERING
STEERING WHEEL • Kick back • Bump steer

KICK/ SHOCK/VIBRATION • Rough Steering • Vibration in steering wheel
Prevalent when Engine idling speed low/erratic Adjust the engine speed for steady
turning at low speeds, tending to stall when the steering idling rpm.
particularly at rough wheel is turned affecting steady
roads or turning at minimum flow from pump.
engine idle speed while
car is stationery. Air in the system or Power If oil level is too low, look for
Steering oil too low. external leak. If any, correct & fill
oil and bleed the system.
Looseness or lash in steering Determine by inspection from
system that may be drifting under steering wheel to steered wheels,
load when turning. links/joints/mountings for
looseness/wear/ crack. Renew/
replace the affected part (s).
Improperly adjusted Steering Gear. Adjust the Rack guide to
May be Rack guide (Yoke) has Specification. If problem is not
backed off excessively or worn. corrected, replace the Steering gear.
Front shock absorber/ Replace the defective shock
suspension strut malfunctioning. absorber/suspension strut.
Vibration / shock / kick Pump stops momentarily due to Adjust the belt tension to
felt when turning the belt slipping on drive pulley. specification.
steering wheel to lock.
POWER
COMPLAINT AS MAY BE NARRATED BY THE CUSTOMER STEERING
REDUCED WHEEL TURN • Very high turning • Not enough turn from centre to lock
radius required
• Wheel cut restricted • Unequal number of turns from centretolock

No. of turns not equal Steering Gear mid position not Allign the Steering Gear mid
from centre to lock aligned to straight ahead condition position to straight ahead condition
(with Power Off of steered wheels. of steered wheels. Do the wheel
condition). alignment to the specification.
Bend in steering links due to heavy Determine by inspection the
impact load/accidents. affected steering link and replace
with new one. Do not attempt to
straighten the bend on the links.
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POWER STEERING

DIRECTIONAL PULL • Vehicle pulls to one side • A constant force needed
to hold steering

Pulling felt while Unequal braking force on steered Check and adjust the brakes of
braking only wheels steered wheels. Replace the
brakes if necessary
Uneven or badly worn tyres Replace the tyre
Pulling prevalent Deflection in suspension or Determine by inspection the
while accelerating steering links suspension and steering links and
only replace affected parts
Wheel bearings improperly Check and adjust to specifications
adjusted
Unequal tyre pressure on front tyres Inflate the front tyres to equal
pressure
Improper wheel alignment Check and correct wheel
alignment
Constant force is Motoring (automatic steering) due Replace the Steering gear
required to hold to unbalanced control valve in
steering wheel Steering gear

ROAD WANDER / LASH • Lash in steering • Constant correction is
IN STEERING • Lost motion in steering needed at steering
wheel to keep the
vehicle from wandering

Vehicle wanders Uneven or extreme tread wear Replace tyres with new one
requiring constant
correction at steering Unequal tyre pressure on steered Correct tyre pressure to
wheel wheels specification
Lash in steering due to any Determine by inspection to identify
looseness or wear or cracked the cause for lash and tighten or
components from steering wheel to Replace the affected component as
road wheels (Steering wheel, necessary
steering column, joints, inner/
outer ball joints)
Steering gear rack guide Adjust rack guide to specification
adjustment improper/disturbed -
Backed off excessively.
Wheel alignment out of Correct wheel alignment to
specification specification
Wheel bearings not adjusted Adjust or replace the bearings as
properly or worn out necessary
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POWER STEERING

POOR SELF CENTERING • Steering does not return • Steered wheels don’t
smoothly return to straight ahead
• Poor self centering position
Resistance or binding Poor tyre condition/uneven tyre Replace with good recommended
felt preventing wear/mismatched tyres tyres, inflate to specified pressure
smooth/quick return
of steered wheels
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 Determine by inspection the cause
with any other part during steering for rubbing/interference and
movement. correct the same
Improper mounting causing Remove the Steering gear and
distortion to Steering gear. determine by inspection what
interference or condition is causing
the gear to distort and correct the
problem.
Deformed/damaged Feed pipes Replace the Feed pipes
on Steering Gear
Input torque high due to improper Remove the Steering gear. Check POWER
STEERING
adjustment of Steering gear. and adjust Rack guide adjustment
to specification. If the problem is not
corrected, replace the Steering gear.
Binding in Steering axle (Upper/ Determine by inspection and
lower links) renew/replace Steering axles/
links/bushes / ball joints
Insufficient oil flow to steering Repair or replace the Pump if flow
gear for adequate steering speed. is less.
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POWER STEERING

NOISE AND VIBRATION • Humming noise while • Clicking sound while
steering steering
• Squealing noise • Hissing noise
• Rattling noise
Humming noise that This is not a defect. The noise is -
increases with engine due to pulsation of fluid when the
speed pump is running which is normal
Hissing noise when This is not a defect. The noise is -
turning right or left due to actuation of Flow Control
Valve during steering operation
which is normal.
Noise evident when This is not a defect. This noise is Caution : Do not hold the wheels
wheels are held on from the relief valve in the Pump at full lock for more than 5 seconds
full lock.
Gratting noise from Cavitation caused by air bubbles in Check fluid level in reservoir. If
pump the fluid, due to low or insufficient low top up the oil. Correct external leaks,
oil in system 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 Low belt tension or worn out belt Tighten the belt or replace as
pump necessary
Abnormally loud Pump internals excessively worn out or Replace the pump
noise from pump damaged
Rattling or chattering Loose pump pulley Tighten or replace the pulley. If
noise shaft is found damaged, replace
the Pump
Loose or worn steering columns/ Tighten or replace the parts as
intermediate joints necessary
Loose inner or outer ball joints Tighten to replace the parts as
necessary
Rack guide adjustments improper Adjust to specification if not
or disturbed. corrected, replace the Steering
gear
Clicking noise heard Some component is loose and Determine by inspection, tighten or
during a turn or when shifting under load replace if necessary
changing direction
Vibrating Noise Unclamped/Rubbing/damaged/ Determine by inspection and
deformed pipe lines correct or replace if necessary
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EXTERNAL LEAKS • Loss of steering fluid • Oil puddle under vehicle

• Frequent adding of fluid after parking
is required • Leak at steering gear /
• Oil wetness pump/reservoir
Leak through fittings/ Improper tightness of fittings Tighten and clamp suitably to
sealing washers avoid loosening under vibration
End fitting/Sealing washer is Replace the end fittings/sealing
damaged or cracked due to washer & tighten properly
improper tightening
Leak through hoses Loose connection Tighten & clamp suitably
Heat or age cracks Replace the hose with new one
Twisting or Abrasion wear due to Replace the hose & route and
improper routing/fouling/kinking/ clamp suitably
twist
Leak through Foaming or oil throwing out due to Check proper connection of
Reservoir air in the system suction line. Fill and bleed the
system.
Reservoir is overfilled. Drain the oil in reservoir to proper
level
Broken or cracked bracket/cover/ Replace the reservoir assembly
shell of reservoir due to improper with new and clamp properly
clamping/vibration
Leak through Pump Through shaft seal, due to defective seal Remove the seal. If seal bore is OK,
hardened or cracked Fill and bleed the system. replace with new seal.
seal. If it still leaks, replace the pump.
Leak through Pump assembly Replace the seals/ “O” rings. If it
POWER
housing/ cover/ joint face seals/ still leaks, replace the pump. STEERING
“O” rings
Leak through Leak through Input shaft seal Remove input shaft seal. If seal
Steering Gear Assy. bore is OK, replace the seal with
new one.
Leak from Cylinder (Rack tube) Replace the Rack seal using
through Rack seal into right/ left special tools taking care not to
bellows. cause any damage/scorings to
inner walls of Cylinder (Rack tube)
Leak through pinion seal in valve Replace pinion seals using special
housing into RH bellows. tools.
Leak through feed pipes Tighten the connection properly.
connection to Rack tube at flare
nut.
Cracked/damaged feed pipes Replace feed pipes.
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WHEEL AND TYRES
NEXT
GROUP INDEX
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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
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WHEELS AND TYRES
CONTENTS
1. Technical specification
a. Tyres 1
b. Wheels 1
2. Tightening Torque 1
3. Exploded Views :
a. Steel Wheel Rim 2
b. Alloy Wheel Rim 3
4. 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
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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 accel-
eration, 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
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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)

WHEEL RIM (4.50J X13) (for LEi & LSi versions)
TYRE 175/60 R14 (for LX & LXi versions)
TYRE 165/65 R13 (for LEi & LSi versions)
ASSEMBLY KNOB (SPARE WHEEL)
WHEELS
AND
TYRES
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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
BALANCE WEIGHT 5gms TO

TYRE 175/60 R14 (for LX & LXi versions)
140 gms IN STEPS OF 5 gms
TYRE 165/65 R13 (for LEi & LSi versions)
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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 To measure wheel runout, it is necessary to use an
be of the same size, load range and construction as accurate dial indicator. The tyre may be on or off the
those originally on the vehicle. Use of any other size wheel.The wheel should be installed on a wheel
or type tyre may affect ride, handling, speedometer/ balancer for proper measurement.
odometer calibration, vehicle ground clearance and tyre
clearance to the body chassis. Take measurements of both lateral runout and radial
runout at both inside and outside of the rim flange.
It is recommended that new tyres be installed in pairs With the dial indicator set in place securely, turn the
on the same axle. If necessary to replace only one wheel on full revolution slowly and record every
tyre, it should be paired with the tyre having the most reading of the indicator. (fig 1)
tread, to equalise braking traction. Also do not mix
different types of tyres (viz. radial, bias etc) on the When the measured runout exceeds the specification
same vehicle, because it badly affects the handling of and correction by the balancer adjustment is
the vehicle. impossible, replace the wheel. If the reading is affected
by welding, paint or scratch, it should be ignored.
Replacement of wheels :
Radial Lateral
Wheels must be replaced if they are bent, dented, runout limit runout limit
have excessive lateral or radial runout, air leak through
welds, have elongated bolt holes, if wheel bolts will Steel wheel 1.14 mm 1.4 mm
not stay tight, or if they are heavily rusted. Wheels / alloy wheel (0.045 in) (0.055 in)
with greater runout than specification may cause
vibrations.
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
1.Radial Runout 1
2.Lateral Runout
* Ignore high points due to welds,
scratches, etc.
Fig 1.
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WHEELS AND TYRES
Matched tyres and wheels :(Provisional) Paint Paint
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 Fig 2
paint dot as shown in the fig2. Whenever a tyre is
dismounted from its wheel it should be remounted so Valve caps should be on the valves to keep dust and
that the tyre and wheel are matched. If the tyres paint water out.
dot cannot be located, a line should be marked on the
tyre and wheel before dismounting to assure that it is Lower than recommended pressure can cause :
remounted in the same position.
1. Tyre squeal on turns.
Inflation of tyres : 2. Hard steering
The pressure recommended for any model is carefully 3. Rapid and uneven wear on the edges of the tread
calculated to give a satisfactory ride, stability,
steering tread wear, tyre life and resistance to bruises. 4. Tyre rim bruises and rupture
Tyre pressure with tyres cold, (after vehicle set for 5. Tyre cord breakage
three hours or more or driven less than one mile) should
be checked monthly or before any extended trip. It is 6. High tyre temperature
normal for tyre pressure to increase (0.28 bar, 4 psi)
when the tyres become hot during driving. Do not 7. Reduced handling
bleed or reduce tyre pressure after driving. Bleeding
reduces the Cold inflation Pressure. 8. High fuel consumption WHEELS
AND
Front Rear TYRES
Tyre Rotation :
LX & LXi (14 Rim) 28 psi 24 psi
LEi & LSi (13 Rim) 30 psi 28 psi To equalise wear, rotate tyres according to Fig 3
periodically. Set tyre pressure.
Higher than recommended pressure can cause :
1. Hard ride NOTE :
2. Tyre brushing or carcass damage
3. Rapid tread wear at center of tyre Due to their design, radial tyres tend to wear faster in
the shoulder area, particularly in front positions.
Unequal pressure on same axle can cause :
1. Uneven braking
2. Vehicle pull
3. Reduced handling
4. Swerve on acceleration
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WHEELS AND TYRES
This makes regular rotation necessary. Do not use

Trye Rotation with Steel Wheel Rim
spare steel wheel rim for tyre rotation, when vehicle is
fitted with alloy wheel rims.
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 (Spare Wheel with
Fig 4 and to proper torque to avoid bending wheel or Steel Wheel Rim)
brake disc.
Fig 3 (RHD)
NOTE :
1
3
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 manufacturers instructions.
Do not use hand tools or tyre irons alone to change 4
tyres as they may damage tyre beads or wheel rim.Rim 2
bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, old rubber and Fig 4
light rust.
WHEELS
After mounting, inflate to specified pressure so that
AND beads are completely sealed.
TYRES
Warning :
Do not stand over tyre when inflating. Bead may break

when bead snaps over rims 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.
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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
Deposits of mud, etc.must be cleaned from inside of C / L OF SPINDLE
rim. HEAVY SPOT
WHEEL TRAMP
Warning :
Remove stones from tread, clean the tyre and rim before Fig 5.
balancing for safety to achieve better results.
Each tyre should be inspected for any damage, then

balanced according to equipment manufacturers
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
1) Permissible imbalance for assembly tyre with rim, AND
95 gmcm Max. TYRES
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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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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CONTENTS
A. Tightening torques 1
B. Precautions :
1. Instructions to be followed while removing, installing & handling air bag modules 2
2. Safety Precautions 2
3. General Precautions 3
C. 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 BODY
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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CONTENTS
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
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A. TIGHTENING TORQUES :

No. (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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B. PRECAUTIONS not even connect multimeter or other electrical

measuring equipments to the inflators.
1. Instructions to be followed while 11. Do not try to open, repair or dismantle the air
removing, installing and handling bag module.
of air bag modules.
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. Always wear safety glasses when repairing an belt pre-tensioners as well.
air bag Supplementary Restraint System (SRS)
vehicle and when handling air bag module. 2. SAFETY PRECAUTIONS
3. Carry a live air bag module with air bag Some important precautions need to be taken while
deployment door pointed away from your self and handling air bag units. They are as follows :
others. This will reduce the risk of injury in the
event of an accidental deployment. Service
4. Do not keep a live air bag module with the • The inflator is intended not to fire below the
deployment door faced down. threshold current. To avoid inadverdent triggering
of the air bag, NEVER apply a current through the
5. Do not lift the module by connected wires and squib except with the specified test equipment
cable harnesses. and procedures
6. After deployment, the air bag surface can contain • The system has backup power for about 30
propellent residue. Wash your hands with soap seconds after the battery is disconnected. Wait
and water afterwards. for at least ONE minute after disconnecting the
battery before servicing the vehicle to prevent
7. Never probe the connectors on the air bag module accidental deployment and personal injury.
Doing so can result in air bag deployment which
will lead to personal injury. • Never dispose the air bag module un-deployed
without proper instructions as this may result in
8. Air bag modules with discolored or damaged possible injury. All deployments must follow
deployed doors must be replaced & should not special instructions to be safe. All units shall be
be repainted. activated (deployed) prior to disposal. It is
recommended that the module assembly be
9. To avoid accidental deployment and possible dismantled for recycling of the individual
personal injury, the backup power supply must components. The gas generator after activation
be depleted before repairing or replacing any air can be scrapped as metal or depending on
bag Supplementary Restraint System (SRS) design, recycled for reclamation of steel and
components. To deplete the backup power aluminium. The air bag modules or their
supply energy, disconnect the battery ground components must not be adapted or installed in
cable and wait for one minute. Be sure to any other vehicle other than the specific vehicle
disconnect auxillary batteries and power for which they are designed and manufactured.
supplies (if equipped) as well. Any attempt to adapt or install air bag modules or
their components in any other vehicle can result
10. Do not apply or connect electric current to the in personal injury to the occupants in the event of
module except as specified for installation. Do accidents.
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• Vehicles should not be fitted with additional • If the air bag cover has opened during transport or
protective devices like bull bars etc. handling, the air bag must be returned to the
supplier.
Storage
• Do not attempt to refold the bag into the cover.
• Store air bag module in a dry, cool and secure Deployment protection may be compromised or
area. injury may be induced. This is because foreign
objects could enter the bag, or the vehicle
• Deployed air bags are safe to handle and may be specific bag-folding pattern could be altered from
stored as scrap material or in accordance with its original optimised design.
company policy.
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, prefer-
ably 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 pre-

tensioner 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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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. HOOD LATCH CABLE a) Insert the loose end of the cable into the passenger
cabin through the opening in the firewall (2).
REMOVAL : (RHD) Fig 1.
b) Fit the end of the cable to the hood latch release
a) Open the hood (bonnet) and support it on the stay lever (1).
rod.
c) Route the cable to pass along the wheel arch and
b) Remove the end of the cable from the hood latch under the member radiator support top, as shown
release lever (1) in the passenger cabin. in Fig 1.
c) Pull out the cable through the firewall (2) from the d) Fit the loose end of the cable to the hood latch
engine house side (3).
d) Remove the end of the cable from the hood latch e) Finally strap the cable to the bowden clip (ref.
(3). section A - A)and snap the bowden clip to the
e) Unclip the bowden clip (4) and pull the cable free member radiator support (4) as shown in Fig 1
from the vehicle. and section A - A.
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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 Fig 2
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 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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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
1 2
order but tighten all the mounting screws to the STAY 3
specified torque. ROD 4
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 8
ROD
Fig 6
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PANEL HOOD INNER
HOOD INSULATION
Fig 7
4. HOOD INSULATION : c) Finally fix the 14 numbers of hood insulation clips

(2) at the location (shown in the fig) to hold the
REMOVAL : FIG.7 hood insulation to the inner panel firmly.
a) Open the bonnet and support it on the stay rod.
b) Remove the 14 clips that support the hood
BODY
insulation to the hood shell and remove it.
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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BODY
5. FIXING OF WIND SCREEN GLASS & Materials Required :

TAIL GATE GLASS 1. Cleaner Betaseal 43518 - for glass & body shell.
The glasses are directly pasted to sheet metal flanges 2. Primer Betaseal 43520A - for glass.
using sealant. We give below the Equipment /
3. Primer Betaseal 43533AT - for body shell.
materials required and the procedure for fixing the Wind
screen and Tailgate glasses. 4. Sealant Betaseal 58702 - for glass.
Equipments required : Procedure for fixing Wind Screen glass :
1. Pneumatic applicator gun with holding Before fixing the Wind screen glass following
arrangement for sealant cans. preparation needs to be done on glass and body shell
flange area.
2. Vacuum cups for holding glasses.
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 Clean the Body shell flange area
43518. Allow it to dry completely. conforming to glass with Cleaner Betaseal
Assemble the rubber mould to the glass. 43518. Allow it to dry completely.
2. Apply a thin & even (Approx. 0.5 mm thick Apply a thin and even coat (Approx 0.5 mm
wet layer) of Primer Betaseal 43520A on thick wet layer) of Primer Betaseal
glass. Allow it to dry for minimum 2 minutes. 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 Repeat the above procedure for Tail gate glass.
body flange from outside. This operation should be
For Tail gate glass, after fixing, use ‘C’ clamps both
done within 15 minutes of the application of sealant
at LHS/RHS side for holding the glass with flange.
on the glass.
After mounting the glass, the same has to be pulled
Tailgate Glass
towards inside of body with the help of vacuum cups.
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
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6. OUTER REAR VIEW MIRROR :

REMOVAL :
a) Pull out the inside cover plate with rubber boot of
the RH side RVM. 1
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 . 3
d) Similarly remove the RVM from LHS. 2
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. FRONT DOOR TRIM : Fig 10

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 1
5
Door trim i.e screws no. 1 2 & 3 Fig 11 6
4 7
e) Take out the Speaker cover and remove the
mounting screw no. 8 Fig 11
f) Remove the lock ring and pull out the window- 3
winding handle. Fig 12 (only for manual winding) 2
8
g) Pull out the Inner belt mould of the Door. 9
h) Pull out and remove the inner trim from the door.
Fig 11
BODY
Fig 9 Fig 12
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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. 1
c) Tighten all the 8 mounting screws.
d) Fit the Inner belt mould back properly in its groove.
NOTE :
Do not Overtighten the Door trim mounting screws.
2 3
8. FRONT DOOR LATCH :
REMOVAL : (Trim already removed)
a) Remove 3 mounting screws at the side of the Fig 13
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.
LINK FROM
c) Remove the Linkage from latch to link connector. INNER HANDLE
Fig 14 TO THE LATCH
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 LINK FROM LATCH TO LINK
CONNECTOR (PIVOT)
being removed)
LINK FROM
FITMENT :
DOOR LOCK TO
a) Insert the latch from inside. LATCH
Fig 14
b) Tighten the 3 Nos. of mounting screws on the
door.
9. FRONT DOOR LOCK :
c) Connect the linkages from link connector, Door REMOVAL :
outer handle and Door Inner handle by inserting
them into the plastic grooves. (Front Door trim already removed)
a) Pull out the link connecting the door lock and
d) Insert linkage connecting the door lock and the the door latch from the groove from the door lock
latch into the plastic groove in the door lock. Fig 14.
NOTE : b) Remove the Lock ring from inside.
1. Apply little grease on the sliding levers of the c) Take out the lock from outside.
latch. FITMENT :
a) Insert the door lock from outside.
2. Replace the latch if any of the parts is found
corroded or spring is damaged. b) Lock the Door lock in the panel by inserting the
lock ring from inside.
3. Check the links for bends/twisting. c) Insert the link connecting the door lock and the
door latch from the groove.
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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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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) Window winding
b) Also remove the 3 Nos. of mounting screws of regulator screws
the Window winding regulator Fig 18.
c) Pull out the regulator along with the bracket
through the Panel hole from inside.
Fig 18
For removal of Extended Boltable Window Glass

Guide Channel
Positioning Holes
a) Remove the 2 Nos. of mounting bolts of the
1
window glass channel bracket i.e bolt no. 1 & 2
Fig. 19
b) Take out the glass channel from inside. 3
For removal of glass guide rear channel,
a) Remove the 2 nos. of mounting bots of the 2
window glass channel bracket i.e. bolt no. 3 & 4.
Fig. 19.
b) Take out the glass channel from inside. 4
Fig 19
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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 8 9
kept loose as shown in Fig. 20 (For power
regulator connector to be connected to winding
motor)
5. Insert the glass and slide it inside the GRM to
5 6
ensure its free movement.
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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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 8 9
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)
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
Fig 24
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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 Fig 25
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
LINK-1
in the respective plastic clips (Longer linkage in 2 1
the Top clip and the Shorter one in the bottom
clip).
c) Tighten the mounting screws 1 & 2.
LINK-2
3
4
5
Fig 26
BODY
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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 Fig 27
reverse order.
a
For removal of Window glass :
HOUSING DOOR PULL DOOR PULL
REMOVAL : 3 OUTER
( Door Inner Trim already removed) b FRONT
1 DOOR
a) Pull out the Plastic membrane DOOR PULL INNER 2
FRONT DOOR
b) Raise the window glass to half the height. c
c) Remove the 2 mounting screws from the glass
holding bracket on the w/w mechanism (channel)
slider by holding the glass. 4 2
1 2 4
3 1
3
Without power window with power window
Fig 27a
LOCK NUT
WINDOW WINDING HANDLE
Fig 28
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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,
2 3
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.
FITMENT : 1
1. OUTER WAIST SEAL

a) Insert the glass support channel from inside panel 2. INNER BELT MOULD
such that the longer arm is towards the opening 3. QUARTER GLASS
side of the Door.
b) Tighten the mounting screw (i.e screw no. 1, 2 & Fig 29
3) as shown.
c) Slide the Rubber beading with bush on to the 2 3
Channel guide.
FRONT OF CAR
GLASS DIVISIONAL
CHANNEL
BODY
Fig 30
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14. REAR DOOR :

REMOVAL : 1
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) Remove the 2 Nos. of mounting bolts of the

check strap i.e bolt no. 2 & 3. and remove the
check strap. Fig 32
d) Lift the door vertically and remove it.
Fig 32
FITMENT :
Follow the reverse procedure of Removal for Fitment. 4
Removal of Striker ( Both For Front and Rear 4
Door) :
a) Unscrew the 2 mounting screws 4 & 5 with
5 mm Allen key. Fig 33 5 5
b) Pull out the striker.
FOR FRONT DOOR FOR REAR DOOR
Fig 33
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15. REAR DOOR LATCH :

REMOVAL :
3
(Trim already removed)
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 22222222222
2
4
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 1 5
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)
FITMENT :
a) Insert the latch from inside.
b) Tighten the 3 Nos. of mounting screws on the
door.
2
c) Connect the linkages from link connector, Door
outer handle and Door Inner handle by inserting
them into the plastic grooves. 1
Fig 33b
1 BODY
3
3
LINK FROM LATCH TO
DOOR OUTER HANDLE
Fig 33a Fig 33c
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16. SUPPLEMENTARY RESTRAINT CAUTION :

SYSTEM • Airbag systems components get hot after
DRIVER AIRBAG (standard) inflation. Do not touch them after inflation.
PASSENGER AIRBAG (if fitted) : • The smoke could cause breathing problems for
The vehicle is fitted with an airbag for the driver, people with a history of asthma or other breathing
located in the steering wheel, and a passenger airbag trouble. If such a case occurs after deployment
(if fitted) is located above the glove box compartment. of airbag, get fresh air promptly.
Vehicles fitted with airbag can be identified by the
“AIRBAG” label on the steering wheel. The airbag is • Always turn the PAB switch to PAB in case the
supplementary restraint system. It is designed to be front passenger seat is occupied.
used in addition to seat belts to help protect against
head and chest injuries in certain moderate and
severe frontal and front angular collisions.
AIRBAG WARNING LIGHT : SRS
The airbag is not visible until it is activated. Because
the system senses crash severity, some frontal/ The diagnostic system continually monitors the
angular collisions will not inflate the airbags. Airbags readiness of the SRS AIRBAG while the vehicle is
are not designed to inflate in rollover, rear side or slow being driven. The airbag warning light on the instrument
speed frontal/angular crashes because the necessary panel will illuminate for approximately 5 seconds when
protection can be achieved by the seat belt alone. the ignition is switched ON. This is normal and
indicates that the system is performing a self check.
OPERATION : The following components are monitored by the
Sensors in the ECU detect the degree of severity of indicator :
frontal/angular impact. The airbag(s) are designed to • Airbag control module
deploy if the collision suits the criteria for deployment. • Driver airbag
• The sensor switches close the circuit and the • Passenger airbag
• Retractor Pre registrations
propellant rapidly burns in a container producing
• All related wiring
mainly nitrogen gas to fill the airbag.
If light does not illuminate when ignition is switched
• The inflating airbag deploys out of the steering on remains illuminated after the initial check period &
wheel in the front of the driver and passenger during driving a fault may exist with airbag/seat belt
airbag (if fitted) of the dashboard in front of the pre-tensioner.
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
PAB SWITCH
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.
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(Ensure that the battery is disconnected while

DRIVER AIRBAG
working with the air bag/belt pre-tensioners). MODULE
STEERING WHEEL
17. STEERING WHEEL

STEERING COLUMN
REMOVAL : (Driver airbag removed)
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 :
PASSENGER AIRBAG
1. Ensure that the vehicle is in Straight Ahead INFLATOR COVER
CONTAINER
Position (SAP). DASHBOARD
2. 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
COVER PAB ASSY. CROSS
BASE PLATE.
MOUNTING MEMBER
DASHBOARD
3. Remove the steering wheel and re-orient it in the
BRACKET PAB MOUNTING
desired SAP orientation.
Fig 35 (RHD)
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.
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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FITMENT : 4. Disconnect battery ground cable and wait for one

1. Disconnect battery ground cable and wait for one minute.
minute. 5. Put on the air bag connector located sidewise
2. Connect the air bag inflator and horn function with and snap fit the PAB covers.
the clock spring. Install the plastic clamp on 6. Connect the battery ground cable.
floating horn function base plate for inflator
connector. 20. SAFETY BELTS WITH
3. Insert the air bag module in steering wheel. Press PRETENSIONERS & LOAD
the module fully and align the mounting tabs with LIMITERS
respect to bottom mounting lugs provided on
steering wheel. Make sure that gaps at all spokes FITMENT :
are maintained uniformly. 1. Disconnect battery ground cable and wait for one
4. Tighten the screws located sidewise the minute.
steering wheel with specified torque (2.5 kg.m.) 2. Connect the pre-tensioner to the wiring har-
5. Put on the side caps on steering wheel bottom ness.
cover. 3. Install the retractor as per the usual recommended
6. Connect the battery ground cable. procedure.
19. CO-DRIVER AIR BAG

REMOVAL :
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 Fig a (RHD)
the dashboard.
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)
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4. Make sure that the load limiter belts are installed 8

1 9
for the occupant provided with air bag. (IF THE 3 2
10
VEHICLE IS “DRIVER AIR BAG ONLY” VERSION
THE CO-DRIVER SEAT BELT SHOULD BE OF
PRETENSIONER ONLY CATEGORY).
• Observe the SRS warning lamp status for any

error codes after the air bag/belt pretensioner
connections.
4 7
6
5
RHD Version
Fig 36
21. DASH BOARD Fig 36 1. DIGITAL CLOCK
(Steering Wheel, Driver airbag, and Floor console 2. FACIA CENTRAL CLUSTER
removed) 3. SPEAKER GRILLS
a) Remove the A pillar trim (LH & RH) Fig 37
4. VENTILATION CONTROLS
b) Remove the 2 bottom mounting screws of the
5. POWER SOCKET
Facia A/c control on Facia central cluster, then
pull out the Facia A/c control. 6. POWER WINDOW SWITCH PACK
c) To remove the central cluster remove 2 mounting 7. ACCESSORY SWITCHES

screws in A/c control area which are fitted on 8. INSTRUMENT PANEL
dashboard skin and remove one screw in the ash
tray area which is fitted on cross member. Then 9. DRIVER AIRBAG MODULE
pull out the central cluster. (Disconnect the 10. PASSENGER AIR BAG MODULE
connection of A/c control switches, and electrical
connection of the Hazard switch.)
A- PILLAR TRIM
BODY
Fig 37
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d) Remove the digital clock by disconnecting the DIGITAL CLOCK

electrical connections. Fig 38 DASHBOARD SKIN
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 FACIACENTRAL
airbag removal. CLUSTER
STEERING NACELLE
NOTE : DO NOT REMOVE THE AIRBAG ASSEMBLY (TOP & BOTTOM)
FROM DASHBOARD
g) Remove the steering nacelle by removing two Power socket
screws mounted on combi- switch and one screw
for fitment of top and bottom nacelle. Fig 40 (For Fig 38 RHD Version
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 Fig 39
(bezel front) Fig 40
Fitment :
Follow the reverse procedure of Removal.
Fig 40
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22. ROOF TRIM : Fig 41

REMOVAL :
SUNVISOR
a) Remove the Grab handles (3 Nos.) after removing ANTI GLARE REAR VIEW MIRROR
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) Fig 42
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.
VALENCE
b) Similarly remove the 2 rear mounting bolts of the
front seat. Fig 44
c) Take out the seat from its position. FRONT SEAT (RH)
NOTE : Refer to Exploded View Fig. A
FITMENT : FRONT SEAT RISER
Follow the reverse order of removal for fitting back
the front seat. Fig 43
TREE CLIP
BODY
GRAB HANDLE
ANTIGLARE REAR VIEW
SUNVISOR ROOF LAMP
Fig 41 Fig 44
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HEAD RESTRAINT
ASSY FRONT SEAT BACK

RECLINER COVER OUTBOARD
PLATE PROTECTOR
SIDE VALANCE SPRING RETAINER PLATE
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
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24. REAR SEAT :

REMOVAL : REAR SEAT
a) De-latch the Rear seat from 2 latches, provided LATCH HANDLE
(RH)
on back of backrest. Fig. 45
D-
b) Fold the rear seat into two folds towards the front REAR SEAT PILLAR
side. LATCH STRIKER TRIM
(RH)
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.
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 : Fig 46
Fitment procedure is reverse of the removal procedure.
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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TAILGATE LATCH
TAILGATE HINGE
TAILGATE LOCK
TAILGATE STRIKER COVER

T A I L G ATE TAILGATE STRIKER
BALANCER 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. Fig 50
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 51
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FITMENT :
1
a) Insert the cable in the hook of the Tail gate striker. 3
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.
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.
TAIL GATE TRIM
d) Pull out the lock from outside.
FITMENT : TAIL GATE LOCK
a) Insert the lock unit from outside into the tail gate. Fig 53
b) Slide back the lock ring on to the lock unit from
inside the Tail gate panel.
BALANCER :
REMOVAL :
a) Remove the balancer from the tail gate by pulling
it out from the ball pin.
BODY
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. 1
c) 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.
Fig 54
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T/G SILL INNER CUTOUT

7
4 1
FUEL LID LATCH

CABLE
SECTION A-A
8
T/G SILL
INNER
CUTOUT
9
REINF. REAR QUARTER
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.
a) First remove the carpet on the right hand side of
the vehicle so that the cable routing is visible. b) Connect the end of the cable to the tailgate
release lever (4) and the tailgate latch (4) through
b) Next remove the rubber foam pad (3) that is
the opening in the tailgate sill. (for end connection
adhesively bonded to the floor.
refer section A - A)
c) Disconnect the end of cable from the Tailgate
c) Fix the cable in place using the 5 Nos adhesive
release lever (4) and the latch (5) (refer section A
pads as shown in fig.
- A for end connector)
d) Fit the carpet finally.
d) Pull the cable free from the vehicle.
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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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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. Fig 56
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.
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)
Fig 57
c) Unscrew the seat belt top mounting bolt.
d) Pry out the C-pillar trim (both top and the inner
trims).
1
FITMENT :
a) Fit back both the trims (top and inner trims) and
tighten the 5 mounting screws. 2
b) Align the seat belt top mounting and tighten the 3 5
bolt. C - PILLAR INNER TRIM 4
c) Fit back the parcel shelf.
Fig 58
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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 )
minute (while working with seat belt with
pretensioner and load limiters).
2. Remove B- pillar lower trim by removing 4 plastic
rivet buttons. Lap belt
3. Disconnect the pretensioners from the wiring
harness.
4. Remove lower seat belt mounting hex screw on
the floor.
Fig 59
5. Remove plastic cap & unscrew top seat belt
mounting hex screw.
6. Then Remove two hex screws of retracting unit Top
at bottom of B- Pillar. mounting
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.
Installation :
Follow the reverse sequence of removal. Retracting
(Also refer airbag section, procedure for installation of Unit
seatbelts with pretensioners & load limiters) Bottom
Rear Seat Belt Removal Fig. 61 mounting
1. Remove C- pillar upper trim Fig 60

2. Remove retracting unit mounting hex screw, top
mounting hex screw & one bottom seat belt
mounting hex screw on front side of rear wheel
Top mounting
arch.
3. For removal of buckle remove hex screw from
floor below rear seat. Retracting Unit BODY
Important Note : Lap Belt

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.
Installation :
Bottom Buckle
Follow the reverse sequence of removal. mounting mounting
Ensure for proper retracting of seat belts after
installation. Fig 61
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FRONT BUMPER :
2 2
7 6 5 A B C D F
6 7
E
5
G H I J K
4 3 3 4
View from inside of bumper
Fig 62
d) Next tighten the splash guard and the Bumper
31. FRONT BUMPER : FIG. 62 to the vehicle using mounting screws (3) & (4)
REMOVAL : e) Match the surface of the bumper with the surface
a) Remove the front wheel arch liner on both the left of the fender and then tighten the screws (6) &
hand and right hand side by removing the self (7)
tapping screws (8) f) Tighten all remaining screws (1),(2),(3),(5),(6) &
b) Next remove the bumper by unscrewing the (7) The screws should be loosely fitted.
screws marked (2),(3),(4),(5),(6), & (7) Fig 62. g) Fix the front bumper to the vehicle by using
c) Disconnect the wiring harness connection to the screws (2),(3),(6) & (7) Fig 62. They should be
fog lamps (if fitted) partially tightened.
c) The splash guard if required is removed by h) Next fix the front wheel arch liner (align the holes
removing the screw marked (1) with the mounting locations on the bumper & the
vehicle body) Tighten the bumper to the BIW an
FITMENT :
bumper using self tapping screws (8)
a) First fix the splash guard to the BIW (vehicle body) NOTE :
by partially screwing the screws (1). The screws
should be loosely fitted. The procedure for fitting LH / RH liner is similar.
b) Connect the wiring harness connection to the 31a. GRILL REMOVAL AND FITMENT :
fog lamps (if fitted) a) It can only be removed after removal of front
c) Fix the front bumper to the vehicle by using bumper as it is fitted from inside.
screws (2),(3),(6) & (7) Fig 62. They should be b) To remove unscrew 11 nos. screws (A to K)from
partially tightened. inner side of bumper.
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32. FRONT EYEBROW : FIG A

REMOVAL : 9 8 7 6 5 4 3 2 1
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.
Note : Follow the reverse procedure of removal
Fig A
33. VALANCE COVER : FIG B

5 4 3 2 1
REMOVAL :
a) Remove 5 bolts (1,2,3,4,5) & 2 screws.
Unsnap clips (6,7,8) by pulling it carefully.
6 7 8
Fig B
33. REAR EYEBROW : FIG C

b) Remove 2 bolts (1&3) & one screw (6) from body, 2 1
6 5 3
then remove lug from rear bumper & then unsnap 4
clips (2,4,5,) by pulling it carefully.
BODY
Fig C
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REAR BUMPER : Energy

absorber (LH) Energy
10 absorber (RH)
5 6
1
2
3 10
4 5 6
7
8
8
7
6 5 5 6
10 1 2 3 4 10
7 8 8 7
View from inside of bumper
Fig 63
32. REAR BUMPER : c) Match the bumper surface with the body side
outer surface and then tigten the screws (5)
REMOVAL :
& (6).
a) First remove the rear wheel arch liner by removing
d) Next tighten the remaining screws (1),
the self tapping screws.
(2),(3),(4),(7) & (8) The screws should be loosely
b) Next remove the rear bumper by removing the fitted.
screws marked (1),(2),(3),(4),(5),(6),(7),(8) & (10)
e) Then fix the wheel arch liner (aligning the holes
Fig 63.
of the liner to the corresponding location in the
c) Disconnect the connection of wiring harness to bumper/BIW) by using self tapping screws.
the registration plate lamp before removing the (Procedure for both sides liner fitments are
bumper free. similar).
FITMENT : f) Then fix the wheel arch liner (aligning the holes
a) Connect the wiring harness to the registration of the liner to the corresponding location in the
lamps. bumper/BIW) by using self tapping screws.
(procedure for both sides liner fitments are similar)
b) Fix the rear bumper to the vehicle body using
screws (1),(2),(3) & (4) Fig 63. Keep the screws g) Removal the rub rail by unscrewing 3 screws,
loose (i.e. partially tightened). after removing rear bumper.
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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
Similarly unscrew & remove the side bottom 1
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.
Fig 65
34. REAR SPOILER : (Fig. 66 & 66a)

REMOVAL :
1) Remove the 5 nos. mounting screw from inner
side of tailgate.
BODY
2) Take out spoiler from tailgate shell.
3) Disconnect the wiring harness connector
(Provided for high mount lamp wiring harness
connection).
FITMENT :
Fig 66
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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 sill cover (with valance cover)
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 sill cover (with valance cover removed)
wheel house front LH (only on LH side).
Fig 67
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.
FITMENT :
Fig 67a
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D. BODY REPAIRS : Repairs done without use of proper fixture and

Indica Body shell is a semi monovolume minisize hatch procedure could adversely affect the performance of
back, steel monocoque body. In case of minor collision the car.
Indica body shell can be repaired by use of the Use proper measuring tools for measuring point to point
recommended body collision repair fixtures. The dimension dimensions given in the sketches.
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.
SIDE VIEW :
P
M
K
TABLE FOR SIDE VIEW :

K : OUTER REAR VIEW MIRROR HOLE BODY
MEASUREMENT POSITION LENGTH (in mm)
L : CHECK STRAP MTG. HOLE
K-L 330
L-M 1033 M : REAR DOOR TOP HINGE MTG. HOLE
M-N 221
N : CHECK STRAP MOUNTING HOLE
N-P 841
K-M 1020 P : REAR DOOR STRIKER MTG. HOLE
L-N 1026
M-P 840
K-N 1082
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REAR VIEW :
W
Z
X
Y
TABLE FOR REAR VIEW :

V : REAR RH SUSPENSION TOWER HOLE CENTRE.
MEASUREMENT POSITION LENGTH
(in mm) v : REAR LH SUSPENSION TOWER HOLE CENTRE
W : TAILGATE HINGE MTG. HOLE
W-V 997
X : STRIKER (TAIL GATE) MOUNTING HOLE
V-Y 1066
Y : BUMPER MOUNTING HOLE.
Y-V 370
V-X 682
X-Z 364
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TOP VIEW :
B C D E
F
c f
b d
TABLE FOR TOP VIEW :

A : BONNET
MEASUREMENT POSITION LENGTH (in mm)
B : RH SUSPENSION TOWER CENTRE (FRONT)
A-B 862
b : LH SUSPENSION TOWER CENTRE (FRONT)
A-b 789
C : DRAIN HOLE NEAR DRIVER SEAT FRONT
B-b 1045 RH MOUNTING
b-C 1398 c : DRAIN HOLE NEAR CO-DRIVER’S SEAT
FRONT
C-c 787
LH MOUNTING
C-d 1029
D : FUEL TANK FRONT RH MOUNTING POINT
c-d 834 BODY
d : FUEL TANK FRONT LH MOUNTING POINT
D-d 460
F : REAR RH SUSPENSION TOWER CENTRE
d-E 534
f : REAR LH SUSPENSION TOWER CENTRE
D-F 979
E : FUEL TANK REAR MOUNTING POINT
D-f 1212
F-f 1110
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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. Fig 68
Thickness to be applied (minimum 500 microns)
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 Fig 69
Allow to dry for two hours.
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
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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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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
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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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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)
Fig 76
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 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
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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.
Fig 79
Certain environmental conditions or particular
locations where the vehicle is driven may precautions need to be taken.
accelerate the rate of corrosion. Hence special
care needs to be taken to repair any damage to • The underbody must be thoroughly pressure
the paint or protective coating, as soon as washed after every three months.
possible, in such areas. Please be very careful • In case the car is driven near coastal areas or on
in case of the following situations.
salted roads in icy cold winter conditions the
• If the car is driven in areas having hot and sultry underbody must be pressure washed once a
weather. month.
• 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.
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 :
BODY
• 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.
In addition to regularly washing, the following
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• 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.
Fig 81
• 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.
INSPECT MUD LINERS
FOR DAMAGES
Fig 82
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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 Fig 83
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.
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 Fig 84
using a soft cloth or sponge. Please do not use soap
but a car shampoo recommended. check immediately afterwards for any stains and
clean them.
Please take the following precautions.
• External contamination in the form of sap or
• Always wash in shade, avoiding direct exposure industrial fallout may mar or develop spots on a
to sunlight during washing. new finish. Hence avoid parking Indica near trees,
BODY
• Dry wiping may lead to the formation of scratches which are known to drop sap, or near factories,
and hence always use a soft cloth and clean which give out heavy smoke.
water while wiping your Indica. • The acid content in bird droppings may damage
• Always keep Indica parked in a well ventilated the newly painted finish and hence any bird
shade. Exposure to heat with entrapped moisture droppings must be immediately washed off.
promotes corrosion. • The paint finish is susceptible to damage in case
• Avoid driving on gravel roads, as the possibility petrol, brake fluid, liquid from car battery, oil,
of paint chip off due to the impact of stones is antifreeze, transmission fluid or windshield solvent
high. If the car is driven on freshly tarred road,
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spills onto the painted surface.. In case of such • It is recommended that you wax your Indica after
a spillage immediately rinse the affected area a wash as wax forms a protective layer over the
with water. Avoiding wiping the area as far as painted surface.
possible, however if wiping is required, ensure to
wipe the area gently with soft cotton cloth. • Always keep the drain holes and channels clear
so that water drains off freely and does not
• Avoiding using sharp objects to scrap off tar or accumulate in crevices and box sections.
mud from a painted surface as it may develop
scratches or may peel off the paint. • Any damages in the paint film such as dents
and scratches are prone to corrosion and hence
IN THE FIRST 90 DAYS :
must be rectified immediately.
It is recommended not to wax or polish your Indica in
the first 90 days. This will allow the paint finish to
• A higher salt contents in the air accelerates
completely age and cure. When the car is ready to corrosion in coastal areas and hence more care
wax, do not use silicone containing or super polymer should be taken in case your Indica is driven in
containing waxes or polishes, (e.g. Teflon). Indica's these areas in wet season.
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.
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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.
Fig 85
• Periodically check the car for any scrapes on
the underbody caused due to speed-breakers or
due to stones.
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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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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AIR CONDITIONING
CONTENTS
1. Technical specification 1
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
AIR
CONDITIONING
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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 120 ml.

components are changed :
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 15 kg / cm2 to 20 kg / cm2
Suction Pressure 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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SR. JOINT TIGHTENING TORQUE
NO.
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 %
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Fig. 1
SCHEMATIC DIAGRAM OF AIRCONDITIONING CYCLE
INDEX
COLD AIR
Expansion
Valve
LOW TEMP
LOW PRESSURE VAPOUR
Evaporator
AIR CONDITIONING
HIGH
TEMP
HIGH
PRESSURE
GAS
HIGH
Compressor TEMP
HIGH
PRESSURE
LIQUID
TRINARY
Condenser PRESSURE
SWITCH Blower
GROUP INDEX
Condenser Fan
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ENGINE COMPARTMENT CAB
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3
AIR
CONDITIONING
4
Fig. 2
LAYOUT OF A.C. SYSTEM (BEHR)
HVAC Climate Box
INDEX
Hose suction
Hose discharge
AIR CONDITIONING
Heater
outlet
Magnatic Clutch Servo motor
A. C. Compressor
Heater inlet
with water
valve
Compressor
Mounting Bracket Drain hose Blower motor
GROUP INDEX
Condenser Assembly
Tube liquid
Trinary Pressure
Switch
NEXT
Condenser fan
Receiver Drive
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AIR CONDITIONING
MAIN PARTS OF A. C. SYSTEM 7. ANTI FREEZE SWITCH : It is a temperature sensing

device, which protects the A. C. systems from
1. COMPRESSOR : It is the heart of A. C. system where,
damage. It switches off the compressor when
low temperature, low pressure vapour refrigerant is
condensed water tends to form ice on the fins of
compressed and converted to high temperature high
evaporator. Thus it maintains the evaporator
pressure gas.
temperature within a specified range.
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.
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 & AIR
CONDITIONING
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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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
Principle : (I)
When the current is fed to the coil (as shown fig. on the IRON
(II)
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 Fig. 3
pressure plate is attached to the compressor shaft.
Two ball bearings are used between the inner surface of STATOR
the rotor and the front housing of the compressor. BALL BEARING
PRESSURE PLATE
Operation : SNAP RING
Whenever the engine is operating, the pulley is rotating

since it is connected to the crankshaft by a belt, but the SNAP RING
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.
PULLEY
Fig. 4
ATTRACTED
ELECTROMAGNET
STATOR PULLEY PRESSURE PLATE
Fig. 5
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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 A B C
to achieve desired temperature. The air mix is done at the Fig 7 HVAC Controls
part shown by dotted lines, to attain comfortable air
conditioning.
D E
A. Temperature Control Knob :(For Heater Version)
The air temperature in the car can be controlled by AIR
operating the temperature control knob at the left hand CONDITIONING
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 C
A B
manually to achieve desired comfortable temperature.
Fig 8 Heater controls
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B. Blower Speed Regulation Knob : HEATERCORE

The ventilation system has a three/four speed blower.The OUT
blower speeds can be regulated to any one of the following SIDE
speeds by operating the knob at the centre of the control AIR
panel (B).
LOW MEDIUM HIGH VERY HIGH
TEMP.ADJUSTDAMPER
COOLING
This is similar for heating version COIL AIR HOTAIR AIR COOL AIR
OUTLET OUTLET OUTLET OUTLET
C. Air direction control knob :
Fig 9 Schematic layout - Air flow
The air flow can be changed by turning the switch to the
desired direction (C)
The condenser fan works only with the A. C. switched
Towards face ‘ON’ and when the engine is running.The condenser
fan is a two speed fan.
Towards face and feet The A. C. compressor gets switched ‘OFF’
automatically when the engine gets over heated.
The A. C. is automatically switched ‘ON’ when the
Towards feet
engine cools down.
Towards feet and windshield NOTE :
Recommended for clearing fogging on If your car is has been left in the sun with the windows
windshield) closed, to quicken the cooling open the windows briefly
Air demist / defrost windshield while you operate the air conditioner with the air
(Recommended for clearing heavy fog circulation switch in fresh air mode and the fan at a higher
speed.
and snow)
Maximum Cooling Effect :
This is similar for heating version Switch ‘ON’ the A. C. and keep the blower at maximum
speed. Keep air direction in face mode. All vents should
D. A. C. ON/OFF switch be opened completely. Keep the air circulation switch
The A. C. can be switched on by pressing the switch (D) on in the recirculation mode and temperature control
the A. C. control panel provided the blower is ‘ON’ and the switch in the maximum cooling (Blue) position. At
maximum cooling, A. C. trips OFF automatically when
engine is running. The indicator lamp will show that the the desired temperature is acheived.
A. C. is ‘ON’.
Front Windshield Demister / Defrost :
(In heater version : This is absent and a dummy knob (D) is
provided on control panel). First start the engine and accelerate to warm up. Select
defrost / demist mode on air flow direction control. Then
E. Fresh Air switch set the blower to maximum speed and temperature control
knob to maximum heat ensuring that A. C. is ON. These
Fresh air can be circulated by pressing switch (E) on the settings direct all air flow to the base of the front windshield
panel for DLX version. For DLE version rotary knob has and towards front door glasses. The hot air clears the frost
been provided.This should be put on only when discomfort from the windshield and door glasses. Electrical heater coil
is felt, as cooling effect reduces with fresh air entry. 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’. First start the engine and accelerate to warm up. Select
Engine fast idling control has been provided. When the defrost / demist mode on air flow direction control. Then
A. C. is switched ‘ON’, the engine idling RPM increases set the blower to maximum speed and temperature
marginally to adjust to the A. C. compressor load. When control knob to maximum heat .
the thermostat cuts off the A. C. engine idling RPM
decreases to normal idling.
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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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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
Distribution Box Assy. Hvac
Temperature
Cabele Movement
Cable Movement Towards Face Mode
Bowdon Cable
Temperature Towards Full Warm
Clip Bowdon Cable
Distribution
Clip
Towards Full Warm
Towards Face Mode
Base Plate
Front Plate
CONTROL PANEL HVAC (TOP VIEW)

Fig. 9a
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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. Fig. 10 Climate Box
Remove 2 screws from bottom of facia & disconnect FITMENT :
PCB wiring.
Fit the climate box with drain hose at it’s position on
Slowly remove the front plate without breaking of the firewall and tighten the seven hex nuts at its
latches. position for mounting the climate box.
Remove 1 screw at top side of base plate and one at Check & ensure that the wire harness connections
the bottom. are properly made. Climate box main connector to
Remove the central cluster switch connection from vehicle cabin wiring harness. Earth terminal to the
stud.
the wiring harness.
Fit the vertical support for dashboard, route the Mode
Keeping the Mode knob at Face position, remove
Bowden cable (control cable) & Temperature control
the Mode Bowden cable (control cable) plastic clip Bowden cable (control cable) from outside of the
from the Base - plate assembly. vertical support member cross member and fit the
Rotate the Mode Knob towards defrost position in dashboard at their position.
anti clockwise direction to remove the Mode Fit the Base Plate Assembly on dashboard & tighten
Bowden cable (control cable) eyelet from the bevel the 2 screws. Make sure that all the electrical
gear. connections are made properly with blower switch
Keeping the Temperature control knob on Max Cold & illumination lamp.
position, remove the temperature control Bowden Rotate the Temperature control knob at Max cold
cable ( control cable ) plastic clip and the eyelet position & fit the plastic clip of Temperature control
from the bevel gear form the Base – plate assembly. bowden cable (control cable) on Baseplate Assembly,
ensuring proper routing of the cable through the slot
Disconnect the electrical connectors for Blower
on the bevel gear and check for free rotation of
Switch, PCB Assly and lamp assembly. temperature control knob.
Remove the base plate assembly. Keep the Mode knob at Defrost position & put the
Remove cross member & vertical support. eyelet of the Mode Bowden cable (control cable)
on the bevel gear. AIR
Disconnect the electrical supply to the Climate box CONDITIONING
wiring harness by removing the connectors. Rotate the Mode knob at Foot – Defrost position 8 fit
the plastic clip of Bowden cable (control cable) on
Disconnect the earth terminal while removing the Baseplate Assembly, ensuring proper routing of the
climate box. Remove the hex nuts from the cable through the slot on the bevel gear.
mounting points of the climate box on the fire wall
Check for free rotation of the Mode knob.
and then remove the climate box with drain hose.
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Fit the center cluster connect electrical connection base-plate. In case it is not convenient in some cases,
to PCB and front plate, without breaking the latches. the dashboard should be removed.
Fit 2 screws of the front plate. Ensure that the hazard
Remove the wiring harness connector from the
warning switch connector is connected properly.
resistor.
Connect the refrigerant pipes to Expansion valve
Connect the wiring harness connector to the resistor.
ends. Make sure that o-rings are properly smeared
with lubricant oil before connecting. Fit the dashboard ensuring the routing of both the
bowden cables (control cable) from outside the
Remove the tape from the heater inlet & outlet ends.
vertical support for dashboard.
Connect the hoses to the heater inlet & outlet end.
Fit back the control panel on the dash - board.
Check the system for leakage and charge the
4. Housing Evaporator Assly :
system.
Evaporator housing holds the complete evaporator (cooling
2. Blower Complete :
coil) assembly. When it is required to replace the
Remove the climate box as explained above. evaporator, it is better to replace along with the housing
assembly.
Remove the connector for blower motor, resistor &
anti freeze switch. Replacement procedure :
Remove the screws between the blower housing Remove the climate box from the cabin.
and evaporator housing.
Separate the evaporator housing assly from the
Remove the screws on top side of the blower blower housing assly & distribution housing assly by
assembly. removing the screws between the housing
assemblies
Replace the Blower assembly with a new one & fit
the screws. Replace the Evaporator Housing Assembly with new
one. And assemble with blower housing &
Put the climate box at it’s position.
distribution housing assly, with self tapping screws.
Tighten the nuts at mounting points & the earth
Fit back the climate box assembly in the cabin.
terminal to the firewall.
5. Anti Freeze Switch :
Put the connector to the blower motor, resistor &
antifreeze switch. The function of antifreeze switch is to protect the
refrigerant system from the damage. It switches off the
Fit the dashboard (Refer Climate Box section for
compressor when the water is condensed and forms to
details)
ice on the fins of evaporator. Suction pipe becomes extra
3. Resistor : cool and sometimes iced up, liquid refrigerant remains
after expansion valve due to insufficient heat transfer
The resistor is meant for regulating the speed of the
across the evaporator surface and eventually the
blower as per the user’ s requirement. The speed is in 4
compressor will get damaged due to liquid refrigerant
steps. It has 3 coils in series for regulating the speed of the
inflow.
blower, as per the user’ s requirement. The speed is in 4
steps. NOTE : Please do not tamper the set screw of anti
freeze switch as it is factory set.
It also has a temperature safety fuse. This fuse blows off
when the resistor temperature in creases beyond the Replacement procedure :
permissible limit.
Remove the wiring harness connector from the anti
Replacement procedure : freeze switch.
Remove the Control panel base plate (Refer Climate Remove the mounting screws from mounting
Box removal for details). bracket on the housing evaporator assembly.
Resistor becomes accessible through the opening Remove the probe carefully from the Evaporator
in the dash – board after removing the control panel core.
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NOTE : The feeler is a capillary tube and must Fit the Base-plate Assembly & Front-plate as.
not be bent or twisted sharply as it may
9. Rotary Knob for Mode :
damage the unit.
Remove the Base-plate Assembly.
The feeler of the new switch must be inserted to
the same depth that is 100 mm and the remaining Pull out the knob by slightly flexible the snap-fits &
bend to be made so as to keep the feeler as close as replace it with a new one.
possible to the housing.
Fit the Base-plate Assembly Front-plate.
6. Housing Distribution Assembly :
10. Rotary Knob for Blower switch :
Remove the climate box .
Remove the front-plate by removing the 2 screws
Separate the distribution housing from the entire from the bottom.
assembly by removing the screws between the
Gently pull the knob of blower switch & replace it
Housing Evaporator assembly and the Housing
with new one.
Distribution assembly.
Put the front-plate in it’s position 8 tighten the 2
Replace the Housing distribution assembly.
screws.
Fit the new Housing Distribution Assembly to the
11. Lamp Assembly :
Housing Evaporator assembly with the help of
screws. Remove the Base-plate Assembly.
7. Kinematic Assembly : Disconnect the connector of lamp assly and pull out
the three lamp holders from the Base - plate, replace
Kinematic assembly controls the flap movement and
with new lamp assly and connect the connector.
distributes the air as required at different outlets.
Wires of the lamp assly should be snap-fitted into
Replacement procedure : the wire clips.
Remove the Bowden cable (control cable) holding Fit the Base - plate Assembly & Front-plate.
clip on the kinematic base plate with a nose plier
12. Lamp (Bulb) :
and remove the eyelet of Bowden cable (control
cable) from gear partly. Remove the front-plate by removing the 2 screws
from the bottom.
Remove the mounting screws from the kinematic
base plate that is fitted on the Distribution Housing. Gently pull out the bulb and fix the new bulb with
blue caps.
Replace the Kinematic Assembly with a new one.
Put the front-plate in it’s position & tighten the 2
Keep the Mode knob at Defrost position & put the
screws.
eyelet of the cable on gear partly.
Re - Installing the original Compressor :
Now fit the Bowden cable (control cable) on the
Kinematic baseplate with the clip. Oil should be changed at the time of re-installing the
original compressor. Drain and measure the refrigerant oil
8. Control Panel Assembly :
contained in the compressor. Charge oil through the
In each switching position 1 to 4, It should show discharge port of the compressor with the same amount
continuity between the respective terminal and the of new refrigerant oil.
ground.
NOTE :
Remove the Base-plate Assembly (Refer Climate Box AIR
In case for some reasons the flushing is not possible, ensure CONDITIONING
removal ).
that the complete system contains 120 ml oil.
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.
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Installing a New Compressor : Drain and measure the TROUBLE SHOOTING TIPS
compressor oil from the original compressor.
The most basic and important element of effective trouble
Drain the oil quantity equal to Tolal oil – Drained oil from shooting is safety.
the new compressor (New compressor comes with 120
ml of oil). The basic steps are:
Eg : 1. Switch off the engine before you open the bonnet

while looking for fault identification.
Drained oil from the old compressor : 40 ml
2. Use gloves and safety glasses when handling
Total oil in the new compressor 120 ml refrigerants used compressor oil.
Oil to be drained from the new compressor 3. Keep our environment safe by practicing proper
= 120 ml – 40 ml = 80 ml. recovery, evacuation and charging procedures. Do not
NOTE : Please ensures that the ports are covered with a release refrigerant to atmosphere.
tape to avoid entry of dirt, foreign particles, coolant, etc. 4. Never use oxygen for pressure testing a system. It
and change the O Rings if damaged. may explode in presence of oil. Instead use Nitrogen
Condenser or Evaporator : from a cylinder equipped with proper pressure
regulator.
Drain as much of the original oil as possible from the
evaporator or condenser. Add the same amount of new The problems fall in two categories
refrigerant oil, either to the original or new condenser or 1. Electrical problems
evaporator.
2. Mechanical refrigeration system / component
If replacing condenser, add approximately 20 ml oil. problems
If replacing evaporator, add approximately 20 ml oil. Many times the problems overlap. For example, a
Receiver Drier : If replacing the RD, add approximately malfunctioning of relay or contact may make compressor
20 ml oil. cycle on / off too frequently and damage compressor.
The RD must be replaced whenever the system has been Although the problem is electrical, it results into
opened to the atmosphere for repair. mechanical failure.
New RD must never be left open as it will absorb moisture Similarly, a system not evacuated properly may have
from the air and become unserviceable. moisture present leading to acid formation and destroying
Blown or Ruptured Pipe / Hose : When replacement is electrical contacts. This is a refrigerant side problem
required, add approximately 10 ml oil per pipe. disguised as an electrical issue.
Note: In case of sudden refrigerant leakage on any Before attempting any troubleshooting procedure, learn
of the A. C. component, it is recommended to flush the Operating sequence of the unit.
the system completely and then ensure that the Most refrigerant - side problems, if permitted to continue
complete A. C. system contains 120 ml compressor result in compressor failure. For example, an overcharged
oil. 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 :
1. Condenser dirty
2. Fan direction reverse
3. System over / under charged
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4. Evaporator / Blower damage Procedure

5. Expansion valve malfunctioning STEP 1 - Collect as much information from customer as
possible. It could give vital clues.
6. Filter - Drier choked
7. Non condensibles STEP 2 - Conduct preliminary checks - engine off
8. Leakage of refrigerant Sr. No. Problem Solution

9. Compressor clutch worn out a. Dirty condenser Clean
/Radiator coil
10. Belts snapped or slipping and many more other
causes. b. Dirty or loose fins Clean
It is always therefore essential to go to the root cause and c. Loose belts Adjust belt tension
not jump to conclusions or quick fix solutions based on
d. Damaged-loose
symptoms.
interconnecting
Proceed in a logical manner to rectify the defect. piping Repair
Ensure following minimum equipment are available at e. Disturbed alignment Rectify
service point
f. Idler pulley loose Align / tighten
1. Safety equipment ( Gloves, Glasses )
g. Oil / Dirt patches at joints
2. Manifold gauges - indicating oil
Refrigerant leak Locate & rectify
3. Vacuum pump
h. Indications burn out Repair
4. Contact thermometer digital
Piping / Wiring touching
5. Leak detection equipment hot parts of engine,
6. Weighing scale clutch burn out due to dirt
dust or any other reason.
7. Refrigerant recovery unit
i. Cables loose
8. Recovery cylinder Condenser / Radiator
9. Sealed lubricant container / EBA /Clutch / Pressure
Switch Refix
10. Container for recovered lubricant
j. Control Cables
11. Replacement Refrigerant (R134a) in sufficient quantity Loose / stuck Repair
& of proper quality
k. All AC fuses Check & replace
12. Replacement filter / drier
l. Air Mix door operation Check - It may be stuck
13. Multimeter
m. Fresh / Recirculation
Door operation Check - it may be stuck
1. 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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Connect gauge manifold in the system before AC system DO NOT ATTEMPT TO TREAT YOURSELF
is made operational through quick couplers.
2. Always use proper workshop practices, do not bypass
This will enable you to record suction & discharge agreed practices
pressures.
3. Always work in a well ventilated area
Based on gauge pressure observations & with the help of
4. Avoid skin contact, as R134a will cause frost bite on
chart given in this manual try to locate the problem.
contact with bare skin
PRECAUTIONS IN HANDLING 5. Do not abuse the refrigerant cylinder, or any other
REFRIGERANT tools you may need to use
Refrigerant (R134a) 6. Do not weld or steam clean on or near any air
(Tetra flouroethane, CF3-CH2F) conditioning components when pressurized.This may
Specifications : HFC 134a cause a dangerous pressure build up in the system.
CH2 F CF3 7. Do not discharge refrigerant into an enclosed area.
Oil : Mineral oil ND - 8
8. When purging a system, discharge the refrigerant
Care should be taken when discharging the air conditioning slowly.
system to ensure the refrigerant is not released to the
atmosphere but captured for recycling. Environment & 9. If it is necessary to transport or carry a cylinder of
friendly refrigerant R134a is not an ozone depleting refrigerant in a car, keep it in a luggage compartment.
substance but its release would add to the green house 10. Refrigerant cylinders should always be protected
warming effect. from the radiant heat of the sun & keep in a cool
Refrigerant R134a is transparent and colourless in both place.
the gaseous and liquid states. At all normal temperatures 11. When filling a refrigerant cylinder, never completely
and pressures it will be a vapour. The vapour is heavier fill it. Always leave space for expansion. If the cylinder
than air and is non - flammable, non-explosive, non- was completely filled and the temperatures
poisonous and non-corrosive (except when in contact increased, hydraulic pressure with its tremendous
with moisture). force would result, leading to cylinder bursting
The following precautions in handling R134a should be accidents.
observed at all times : 12. Never discharge a system or do brazing / welding /
NOTE : operation when the main engine is on.
R134a and R 12 are not compatible and must never 13. Do not drop, dent or abuse refrigerant gas cylinders.
be mixed. 14. Always chain or strap cylinders in place to prevent
l. Always use safety glasses and gloves when handling them from tripping over or damage, from moving
or servicing air conditioning systems. If R 134a does around.
enter the eye, freezing of the eye can occur and could 15. Always keep the cylinders capped.
result in blindness. The procedure outlined below is
16. Never heat a cylinder with open flame or place electric
suggested if R 134a enters the eye.
heater in direct contact.
a. Keep calm.
17. Always double check that you have proper refrigerant
b. Do not rub eyes. container. The refrigerant cylinders are colour coded
c. Splash large quantities of cool water into the eyes to avoid confusion. R 134a is BLUE.
to increase the temperature 18. Use proper size spanners, wrenches to avoid damages
d. Tape a sterile eye patch in place to prevent dirt to valve & threads.
from entering the eye
e. Go immediately to a doctor or hospital for
professional care
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3 4
5
2
1. REFRIGERANT RECOVERY UNIT (RRU)

2. REFRIGERANT RECOVERY CYLINDER
3. MANIFOLD/GAUGE SET
4. LOW SIDE CHARGING ADAPTOR
5. HIGH SIDE CHARGING ADAPTOR
Fig 11
DISCHARGING THE SYSTEM 4. The automatic recovery unit will operate until the air
REFRIGERANT RECOVERY conditioning system has been emptied of refrigerant
down to atmosphere pressure. The cylinder can now
Various Refrigerant Recovery Units ( RRU ) are now be closed.
available. The following procedure is typical for the use of
these units when recovering refrigerant from a car air 5. Measure the amount of PAG (Poly Alkaline Glycol) oil
conditioning system. removed from the A/C system. This oil is normally
separated from the incoming refrigerant into the RRU.
1. Connect the RRU outlet to an R 134a recovery cylinder New clean PAG oil must be added into the system
with a refrigerant hose and open the valve on the before recharging with refrigerant.
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. AIR
CONDITIONING
3. 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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SYSTEM CHARGING AND EVACUATION Charging the system includes the following steps :-
The following equipment is required for system charging 1. Filling charging cylinder
and evacuation procedures. 2. Evacuation and leak test
1. The refrigerant calibration charging cylinder or 3. Charging system
weighing device.
4. Performance test
2. Pressure gauges and hoses.
3. Vacuum pump FILLING A DIAL-A-CHARGE- CYLINDER
4. Refrigerant Recovery Unit (including compressor oil 1. Open valve on bottom of charging cylinder,
collector ) allowing refrigerant to enter cylinder from storage
cylinder.
5. Electronic leak detector
2. Bleed cylinder via valve on top (behind pressure
CAUTION :
gauge) as required to allow refrigerant to enter. This
The wearing of safety goggles and gloves is mandatory valve should be connected via a hose to a Refrigerant
during system charging or discharging. Recovery Unit ( RRU ) and recovery cylinder. When
refrigerant reaches the desired level, close valve at
NOTE :
bottom of cylinder and be certain that bleed valve is
All hoses at point of connection to the system must have securely closed.
isolation valves fitted.
1
6 7
8
2
5
4
3
1. REFRIGERANT RECOVERY UNIT (RRU) 5. VACUUM PUMP

2. REFRIGERANT RECOVERY CYLINDER 6. MANIFOLD GAUGE SET
3. ‘DIAL-A-CHARGE’ CHARGING CYLINDER 7. LOW SIDE CHARGING ADAPTOR
4. R 134A SUPPLY CYLINDER 8. HIGH SIDE CHARGING ADAPTOR
Fig 12
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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 HIGH PRESSURE
LOW PRESSURE
decrease to -1 kg / cm2 and high side gauge should CHARGING
STATION 100KPa = 1 kg / cm2
read slightly below the zero index of gauge. If high
side reading does not register, check system for Fig 13
blockage or leak.
using the RRU and repair the faulty component or
NOTE : connection. Repeat steps 4 to 10 after repair of
When high side gauge is slightly below the zero index of leak.
gauge, open high side manifold hand valve. NOTE :
5. After evacuating the system for 15 minutes, to a Various types and makes of leak detectors are
vacuum of - 1 kg / cm2 close both the low and high currently in use. Whichever leak detector is used, it is
side hand valves, then stop the vacuum pump. The important to follow the manufacturer’s instructions
system must hold the vacuum of - 1 kg / cm2 for a in regard to adjustment and setting of the instrument
minimum of 15 minutes. If vacuum is held then
prior to conducting the test. Inspect for leaks by slowly
the system has no leaks and may continue to be
moving the probe of the detector around all hose
evacuated for a further 15 minutes.
connections and points of possible leakages.
6. Wear safety goggles. Refrigerant R134a is heavier than air and will be more
7. Connect the centre charging hose to the charging apparent at the bottom of a fitting.
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. 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 AIR
CONDITIONING
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.
10. Check system for leaks with an electronic detector. If
a leak is detected, remove refrigerant from system
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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 The compressor is charged at the factory with specified
as follows :- 120ml refrigerant oil which circulates within the entire
A.C. system. Only the recommend oil must be used when
1. Open HIGH SIDE manifold hand valve slowly. Fill
the system with as much of the specified charge adding or changing oil as specified by A.C. system
as possible, then close the high side manifold suppliers. These oils are not compatible with any other
hand valve. PAG oil. Mixing of oils of different manufacturers and
2. Rotate the compressor by hand for 12 revolutions different types can result in glue like substance, failure of
to ensure no liquid refrigerant is trapped in the lubrication and seizure of compressor.
suction side of the compressor. Failure to comply
with this step, may result in irreversible damage Although it is not necessary to regularly check the oil level
to the compressor.
within the system, all the A.C. system components will
3. Start the engine and engage compressor clutch hold a system of the oil circulated. Therefore whenever
and evaporator fan on high speed.
an A.C. system component is replaced, a quantity of new
4. Set engine speed to 1500 - 1700 rpm. refrigerant ( PAG ) oil must be added to the system. Where
5. If the system has been charged with the specified a major loss of system oil has occurred, due to:
amount ( 660 ± 20 gms ), go to step 7.
• A broken hose or severe leak
6. To complete the charging of the system, slowly
open the LOW side of the manifold hand valve until • Collision damage to refrigerant system
the 660 ± 20 gms has been charged into the components, or
system.
7. Perform Cooling System Pressure Test. If unit • If excess oil is suspected to be in the system, then
operates satisfactorily, stop engine, shut stop 1. Recover refrigerant from the system, then remove
valves at hose connections to system and
disconnect hoses taking extreme caution, as the the compressor
discharge hose can have upto 20.5 kg / cm2 stored 2. Carefully drain the refrigerant oil
in it. Install service valve caps as required.
WARNING : 3. Flush remaining oil from the rest of the system using
R134a refrigerant.
Never run compressor without refrigerant in system
as compressor lubricant relies on refrigerant flow. CAUTION :
No sight glass is fitted to the system due to PAG oil’s A Refrigerant Recovery Unit (RRU) should be used to flush
foaming properties, which may be confused with a
low gas charge. Topping up the system is not the system, ensuring that the R134a is not vented to the
recommended. atmosphere. The R134a must be reclaimed via the RRU
Accurate system refrigerant charge may only be into a separate bottle.
determined by charging the correct amount of R134a 4. Add recommended quantity of new refrigerant oil to
i.e. 660 ± 20 gms
the compressor.
Pressure gauge readings together with face air outlet
temperatures are the only method of checking and 5. Install the compressor, If ‘O’ ring is damaged then
diagnosing the system cooling capacity (comparing replace the suction and discharge O-rings. Ensure O-
results with the appropriate graph) rings are not twisted and that the seals and O-rings
If in doubt as to gas charge, e.g: are clean.
Suction pressure low 6. Evacuate, then recharge the system.
Discharge pressure low 7. PAG OIL PRECAUTIONS: DO NOT allow PAG oil to
Air outlet temperature ( face ) above graph range. contact either bare skin or car paint work. IF CONTACT
Recover refrigerant from the system using R134a OCCURS, WASH OFF PAG OIL IMMEDIATELY.
specific equipment.
Evacuate system. Charge with 660 g of R134a.
Carry out cooling system pressure test and suction
(low side) pressure readings comparisons.
20
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AIR CONDITIONING
EVACUATION CHARGING (R 134a 660 ± 20 gms)
SAFETY PRECAUTIONS
OPEN HIGH SIDE VALVES &
ALLOW AS MUCH AS
EVACUATION- REFRIGERANT AS POSSIBLE
CONNECT CHARGING TO ENTER SYSTEM, BUT
STATION NOT MORE THAN SPECIFIED
CONNECT GAUGE CLOSE VALVES & ROTATE

MANIFOLD COMPRESSOR FRONT
PLATE MANUALLY TO
START VACUUM ENSURE NO LIQUID IS
PUMP -HIGH TRAPPED IN THE
PRESSURE & LOW COMPRESSOR
PRESSURE GAUGE
READINGS
(HP BELOW ZERO) START ENGINE SET TO FAST
(LP BELOW ZERO) IDLE. (1500 - 1700 rpm) ACTIVATE A/C
SWITCH. SET CONTROL TO
MAXIMISE COOLING &
EVACUATE / HIGH FAN SPEED
DEHYDRATE
TO -1 kg / cm2
OPEN LOW SIDE VALVE &
COMPLETE THE CHARGING
CONTINUE FOR PROCESS (IF REQUIRED)
15 MINUTES
STOP PUMP CAUTION: DO NOT ALLOW

OBSERVE THAT MORE THAN 2 kg / cm2
PRESSURE DOES NOT TO REGISTER ON THE
RISE ABOVE -0.9 kg / cm2 LOW SIDE GAUGE DURING
WITHIN 15 MINUTES CHARGING
CLOSE ALL VALVES & TAPS.

IF PRESSURE STABILISES
REMOVE HIGH & LOW
AT HIGHER LEVEL
FILLING HOSES. CONNECT
RE-EVACUATE
HIGH SIDE FILLING HOSE
TO RECOVERY UNIT INLET
SIDE. SWITCH ON
AIR
RECOVERY MACHINE & CONDITIONING
IF PRESSURE
REMOVE ALL
CONTINUOUSLY
REFRIGERANT IN FILLING
RISES-LEAK TEST
HOSES
RE-EVACUATE
AFTER
RECTIFICATION.
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AIR CONDITIONING
INVERTED DECANTING
FLUSH GUN CYLINDER (LIQUID)
FLUSH, THEN
REVERSE FLUSH
RECOVERY DEVICE
SELF MADE
FITTING
CONDENSER
Fig 14
FLUSHING THE A/C SYSTEM FOR IMPORTANT :

CONTAMINATION OF LUBRICATING OIL The complete air conditioning system must contain 120
REMOVAL ± 10 cc of factory installed refrigerant oil.
Some oil is lost whenever air conditioning system NOTE :

components are replaced. A new compressor will contain 120 cc of factory installed
Where the system has been ruptured, contaminated, or a lubricating oil.
compressor has to be removed and reinstalled or replaced, 1. Flush individual components.
the system should be checked for contamination and, if
so, the entire system must be flushed. 2. Self made flushing will be required as A/C system
component fittings all differ in size, shape and thread
Currently the only method recommended when flushing size.
is with refrigerant R134a.
3. Invert decanting cylinder to use refrigerant in liquid
CAUTION : form.
A Refrigerant Recovery Unit (RRU) should be used to 4. Reverse flush components.
capture the R134a used for flushing. The R134a, must be
reclaimed via the RRU into a separate bottle. Use only a 5. Do not flush through a compressor otherwise possible
dedicated R134a RRU. internal damage could occur
6. Recover / recycle flushing refrigerant, the recovery
device will remove contaminants through a filtration
system.
22
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AIR CONDITIONING
FAULTY
COMPRESSOR DRAIN PLUG NEW E.G. 100 cc
COMPRESSOR INSTALLED
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
1. Drain and measure the refrigerant oil contained in refrigerant oil, either to the original or new evaporator or
the compressor. condenser.
2. Charge oil through the discharge port of the If replacing condenser - add approximately 20 cc oil.
compressor with the same amount of new refrigerant
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 If replacing the FDR - add approximately 20 cc oil
checked, then approximately 120 cc of new oil should be The FDR must be replaced whenever the system has been
added to the compressor being installed. (This is assuming opened to the atmosphere for repair.
the compressor being installed has first been drained).
Blown or Ruptured Pipe / Hose
Installing a New Compressor
When replacement is required add approximately
1. Drain and measure refrigerant oil from the original 10 cc oil each. If slow leak through any joint.
compressor drain plug.
2. Drain factory installed refrigerant oil from new
compressor drain plug (total lubricant quantity 265
cc).
AIR
3. Measure the same amount of new refrigerant oil that CONDITIONING
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.
23
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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 Connected

Gauges
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 Should be

Reading 25 Kg / cm2 MAXIMUM
Low pressure gauge rating 3 Kg / cm2 MAXIMUM
Ambient temperature 0
c
Grill Temperature
1 2 3 4
Average grill temperature - (1+2+3+4)/4 = ____0 C*
* Performance is satisfactory if temperature measurement is within range as shown in graph 1
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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 Fig 16
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 Shoot-
ing 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 Variation of Centre Grill Temp. for Open Door Test.
area as shown in Graph 1. If it is not refer
Graph 1 AIR
trouble shooting chart for further CONDITIONING
investigation. Ps - Refrigerant suction pressure / Low pressure

B. If it is close door test : Average grill Pd - Refrigerant Discharge pressure / High pressure
temperature should be less than 10 0C
within 10 minutes.
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AIR CONDITIONING
Graph 2
26
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AIR CONDITIONING
DO’S AND DON’TS FOR AC SYSTEM
S. No. DO’s REASON
1 Clean condenser During Regular Dirty & Clogged Condenser

Service of the Vehicle 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 Adequate Quantity of Compressor oil prevents
the compressor during refrigerant charging. poor pumping and premature wearing of internal
components.
4. Clean evaporator periodically to Clogged evaporator results in less air flow and
remove dust and foreign particles. reduced cooling.
5. Educate Customer on proper usage Proper usage of AC control will give optimum
of AC controls cooling
(Refer owners manual)
6. Adjust proper engine rpm. Less rpm will result in stalling of engine and less
cooling.
7. Check coolant level and ensure proper This will prevent overheating of engine.
engine tuning
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 This will result in premature failure

in the system of compressor.
2. Do not leak check the AC system with Higher pressure may result in damage
more than 20 kg / cm2 pressure. 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 Improper or No vacuuming of the AC

system without carrying out proper system results in less cooling
AIR
vacuum. conditions. CONDITIONING
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AIR CONDITIONING
Safety Tips Be careful when working near exposed

evaporator or condenser fins. Painful cuts can be
Never handle refrigerant without eye protection
inflicted by these fins.
goggles. Don’t take chances.
Keep your hands clear of the engine and belts
Never discharge vapour from the system into an
while the engine is running.
area where there is flame.
Installing Hoses and Fittings
Never close the compressor discharge valve whilst
the compressor is operating. 1. Always use Refrigerant Oil not Motor Oil to
lubricate ID and OD of hoses and fittings before
Discharge the air conditioning system slowly.
installation
Never weld or steam clean on or near the system.
2.
Use only refrigerant hose and fittings. When installing
Doing so can result in dangerous pressure build up
new hose on old fittings, use same type of hose to
in a closed system and a possible rupture may occur.
ensure proper mating of hose and fittings.
FUNCTION AND INSPECTION OF A. C. COMPONENTS :
SR. COMPONENT FUNCTION INSPECTION

NO.
1 Fresh / Recirculation Actuates the fresh / Remove the extreme left hand side grill cover & by
actuator motor recirculation flap as pressing the fresh / recirculation switch, see the
per the choice. 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 If the blower is not working at speed no 1, 2, & 3,
blower at various & if it is working only at speed no 4, resistor has
speeds. to be replaced with a new one.
3 Anti Freeze switch It protects the A. C. There should always be continuity, at both the
system from freezing. terminals. If there is no continuity, switch has to
be replaced.
4 Trinary Pressure switch Protects the A. C. Check the continuity. The ohm meter should
system from any indicate zero reading. If, any resistance / open
consequential circuit is observed, replace the switch with
damage. new one.
5 VSV (vacuum Device for opening 1. Remove vacuum hoses & electrical
solenoid valve) 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 1. Disconnect electrical connector

the compressor with 2. Pulley should rotate freely with supply
engine, when the air disconnected
conditioner operation 3. Pulley should operate compressor with
is needed it is controlled supply connected.
by A/C relay & 4. Check for noise.
compressor relay
28
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AIR CONDITIONING
INDICA HVAC TROUBLE SHOOTING

PROBLEM / SYMPTOMS POSSIBLE CAUSES REMEDY
1. LOW SIDE - High Evaporator Flooding due 1. Remove refrigerant
HIGH SIDE - High to Block valve Stuck Open 2. Evacuate / dehydrate
PS > 3 kg / cm2 Dirt in Block Valve. 3. Change expansion valve
Pd > 25 kg / cm2 Moisture in the 4. Change filter drier.
Discharge air warm. refrigerant circuit. 5. Charge correct amount of oil &
refrigerant.
6. Check performance.
2. LOW SIDE - High Non condensables (excessive 1. Remove refrigerant

HIGH SIDE - High air) 2. Evacuate / dehydrate
PS > 3 kg / cm2 1. Large amount of air caused 3. Change filter drier
Pd > 25 kg / cm2 by insufficient evacuation after 4. Charge correct
Suction side piping is too hot to touch. repair or servicing system. amount of oil & refrigerant
2. Leak in the system, allowing 5. Check performance
air and moisture to enter.
3. LOW SIDE - High Expansion valve stuck open. Change expansion valve
HIGH SIDE - High
PS > 3 kg / cm2
Pd > 25 kg / cm2
Frosting on the Suction side piping.
4. LOW SIDE - High Excessive refrigerant 1. Check refrigerant quantity.

HIGH SIDE - High Poor condenser cooling 2. Check the pressure switch
PS > 3 kg / cm2 Engine or condenser fan not and condenser fan
Pd > 25 kg / cm2 operating 3. Clean Condenser
DISCHARGE AIR - Warm Fan direction reverse 4. Check pressure cap clearance
HIGH SIDE TUBES - Very Hot Condenser fins clogged with between condenser / radiator.
COMPRESSOR CLUTCH - Could debris 5. Check coolant and any other
continually cycle on the high Radiator overheating radiator problem.
pressure switch
Pressure does not come to normal
when condenser cooled by water.
5. LOW SIDE GAUGE - Low or Vacuum Expansion valve stuck closed / 1. Remove refrigerant
HIGH SIDE - High or / insufficient refrigerant flow 2. Evacuate / dehydrate
PS < 3 kg / cm2 to Vacuum to suction side of compressor. 3. Change filter drier
Pd > 25 kg / cm2 Foreign material or moisture 4. Charge correct
DISCHARGE AIR - slightly cool entry causing rust formation. amount of oil & refrigerant
5. Check performance
AIR
CONDITIONING
6. LOW SIDE - Low or Vacuum Clogging on HIGH SIDE. 1. Remove refrigerant

HIGH SIDE - Low Clogging between compressor 2. Clean and flush system.
PS < 1.8 kg / cm2 to Vacuum outlet and evaporator inlet 3. Change filter drier
Pd < 25 kg / cm2 (High side) 4. Charge correct quantity
DISCHARGE AIR - slightly cool Very little or no refrigerant flow of oil & refrigerant
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AIR CONDITIONING
PROBLEM / SYMPTOMS POSSIBLE CAUSES REMEDY
HIGH SIDE TUBES - Cool and showing to suction (low) side of 5. Check performance
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.
7. LOW SIDE GAUGE - Normal to Vacuum Excessive moisture in the 1. Remove refrigerant
(Gradual reduction) system. 2. Evacuate / dehydrate
HIGH SIDE GAUGE - Normal Moisture can freeze within the 3. Change expansion valve (check)
PS 3 kg / cm2 to Vacuum expansion valve and cause 4. Change filter drier
Pd 14 to 16 kg / cm2 blockages through rust 5. Charge correct
DISCHARGE AIR- Becomes warmer as formation. amount of oil & refrigerant
low side cycles to a Vacuum. 6. Check performance
8. LOW SIDE - High Compressor Malfunctioning Replace Compressor.

HIGH SIDE - Low Compressor faulty, internal Remove refrigerant Evacuate /
PS > 3 kg / cm2 to Vacuum failure Blockage in Suction Dehydrate Change filter drier
Pd < 25 kg / cm2 Hose after low side filling port. change correct amount of oil and
COMPRESSOR - Noisy refrigerant check performance.
DISCHARGE AIR - Warm
DISCHARGE HOSE - Cool
9. ABNORMAL NOISE 1. Belt slippage/damage 1. Check belt tension for

correct operation. Change belt
2. Idler pulley mis alignments 2. Replace Bearing pulley
3. Compressor clutch 3. Check Bracket mounting /
pulley faulty bolts/engine mounting bolts
4. Compressor internal 4. Replace Compressor
damage
5. Loose A/C plumbing
touching body work
10.HIGH / LOW PRESSURE Faulty Compressor Replace Compressor
Equalise after Compressor discharge or inlet valve
stopping Compressor is not hot to Faulty compressor seal.
touch.
11.Compressor pressure Non condensibles in Recover refrigerant/

drop rapidly after switching off the system Check for leak and repair.
& does not stabilize to
saturation pressure as per ambient
temperature .
12.Line to condenser is excessively hot Restricted flow of Remove, restriction
refrigerant in system evacuate & replace RD &
charge through charging unit.
13.OUTLET GRILL Temperature - 1. Loose connection. Attend
Low; no air flow 2. Capillary loose -sensing
3. Evaporator frosted
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PROBLEM/SYMPTOMS POSSIBLE CAUSES REMEDY

14.Insufficient / no air flow 1. Blower rotation Attend
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
15.Compressor Clutch engagement 1. Open circuit Attend

not satisfactory 2. Weak battery
3. Faulty clutch
relay
4. No refrigerant.
5. Shorted clutch coil
6. Oil / dirt on
clutch plate
16.Check Condenser / Radiator Condenser fan Attend

Fan-Direction of rotation pusher type
Radiator fan puller
If fan not operating
a. Loose connection
b. Loose wiring harness
c. Motor burnout
Note : All Ps, Pd values mentioned in trouble shooting chart are for ambient temp. 350C, for other ambients, refer
graph 2 .
AIR
CONDITIONING
31
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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
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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 (DISTRIBUTION CONTROL) AIR
CONDITIONING
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 18 ASSY W/H CABIN COOLING DLX M/S BEHR
33
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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
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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)
AIR
3 ASSY MF CONDENSER + FAN BEHR 9 ASSY TUBE LIQUID R/D OUTLET (BEHR) CONDITIONING
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)
35
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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
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ELECTRICAL
NEXT
GROUP INDEX
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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
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ELECTRICAL
CONTENTS
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
a) Checks on the car 4
b) Removal & installation from the car 5
6. Instrument cluster indicator gauges
a) Removal & installation of instrument cluster 6
b) Speedo unit, odo unit, trip meter, rpm meter 7
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
8. 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 ELECTRICAL
b) Removal and Installation of Master cum follower / follower unit 23
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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
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ELECTRICAL
1. CIRCUIT DIAGRAM SYMBOLS
SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION
GROUND
OR MAGNETIC
EARTH BATTERY
CLUTCH
DIODE CABLE TEMP.

JOINT 0
t SENSOR
SINGLE WAY CROSSOVER DIGITAL

SWITCH WITH JOINT CLOCK
CROSSOVER
TWO WAY WITHOUT HORN
SWITCH JOINT
FUSE LAMP / BULB
STEERING LOCK CUM IGN. SWITCH
RESISTOR
M MOTOR
LED LOCK ACC. IG. START
(A) (B)
VARIABLE M WIPER
RESISTOR MOTOR
RELAY
THERMISTOR
M W/S WASHER
0
t MOTOR
(E) (C)(D)
CIGARETTE G
3 ALTERNATOR J B G
LIGHTER ELECTRONIC
A D C CONTROLLER /
H E F RELAY BASE
HEATER BLOWER
M
DEFROSTER MOTOR VIEW FROM
CABLE ENTRY
SOLENOID
VALVE COUPLER BUZZER
(A)
(D)
ELECTRONIC FAN THERMOSTAT ELECTRICAL
CONTROLLER SW.
(J)
(B)
(C) (E)
1
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ELECTRICAL
2. WIRE COLOUR CODING

Code Colour Name NOTE :
G Green Wire insulator has one colour or one main colour with
Lg Light Green another tracer colour stripe. (e.g. ‘L’ indicates blue
colour. ‘L / W’ indicates blue main colour with white
SL Sky Blue
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.
3. Position Lamp Front 12V, 5 W W5W, W2, 1X9.5D 2 Nos.
CAP LESS
4. Engine lamp (If Provided) 12V, 5 W W5W, W2, 1X9.5D 1 Nos.

CAP LESS
5. Side Repeater Lamp 12V, 5 W W5W, W2, 1X9.5D 2 Nos.

(Amber colour) CAP LESS
6. Reading Lamp (Spot Lamp) 12V, 5 W 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
Fig. 2
C. LOCATION OF RELAYS / CONTROLLERS / FUSES BELOW CO-DRIVER SEAT IN CABIN COMPARTMENT

MPFI PETROL
ELECTRICAL
Fig. 3
3
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ELECTRICAL
5. ALTERNATOR ENGINE WITH ALTERNATOR

Checks on the car :
Start the Engine : CRANKSHAFT
PULLEY
a. Battery charge indicator does not glow :
Check if lamp is faulty. Check fuse continuity.
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, ALTERNATOR
Heater, Tail lamp and other electrical loads.
Rated current output should be reached without
voltage dropping to 13 volts. If not remove
Alternator for thorough checks.
Reduce the engine speed to nearabout 1500 ENGINE WITH A.C. ALTERNATOR
rpm, and ensure that the ammeter reading falls AND POWER STEERING
around 3 to 5 Amps. Check the voltmeter reading.
It should read between 13.8 to 14.2 volts. If not, CRANK SHAFT
remove the alternator and check the regulator. PULLEY ALTERNATOR
b. Warning indicator continues to glow :

Check the belt tension.
8-9 mm
If found slack, adjust the belt deflection to the
specified value. Repeat test. Fig.4
A. C.
COMPRESSOR 8-9
mm
TENSIONER
POWER STEERING
PUMP
Fig. 4 Schematic
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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 & Fig. 5
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. 6
ELECTRICAL
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ELECTRICAL
6. INSTRUMENTS CLUSTER
INDICATOR GAUGES :
Remove steering wheel as per procedure given UPPER NACELLE
in ‘BODY’ section. Refer to safety precautions
relating to Airbags.
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 LOWER NACELLE
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 Fig. 7
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.
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
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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 Odometer
among preset levels.
LCD has two line display. The first line displays the Tripmeter
Odometer count. The second line displays either of or
Tripmeter A, Tripmeter B, Intensity level of panel Display for Trip - A Intensity level of
illumination. 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. Mode
Set
The 'SET' knob is used to control the chosen function. Selector
Knob Display for Trip - B
Pressing the knob for a few seconds resets the chosen Knob
tripmeter and varies the intensity level of instrument panel
illumination.
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 Intensity Level Indicator
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 :
The meter indicates engine speed in revolutions per
minute (rpm)
Change gears at appropriate engine rpm and car speed to
get optimum fuel economy. ELECTRICAL
The permitted engine rpm upper limit is the start of Red

Zone on the dial.
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8
Petrol
Indicators* Engine RPM Meter

Speedometer
INDEX
ELECTRICAL
GROUP INDEX
Set Knob Fuel Gauge
Mode Selector Knob
Temperature
Gauge LCD
NEXT
* All indicators and Chrome ring may not be provided on some clusters.
PREVIOUS
ELECTRICAL
7. LIGHTING AND SIGNALING : HEAD LAMP MOUNTING LUG
Head Lamps, Front Parking Lamps and Front HEAD LAMP TOP SIDE OF HEAD
MOUNTING LAMP
Turn Signal Lamps 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 BULB FOR HEAD
LAMP DIREC- DIRECTION
HEAD LAMP BULB TION LAMP
4. Take out the head lamp assembly. RETAINER CLIP LAMP HOLDER
5. Remove the rubber cap & take out the retaining Fig. 10
clip. Then take out the bulb.
Installation of head lamp
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. Re-
place 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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Head lamp beam adjustment :

Before adjusting the headlamp beam, 0
1. The tyre pressure should be as specified and 1

the car should be on level ground.
2. The car should be loaded as specified (ECIE
condition) 2
3. The car should be rolled for a few meters after

loading to allow the springs to settle. 3
4. 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 Switch position Loading condition
sharp features. 0 Unladen
The headlamps should be set one at a time. 0 Driver
The setting is to be checked on the car against the 0 Driver+ Co-driver
board and adjust the focussing (Horizontal movement) 1 All seats occupied
and levelling (Vertical movement) only if required using
the headlamp adjusting screws. Fig. 13 2 All seats occupied +50kg in boot
The board details are shown for RHD version. 3 Driver + 290 kg in boot
The headlamp settings on LHD version are mirror
opposite. Fig. 14
Fig. 12
HEADLAMP ADJUSTING SCREWS
VIEW WITHOUT LEVELLING MOTOR
Fig. 13
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ELECTRICAL
HEADLAMP SETTING SCREEN (FOR RHD VEHICLE AT 10M FROM HEADLAMP)
ELECTRICAL
Fig. 14
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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
Installation of Rear Cluster Lamp Fig. 15
TAIL LAMP AIR
Inspection of rear cluster lamp BREATHER TUBE
TAIL LAMP BULB
1) Check if the connectors for any loose terminals
or wires broken at the ter. ends. PIGTAIL WITH
HOLDER
2) 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 SCREW DRIVER
the cut out and press till the catches hold.
NOTE :
Screws are to be tightened gently on plastic flanges.
SIDE REPEATER
LAMP
Fig. 17
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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 Fig. 19
till the catches are released.
Remove the electrical connections from the lamp and
+ 12V
take it out. +
Installation
(12V 5W
(12V 10W)
Insert the lamp into the cut-out in the roof molding 2 NOS.)
and press till the catches are engaged.
A schematic circuit diagram showing the Roof lamp
OFF
is given in Fig. 20 & 20a
The connectors for the roof lamp are as shown in
Fig. 20a OFF
ON
DOOR
Fig. 20
TERMINALS
ELECTRICAL
Fig. 18 Fig. 20a
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Engine lamp (if fitted)

Removal
Remove the two screws (1) & (2) which hold the Push-Pull Switch
engine lamp bracket onto front windscreen bottom
panel (Fig. 21)
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.
Fig. 21
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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 Terminal Description Fig. 22
Active Level Condition

Name 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
ELECTRICAL
be disconnected. Again Ter.A and B get
connected for one wipe cycle. This cycle
continues as long as Ter.D is high.
Fig. 23
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• When wash input (J) becomes active, output Ter. WIPER ARM
A should get connected to terminal B after 0.7 MOUNTING NUTS
WIPER ARM
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.
Alternately use the test rig for Front wiper control
unit (Part No. 2699 5420 9928) and check the
proper functioning. WIPER MOTOR
LEAF SCREEN MOUNTING
Removal of front wiper system BRACKET
1. Disconnect the battery negative terminal WIPER MOTOR

MOUNTING
2. Remove both the front wiper arms and blades by WIPER MOTOR SCREWS
removing the wiper arm mounting nuts. Fig. 24.
Fig. 24
3. Remove the six hex screws holding the wiper
motor mounting bracket beneath the leafscreen WIPER ARM
bottom panel. Fig.24 REAR WASHER NOZZLE
4. Take out the bracket along with the motor and
the links.
Installation WIPER ARM
MOUNTING
Follow the steps given above in the reverse order. 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 Fig. 25
completed when Ter.C goes to GND from VCC
level). Then for time of 6 seconds Ter. A and B Removal
should be disconnected. Again Ter.A and B get
connected for one wipe cycle. This cycle 1. Disconnect the battery negative cable.
continues as long as Ter.D is high. 2. Remove the arm and blade of the rear wiper by
• When wash input (J) becomes active output Ter. removing the mounting nut.
A should get connected to terminal B after 0.7 3. Remove the rear wiper cover.
sec. (Delay provided for water to reach from the
4. Remove the rear wiper bracket and take out the
nozzle to glass) and when Ter. J goes low Ter. A
motor. .
get disconnect from Ter. B after 2 sec. The wash
should have higher priority than the intermittent Installation
signal.
Alternately use the test rig for Front wiper control
Detailed connections in the circuit for Rear wiper are
unit (Part No. 2699 5420 9928) and check the
as given in wiring diagram section.
proper functioning.
NOTE : FOR DETAILED DESCRIPTION REFER
WIPER SECTION.
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Wiper Care : WINDSHIELD

GLASS
Wiper blade attack angle on windshield glass should OK NOT OK
be 900 i. e. perpendicular.
WINDSHIELD
Remove wiper and set wiper arm on windshield glass 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
OK NOT OK TO
WINDSHIELD OL
GLASS 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 SECONDARY
again as shown in Fig. 27 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 ELECTRICAL
(ONE DROP
EACH)
Fig. 28
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Windscreen Wash
Removal
1) Disconnect the battery negative cable
2) Remove the front bumper
3) Disconnect the windscreen washer tube from the WASHER BOTTLE
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.
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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 Description Active Condition

Name Type Level
Fig. 30
C Input Heated Rear VCC Switch on
Window Switch
B Supply Ignition VCC I/G
Switch ON Position
E Ground Ground to GND Permanent
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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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
Fig. 32 WELD NUT
HEX PL SCREW
ASSY. BRACKET
HEX FL NUT
HEX SCREW
Fig. 31
Fig. 33
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10. BUZZER UNIT

Function _ A
Its function is to generate the warning sound to alert C

+
the driver about any abnormal condition of the car. It
receives the input from the chime unit.
Location
In cabin fuse box
Ter. Description Active
Name Type Level
C Input Chime Unit output VCC
A Ground Ground to Unit GND Fig. 34
Performance check
Sound : Sound output should not show a
cracking sound. Tone should be good
for entire voltage range.
Buzzer type : Beep at the rate of 1 beep/second.
ELECTRICAL
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11. ANTI THEFT CUM KEYLESS ENTRY

SYSTEM :
Fig. 35
This vehicle is fitted with an integrated unit for anti-
theft 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 Fig. 35
cluster indicates system status.
Preliminary checks
Carry out the following preliminary checks as per given Control Unit
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
Coded Plug
system. Locate the faulty unit and carry out
repairs as given in subsequent paras. Fig. 35a
• Operate LOCK & UNLOCK buttons on the user
remote and check functioning of the system. Check the mechanical link between the master unit
During locking, the system responds with two and door lock for proper functioning. The link should
flashes of the direction indicators, if the operation operate the master unit on rotation of the key.
is succesfull. During unlocking, the system Removal of Master cum follower unit/Follower
responds with one flash. Incase a LOCK unit.
command is unsuccesfull the system will give
only one flash. If so, check for proper fitment and a) Take the driver’s side door window glass to upper
operation of master actuator on drivers door. most position.
• If the keyless entry or central locking functions b) Remove door inner trim. (Refer Body group in
this manual). Open out required portion of plastic
are found inoperative, check if the LED on the
membrane.
user remote is blinking when the LOCK/UNLOCK
buttons are pressed. If so, replace the battery in c) Disconnect electrical connectors of master cum
the user remote. If user remote is O.K. check for follower.
proper fitment of connectors and relays at the
control unit. If these are O.K. replace relays first,
followed by control module.
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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 PIVOT
f) 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
(Link connecting master cum follower unit and FROM
the pivot) PIVOT
TO
Inspection MASTER
• Check proper operation of door handle, inner CUM
handle and door lock. Rectify any defect. FOLLOWER
• Check the proper functioning of the replaced UNIT
master cum follower unit/follower unit on the rig. Fig. 36
Hold the output lever lightly to check that unit is
exerting force. If not, replace with a working unit.
MASTER
For any of the ter. connection details for master CONNECTOR
WIRING DIAGRAM
and follower unit refer Fig. 37
Installation of Master cum follower unit / follower RED/
unit : C BLACK
NO NC TER.1
a) Fit master cum follower unit on the door. TER.4
b) Tighten the 2 mounting screws. TER.5
TER.2
c) Assemble the solenoid link from master cum
3 2 5 4 1
follower to link connector. BROWN/
BROWN/YELLOW TER.3
BLUE
NOTE :
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.
BRACKET
SCREW
d) Assemble the front door to door latch.
e) Connect electrical connectors of the master cum
follower to wiring harness connector.
FOLLOWER
f) Follow the above procedure (‘a’ to ‘e’) for installation
of follower units on the co-driver side door, rear WIRING DIAGRAM
GREEN/RED
RH door and rear LH door. TER.1
NOTE : A A’
M TER.2
Do not disturb the adjustment of door handle link and
door lock link. If disturbed readjust and ensure proper YELLOW/RED
functioning of door handle and door lock.
Check and ensure proper functioning of the central 2 1
locking system ELECTRICAL
g) Fix plastic membrane, door inner trim.

(For procedure refer Body group from this manual).
Fig. 37
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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. H
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. Fig. 38
Connection details :
Ter. Ter. Description Active Level Condition
Name Type
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
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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.
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
! P +ve
S1 •
• Vcc
EARTH
Fig. 39
ELECTRICAL
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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
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 :

For the circuit of chime unit, refer Circuit diagram
1) AFTER 6.5 ± 2 SEC START OF CHIMING
section
2) CHANGE IN OUTPUT CONDITION MAKING
OUTPUT ACTIVE
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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.
Location ST 30
15aK A
50
Steering Column
15
400 900
P
250
For removal of steering lock cum ignition switch, refer IGN
OFF
Mechanical steering group of this manual.For circuit FOR TERMINAL DETAILS, REFER
connections, refer Fig. 42 and wiring diagram section. THE TABLE GIVEN BELOW
Fig. 42
Connection details :
CONTACT WAY OF SWITCH - 158 O +5O NO DETENT AND SPRING RETURN
LOCK OFF IGNITION START +30

155O-144
123O @ 137O @
15 - 30
50 - 30
15a- 30
P - 30
KA - 30
KA - 30
0O 30O 60O 90O 120O 150O
THIS REQUIREMENT
ELECTRICAL CONNECTION MUST EXIST. MUST BE MET WHEN
KEY IS ROTATED FROM
LOCK TOWARD OFF
ELECTRICAL CONNECTION CAN EXIST. POSITION.
@ CONTACT BETWEEN 30-15a AND

ELECTRICAL
30-50 WILL NOT OCCUR THIS REQUIREMENT MUST
SIMULTANEOUSLY AT ANY BE MET WHEN KEY IS
POSITION OF KEY TRAVEL. ROTATED TOWARD LOCK
POSITION.
Fig. 43
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ELECTRICAL
POSITION
Key out Key in
LOCK LOCK ACC. IGN CRANK
Key in sensor
TERMINALS
Battery
Accessories
Ignition
Crank
Key rotation forward Steering Steering Steering Steering Steering
Locked Locked Free Free Free
Key rotation backward Steering Steering Steering Steering Steering
Locked Free Free Free 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
For removal and installation of combi-switch refer
lamps, parking lamps and number plate lamps.
Steering group from this Manual.
It’s right side lever operates the windshield wiper Connection details : Fig. 53
and washer.
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ELECTRICAL
Fig. 45
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17. FACIA SWITCHES Fig. 46 ‘ON’ STATE LEGEND

INDICATION ILLUMINATION
Function
1 2
Functions of different facia switches are given in the
following table.
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 5 3
Fig. 47
TER. 5
TER. 4
FREE
TER. 3
1 TER. 1 TER. 2
4
✬ ✬
2 3
STICKER LOCATION
Fig. 46 Fig. 48
Sr. Description Colour of Legend Type Colour of

No. illumination for Sticker
ON state
1 Switch Amber Not latched. Red
rear window ON only when
heater Pressed in
2 Switch rear Amber Not latched. Yellow
fog lamp ON only when
pressed in.
Switch front Not latched.
3 fog lamp Amber ON only when White
pressed in
4 Switch rear Green Latched in No sticker
wiper ON position
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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 WINDOW WINDING
and hold the switch towards position marked , and SWITCH ON
CENTRAL CONSOLE
for down, press towards position marked .
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
Inspection ON REAR DOOR
For non functioning of the Window winding mecha-

nism,
• Check fuses (located in fuse box placed below
Driver’s seat). If blown then replace them.
• Check all related electrical connections at con-
nectors.
• If found OK, then check operating switch for
proper functioning. Replace them if required.
TERMINALS
Switch ON the ignition key and check for electri-
cal supply at different stages like
Fig. 49
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
BAT. C
then replace the motor. SUPPLY NC K1
B D
D B E
• Check drive square of the drive unit, if found worn NC
E M
ACC. J A H
out then replace drive unit. NC
SUPPLY C
A R1R2
• Check for the free movement of the Window wind- SW1
720 720
ing mechanism. If found hard and defective, then (UP) K1 K1 SW2
replace the assembly. J
6900 6900 H (DOWN)
Dual Relay 12 V-30A is used for window winding. The

terminals & connection details (circuit) are as shown ELECTRICAL
in Fig. 50
The circuit for the power windows is given in wiring
diagram section.
Fig. 50
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19. POWER SOCKET : Fig. 51

A power socket is fitted on the center console and Power Socket
can be used to connect load upto 10A maximum. To
use, remove the cap first
20. DIGITAL CLOCK : Fig. 52

Function
It indicates time in hours and minutes.
Location
It is located on dash board.
Terminal Connection Function
No. Fig. 51
1. Battery Supply
(B+) connection
2. Ground Ground
connection
3. Parking Display
switch Intensity control
4. Ignition Display
switch ON/OFF control
Setting procedure
After connecting the BATTERY, GROUND AND IGNI-
TION-
The display shows 1.00, display blinking (Clock Run-
ning)
Display blinking stops when any of ‘H’ or ‘M’ is pressed Fig. 52
and dot starts blinking once in one sec.
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 Terminals
Ter.1
on incrementing at a rate of 1 count per second for PART NO.
first five counts and subsequently at a faster rate. XXXX XXXX XX XX Ter.2
SR NO. Ter.3
If ‘Z’ switch is pressed, the internal seconds count is
reset to ‘0’.
When any of pressed switch is released, clock starts Ter.4
running from that time. (Dot blinking).
Fig. 53
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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
It is located in cabin fuse box. Fig. 54
Connection details
FLASHER
Connection details are shown in Fig. 54 L
Checking flasher unit

B E
a) Connect bulb to the flasher unit and battery as
shown in Fig. 55. The bulb should blink at 90 ±
30 cpm.
10 A 12 V
b) Disconnect one of 21 W bulbs. The remaining 21 W x 2
Fuse
bulb should blink atleast 1.8 times of (a) or
140 cpm whichever is greater.
SWITCH
+
Fig. 55
ELECTRICAL
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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
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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. CUT-OUT IN THE FLOOR
3) Remove the tubes connecting to the tank unit. CARPET FOR FUEL TANK
4) Unscrew the six screws which hold the unit and

take it out.
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 Fig. 58
fuel gauge is given below :
Tank Fuel Level Capacity Position of float Ressistance Tolerence

in mm in Litres in Tank value in Ohm 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 FULL
WIRE SEAL
METER
GAUGE VIOLET
3/4
TERMINAL
(Violet)
1/2
TENK UNIT BRAZED
SOLODERED 1/4 ELECTRICAL
TERMINAL
(BROWN)
EMPTY HIGH
EMPTY LOW
Fig. 60
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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.
NOTE : In addition to these guidelines also
6.4. Window Winder.
refer to the respective sections for additional
troubleshooting of Alternator, Starter motor &
Wiper motor.
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BATTERY & ALTERNATOR :
Fault Possible Causes Remedial Action
• Battery getting discharged 1) Alternator belt loose Tighten belt

frequently
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 Replace alternator voltage
setting wrong regulator
• Battery getting warm 1) Alternator voltage regulator Replace the regulator with a
faulty 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 Tighten the connections
loose
ELECTRICAL
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STARTING AND IGNITION
PETROL MPFI ENGINE - ELECTRICAL ITEMS

● Engine not cranking at all 1) Starter motor terminals Tighten starter motor terminals
loose
2) 4 pole connector from Cabin Fix the connector properly
W/H to Front W/H loose
3) Black-white wire terminal in Fix the connector properly
4 pole connector from Cabin
W/H to Front W/H loose
4) Ignition switch faulty Replace ignition switch
● Engine cranking, but not 1) Starter motor terminals Tighten starter motor terminals
starting loose
2) Battery discharged (Check Recharge battery. Replace
alternator charging system) battery if battery is dead
3) Starter motor solenoid not Replace starter motor
working properly
4) Starter motor faulty Replace starter motor
FUEL GAUGE/FUEL METER :

● Fuel gauge not working 1) Connectors loose at the Fix the connectors properly
instrument cluster
2) 18 pole connector from Fix the connectors properly
Cabin W/H to Floor W/H
loose
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3) 2 pole connector at the tank Fix the connector properly

unit loose
4) Fuel meter faulty Replace fuel meter
5) Fuel tank unit faulty Replace fuel tank unit
● Fuel gauge needle flickers 1) Damping inadequate Replace gauge

when vehicle is moving
TEMPERATURE TRANSDUCER/GAUGE
● Temperature gauge not 1) Connectors loose at the Fix the connectors properly
working instrument cluster
2) 20 pole connector from Fix the connector properly
Cabin W/H to Front W/H
loose or 10 pole connector
from Front W/H to Engine
W/H loose
3) Two pole connector at Fix the connector properly
Temperature transducer
loose
4) Temperature transducer Replace temperature transducer
faulty
5) Temperature gauge faulty Replace temperature gauge
ELECTRICAL
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RPM METER
● RPM meter not working 1) Connectors on the cluster Fix the connectors properly
loose/20 pole connector
from Front W/H to Cabin
W/H loose / 3 pole connector
on alternator loose
2) Alternator phase signal Check the output with an RPM
output is not available at meter in working condition. If
terminal W on the alternator 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
Head Lamps
● Single head lamp (RH or 1) Grounding point no. E5 Tighten grounding properly
LH) not working (RH) or E4 (LH) loose
2) Head Lamp connector Fix connector properly
(3 pole) loose
3) Bulb blown Replace bulb
● Single head lamp (RH or 1) High/Low beam filament in Replace bulb

LH) not working in the bulb blown
high/low beam
2) High/Low beam terminal Insert the terminal into the
(pink/blue wire) has come connector properly
off the connector
● Both lamps not working in 1) Head lamp high / low beam Fix the fuse in the base
high / low beam fuse (15A) in cabin fuse box properly. If blown, check for
loose/blown short in the circuit and then
replace the fuse
2) Head lamp high / low beam Fix the relay properly
relay in cabin loose
3) Head lamp high / low beam Replace relay
relay faulty
4) Connectors at combi-switch Fix the connectors properly
loose/10 pole connector
from Front W/H to cabin
W/H loose
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5) High / Low beam switch in Replace combi-switch

combi-switch faulty
● High beam does not come 1) connector loose at combi Fix the connector properly
on when flash switch is switch
activated
2) Flash switch faulty Replace combi-switch
Front Parking Lamps
● Single front parking lamp 1) Connector (2 pole) loose Fix the connector properly
not working 2) Bulb loose/fused Fix the bulb properly. Replace
bulb if blown
3) Grounding point no E5 Tighten the grounding properly
(RH) or E4 (LH) loose
4) Parking lamp LH/RH fuse Fix the fuse properly in the base.
(5A) in cabin fuse box If blown, check for short in the
loose/blown circuit and then replace the fuse
5) Battery supply not reaching Check the continuity from
parking lamp LH/RH fuse battery to the lamps through the
input combi-switch, Front W/H and
Floor W/H connectors and
rectify the discontinuity in the
circuit.
● Both parking lamps not 1) Combi-switch connectors Fix the connectors properly
working loose/20 pole connector
W/H loose
2) Combi switch faulty Replace combi-switch
Front turn signal lamps
● Front right / left signal 1) Grounding point in engine Tighten the grounding properly
lamps not working compartment i. e. point no. 31/3
near LH head lamp loose
2) Connector at the lamp (2 pole) Fix the connector properly
loose
3) Bulb loose/fused Fix the bulb properly. Replace
bulb if blown
ELECTRICAL
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REAR PARKING/ STOP/ REAR TURN SIGNAL/ REAR FOG LAMPS.

Reverse lamps
● Single reverse lamp not 1) Grounding point no. E13 Tighten grounding properly
working loose
bulb if blown
3) 6 pole connector from Floor Fix the connector properly
W/H to Rear Cluster Lamp
loose.
● Both reverse lamps not 1) Reverse lamp fuse (20A) in Fix the fuse in the base firmly. If
working cabin fuse box loose / blown blown, check for short in the
circuit and then replace the fuse
2) Reverse lamp switch faulty Replace reverse lamp switch
Parking Lamps
● Single parking lamp rear 1) Grounding point no. E13 Tighten grounding properly
not working loose
2) Parking lamp LH/RH fuse Fix the fuse properly in the
(5A) in cabin fuse box loose base, if blown, check for short in
/blown the circuit and then replace the
fuse
3) 6 pole connector from floor Fix the terminal properly
W/H to Rear cluster lamp
loose
4) Bulb loose / fused Fix the bulb properly. Replace
bulb if blown
5) Battery supply not reaching Check the continuity from
parking lamp LH/RH fuse battery to the lamps through the
input combi-switch, Front W/H and
Floor W/H connectors and
rectify the discontinuity in the
circuit.
● Both parking lamps not 1) Combi switch connectors Fix the connectors properly
working at all loose/20 pole connector
W/H loose
2) Combi switch faulty Replace combi -switch
Stop Lamp
● Single stop lamp not 1) Grounding point no. E13 Tighten grounding properly
working loose
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2) 6 pole connector from floor Fix the connector properly
W/H to Rear cluster lamp
loose
bulb if blown
● Both stop lamps not 1) Stop lamp fuse (10A) in cabin Fix fuse firmly in the base.
working fuse box loose/blown Replace if blown
2) Connector (18 pole) from Fix the connector properly
Cabin W/H to Floor W/H
loose
3) Adjustment of stop lamp Adjust the switch to correct
switch not proper setting
4) Brake lamp switch faulty Replace switch
Rear turn signal lamps
● Rear right / left turn signal 1) Grounding point no. E13 Tighten grounding properly
lamps not working loose
2) Bulb loose / fused Fix the bulb properly. Replace
bulb
● No indicator lamp is 1) Flasher fuse (10A) in cabin Fix fuse properly in the base.
working fuse box loose/blown Replace fuse if blown
2) Flasher in cabin fuse box Replace Flasher
faulty
3) Connector at Hazard Fix the connector properly
Warning Switch loose
Rear Fog Lamp
● Single lamp not working 1) Grounding point no. E13 Tighten grounding properly
loose
2) 6 pole connector from Floor Connect the terminal properly
W/H To Rear cluster lamp
loose
3) Bulb loose / fused Fix bulb properly in holder.
Replace bulb if blown
● Both lamps not working 1) Rear fog lamp fuse (20A) in Fix the fuse properly. If blown,
cabin fuse box loose/blown check for short in the circuit and
then replace the fuse
2) Rear fog lamp relay in cabin Fix relay properly ELECTRICAL
fuse box loose
3) Rear fog lamp relay located Replace relay
(near steering column) faulty
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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 1) Bulb loose/fused Fix bulb properly. Replace if
symbol not lighting blown
● Rear fog lamp switch on- 1) Bulb loose/fused Fix bulb properly. Replace if
state indication not lighting blown
● Both legend and on-state 1) Bulb loose/fused Fix bulb properly. Replace if
indication not lighting for blown
rear fog lamp switch 2) Grounding near side Tighten the grounding properly
repeater lamp RH is loose
SIDE REPEATER LAMPS :

● Side repeater lamps not 1) Connectors (2 pole) at the Connect the connectors
working lamps loose properly
2) Bulb loose/ blown Fix the bulb properly. Replace
bulb if blown
3) Grounding point no. E15 Tighten grounding properly
(RH) or E16 (LH) loose
REGISTRATION PLATE LAMPS :

● Single registration plate 1) Grounding point no. E13 Tighten grounding properly
lamp not working loose
2) Lamp connector loose Fix connector properly
3) Bulb blown Replace bulb
4) Parking lamp fuse (5A) in Fix the fuse in the base
cabin fuse box loose/blown properly. If blown, check for
short in the the circuit and then
replace the fuse
● Both lamps not working 1) Combi-switch faulty light stalk Replace combi-switch light stalk
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ROOF LAMPS :
● Spot lamps not working 1) Bulbs loose / blown Fix the bulbs properly. Replace
bulbs if blown
2) Switch erratic Replace roof lamp
● Cabin lamp not working in 1) Bulb loose/fused Fix the bulb properly. Replace
‘ON’ position bulb if blown
2) Switch operation erratic Replace Roof lamp
HAZARD WARNING :
● Indicator lamps are not 1) Connector at the switch Fix the connector terminal
working when hazard loose properly
warning switch is operated 2) Hazard warning switch faulty Replace switch
3) Flasher fuse (10A) in cabin Fix fuse properly in the base.
fuse box loose/blown Replace fuse if blown
4) Flasher in cabin fuse box Replace Flasher
faulty
ELECTRICAL
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FRONT WIPER :
● Front wiper system not 1) Grounding point no. E3 Tighten grounding properly
working at all loose
2) Connector (6 pole) loose at Fix the connectors properly
the front wiper motor
3) Wash wiper fuse (25A) Fix the fuse firmly in the base. If
in cabin fuse box blown, check for short in the
loose/ blown circuit and then replace the fuse
4) Front wiper controller in Fix the controller in the base

cabin loose in the base properly
5) Front wiper controller faulty Replace controller
6) Front wiper motor faulty Replace front wiper motor
● Front wiper system does 1) Terminals in the front wiper Connect the terminals properly
not work in all speeds motor connector loose /
Terminals in front wiper
controller base loose
2) Front wiper controller erratic Replace front wiper controller
FRONT WINDSCREEN WASH :

● Front Windscreen washer 1) Water tank empty Fill tank with Windscreen
not working washer fluid
2) Washer tube joints are open Connect the joints properly
3) Grounding point no. E5 Tighten grounding properly
loose
4) Connection loose at front Fix the connectors properly
windscreen washer pump.
connection from Cabin W/H
to Front W/H loose
5) Wash wiper fuse (25 A) in Fix the fuse in the base
cabin fuse box loose/blown properly. Replace if blown
6) Front windscreen washer Replace pump
pump faulty
7) Front windscreen washer Replace switch
switch in combi-switch stalk
faulty
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REAR WIPER :
● Rear wiper system not 1) Grounding point no. E14 Tighten grounding properly
working at all loose
2) Connector (4 pole) loose at Fix the connector properly
the rear wiper motor
3) Wash wiper fuse (25A) in Fix the fuse firmly in the base. If
cabin fuse box loose/blown blown, check for short in the
4) Rear wiper controller / relay Fix the controller / relay in the
in cabin loose in the base base properly
5) Rear wiper controller / relay Replace the faulty part
faulty
6) Rear wiper switch in facia Replace switch
pack faulty
7) Rear wiper motor faulty Replace rear wiper motor
● Rear wiper switch symbol 1) Bulb loose / fused Fix the bulb properly. Replace if
not lighting blown
● Rear wiper switch on-state 1) Bulb loose/fused Fix the bulb properly. Replace if
indication not lighting blown
● Both legend and on-state 1) Grounding near side Tighten the grounding properly
indication on Rear wiper repeater lamp RH i. e. grounding
switch not lighting point no. E15 is loose
2) Bulb loose / fused Fix the bulb properly. Replace if
blown.
REAR WASH :
● Rear Windscreen washer 1) Water tank empty Fill tank with Windscreen
not working washer fluid
2) Washer tube joints are open Connect the joints properly
3) Grounding point no.E5 Tighten grounding properly
loose
4) Connection loose at rear Fix the connectors properly
windscreen washer pump /
connection from Cabin W/H
to Front W/H loose.
5) Wash wiper fuse (25A) in Fix the fuse in the base
cabin fuse box loose/blown properly. Replace if blown. ELECTRICAL
6) Rear windscreen washer Replace pump

pump faulty
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7) Rear windscreen washer Replace switch
switch in pack of Facia
switches faulty
● Rear windscreen washer 1) Bulb loose/fused Fix the bulb properly. Replace if
switch symbol not lighting blown
● Rear windscreen washer 1) Bulb loose/fused Fix the bulb properly. Replace if
switch on-state indication blown
not lighting
● Rear windscreen washer 1) Grounding near side Tighten the grounding properly
switch illumination repeater lamp RH is loose
not working at all 2) Bulb loose/fused Fix the bulb properly. Replace if
blown
HORN :
● Horn not working 1) Grounding point no.E4 Tighten grounding properly
loose
2) Ring terminals at horn loose Connect the terminal properly
3) Horn fuse (15A) in Engine Fix the fuse firmly in the base.
compartment fuse box in Replace if blown
Cabin fuse box loose/blown
4) Horn relay in cabin loose Fix the relay properly
5) Horn relay coil fuse (5A) in Fix fuse firmly. If fuse d\blown,
cabin fuse box loose/blown check for short in the circuit
and then replace the fuse
6) 20 pole connector from Fix the connector properly
Cabin W/H to Front W.H
loose
7) Horn switch terminal / horn Replace control switch plunger
switch contact in steering topping/Adjust horn switch
pad improper contact in steering pad properly
● Horn sound distorted 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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HEATED REAR WINDOW

● Heated Rear Window not 1) Grounding point no. E14 Tighten grounding properly
working loose
2) Connection loose at Heater/ Fix the connectors properly
Connection from Cabin W/H
to Floor W/H loose or Floor
W/H to Tail gate W/H loose
3) Heated Rear Window fuse Fix fuse firmly in the base. If
(20A) in cabin fuse box blown, check for short in the
loose/blown circuit and then replace the fuse
4) Heated Rear Window timer Fix the timer firmly in the base
loose
5) Terminals loose at Heated Connect the terminals properly
Rear Window fuse base/
Heated Rear Window timer
base
6) Heated Rear Window timer Replace timer
in cabin fuse box faulty
7) Heated Rear Window switch Replace switch
faulty
8) Heater coil open Check for continuity in the
heater coil. Replace rear
windscreen glass if coil is open.
• Heated Rear Window 1) Bulb loose /fused Fix the bulb properly. Replace if
switch symbol not lit blown
• Heated Rear Window 1) Bulb loose/fused Fix the bulb properly. Replace if
switch ON-state indication blown
not lit
• Both the legend and ON- 1) Grounding near side Tighten the grounding properly
state indication on Heated repeater lamp RH is loose
Rear Window switch not 2) Bulb loose/ fused Fix the bulb property. Replace if
lighting blown
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IMMOBILISER / ANTI THEFT SYSTEM :

• One or more of the doors 1) Grounding point no. E12 Tighten grounding properly
(but not all doors) not loose
locking / unlocking
properly 2) ECU connector (34 pole) loose Fix the connector properly
Ground point for Immobiliser
ECU = E1
3) Connection from door W/H to Fix the connector properly
Floor W/H (8 pole for Front
door RH, 4 pole for Front
door LH, 6 pole for rear
doors) loose
4) Central Locking Unit Fix the connector properly.
controller connection loose
5) Link between CLU actuator Fit the link properly. Replace
and latch has come off or is link if broken
broken
6) CLU actuator faulty Replace actuator
• Immobiliser ECU 1) Grounding point no. E1 Tighten grounding properly

System not working at all loose
2) Battery discharged Recharge/ Replace battery
3) ECU connector Fix the connector properly.
(34 pole) loose
4) Immobiliser fuse (30 A) in cabin Fix fuse firmly in the base. If
fuse box loose/blown blown, check for short in the
5) Link between master Fit the link properly. Replace
actuator and latch on Driver link if broken
door has come off or is
broken
6) CLU Master actuator not Replace master actuator
working/ micro-switch faulty
• Vehicle not starting (starter not 1) Air connection or supply not Check the 12V between, Key-in
working) present. & ground, Ignition & ground,
Starter & ground.
2) Inertia switch in operated Release the inertia switch, check if

condition. vehicle is starting.
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3) Low battery voltage Replace/recharge vehicle battery.
• Lock or unlock function is not 1) Discharged battery on remote Check LED on the remote, when any
working with remote. 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 1) Door open or door switch faulty The unit is sensing door open signal
into panic mode, when vehicle One of the door switch is faulty.
is locked by remote Check all the door switches
including Dickey & bonnet.
• Vehicle is not going into panic 1) Door switch faulty. When vehicle is locked by remote
mode, when vehicle is locked then open individual door & check
by remote & door is opened by if vehicle goes into panic mode.
mechanical key. 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 1) Wrong connection. Interchange the two pole connector
locking & rear doors are not wires from patch harness which are
locking. going to the Actuators.
• Vehicle does not go into lock 1) Key present in ignition. Remove key out of vehicle, close
mode when operated by remote the door & lock using remote.
• Vehicle automatically gets 1) Master lock actuator connector Rectify.

unlocked after few kms/miles. is not latched properly.
ELECTRICAL
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WINDOW WINDER :
• One or more of the 1) Fuse (30A) for the respective Fix fuse firmly in the base. If
window winders not door loose/ blown under blown, check for short in the
working driver seat circuit and then replace the fuse
2) Grounding point no.E12 Tighten grounding properly.
loose.
3) Relay in relay box under Push the relay firmly till clicking
driver seat not fixed firmly sound is felt.
4) Motor connections are loose Remove the door trim and fix
the connector properly.
5) Relay faulty Replace the relay
6) Door W/H connector not Fix the connectors firmly.
mating with Floor W/H
● •All Window winders 1) Battery discharged Replace/charge the battery

moving slowly/not
working at all 2) Grounding point no. E12 Tighten grounding properly
loose
3) Cabin W/H to Floor W/H Fix the connector properly
connector (4 pole) loose
4) Relay coil fuse (5A) under Fix the fuse properly. If blown,
driver seat loose/blown check for short in the circuit and
then replace the fuse
5) Accessory supply not coming Connect the Floor W/H harness
upto Coil fuse (5A) and Cabin W/H properly
6) Glass not moving smoothly Align glass and rubber beading
in the rubber beading properly
7) Cabin W/H to Floor W/H Fix the connectors properly
connector (4 pole) loose
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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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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)
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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
6. TEST TEMPERATURE 25 ± 5OC
7. OPERATING TEMPERATURE
RANGE - 20OC — +90OC
8. INSULATION RESISTANCE 1M.ohm MIN
9. 2 Nm LOAD 45 ± 5 RPM
SPEED
10. 14 Nm LOAD > 20 RPM
11. LOCK TORQUE (AT 0 RPM) > 25 NM
12. LOCK CURRENT 20 Amps.
13. NOISE - LOW SPEED / 50 dB (A) MAX /
HIGH SPEED 60 dB (A) MAX
WIRING DIAGRAM :
ELECTRICAL
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EXPLODED VIEW
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SPARE PARTS LIST
ELECTRICAL
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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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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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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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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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7) Unscrew the yoke fixing screws YOKE FIXING SCREW

(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
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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 Fig.16
and smooth. If not, clean with a
smooth emery paper and wipe
of the dust with petrol.
3) 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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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 Fig.19

armature shaft end replaced in
its groove with grease.
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

LOW TEMPERATURE
frictional losses.
GREASE
If the ball gets in between the magnets and KRYOTEX EP2
the armature it will result in motor locking
condition while energising, leading armature Fig.20
burning.
2) 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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4) Ensure that the gaskets are

replaced properly in its
positions at the appropriate
stage of re-assembly.
Ref. Fig.22
Fig.22
BELLIVELI WASHER
5) 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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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
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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 1) Check fuse.

switched ‘ON’ 2) Check connections of both socket
and plug.
b) Motor does not park after 1) Cover plate defective

switching ‘OFF’ --change cover plate.
c) Jerky movement of the motor 1) Look for proper seating of brushes

while running. on commutator.
2) Ensure Armature is free for defects.
d) Intermittant function 1) Ensure the Wiper Motor Switch

contacts are OK.
ELECTRICAL
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26. SERVICE DETAILS FOR REAR WIPER :

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.
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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 :
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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
6. TEST TEMPERATURE 25 ± 5OC
7. OPERATING TEMPERATURE
RANGE - 40OC — +80OC
8. INSULATION RESISTANCE 1M.ohm MIN
9. 0.6 Nm LOAD 38 ± 5 RPM

SPEED
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
BREAK CURRENT - 14 AMPS
TIME:2 - 8 SEC. AT NORMAL AMBIENT OF 30O
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EXPLODED VIEW
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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 ELECTRICAL
thoroughly.
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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 re-
assembly.
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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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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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. Fig.8
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.

Fig.9
If not so replace the brush in ‘SETS’ and not Fig. 9
individually.
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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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 :

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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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

Fig.14
the commutator.
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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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.
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
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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 1) Check fuse.

switched ‘ON’ 2) Check connections of both socket
and plug.
b) Motor does not park after 1) Cover plate defective

switching ‘OFF’ --change cover plate.
c) Jerky movement of the motor 1) Look for proper seating of brushes

while running. on commutator.
2) Ensure Armature is free for defects.
d) Intermittant function 1) Ensure the Wiper Motor Switch

contacts are OK.
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27. SERVICE DETAILS FOR ALTERNATOR :
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.
ELECTRICAL
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PRECAUTIONS :
DO’s : DONT’s :
• Do ensure that all electrical connections are clean • Do not flash the Alternator output leads to check
and secure. the working of the Alternator.
• Do ensure that no electrical connection in the • Do not run the Alternator with the battery discon-
circuit including the battery is open. Do observe nected.
correct polarity while connecting battery to
altenator ie. connect negative to negative and • Do not disconnect any lead of Alternator / Regula-
positive to positive. Otherwise, Alternator will be tor with the engine in running condition.
damaged.
• Do not disconnect battery cables while the en-
• Disconnect all Alternator terminals, while carrying gine is running.
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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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. REG. SET VOLTAGE 14.0 ~ 14.8 V
10. 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 :
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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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5) ALTERNATOR CHARGING SYSTEM CHECKS ON VEHICLES :

before starting ensure the battery condition
SWITCH ON THE IGNITION

CHECK WARNING LAMP FOR ANY DEFECT.
CHECK "WL" TERMINAL IN ALTERNATOR
NO FOR PROPER CONNECTION.
DOES WARNING
LAMP GLOW ?
YES
CHECK THE BELT TENSION. IF FOUND SLACK
RUN THE ENGINE AT IDLE SPEED ADJUST THE BELT DEFLECTION AS PER
PROCEDURE ON Pg4 AND CHECK FOR
NO CHARGING. IF THE UNIT IS STILL NOT
DOES WARNING CHARGING REMOVE THE ALTERNATOR AND
LAMP GO OFF ? 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. REMOVE THE ALTERNATOR
AND CHECK REGULATOR
IS RATED
CURRENT OUTPUT NO
REMOVE THE
REACHED WITHOUT VOLTAGE NO ALTERNATOR AND CHECK
DROPPING BELOW ELECTRICAL
13.0 VOLTS ?
YES
ALTERNATOR FOUND ACCEPTABLE
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EXPLODED VIEW
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ELECTRICAL
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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 a
few seconds till to temperature of the bearing housing i s
15OC over the ambient temperature. Ref. Fig.2
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
Fig. 3
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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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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
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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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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
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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 OHM METER
observed, the bearings should be
replaced.
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.
Fig.18
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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
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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 Fig.22
points one by one on the rectifier
assembly. It should not indicate
open circuit. Replace the rectifier
assembly if it is open circuit.
ii) No Continuity check

Connect as shown in figure 23. Use
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 Fig.23

diodes
i) Continuity check
Connect as shown in figure 24. Use the
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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ii) No Continuity check

Connect as shown in figure 25. Use the
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
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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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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
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5) Tighten the pulley nut.

Ref. Fig.32
Fig.32
ELECTRICAL
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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).
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DEFECT CAUSE REMEDY
1. Warning light does not appear (a) If the bulb does not light,
when Ignition switch is on. ground WL terminal of the
alternator.
(b) If the bulb now lights the
caused are :
(ii) Jammed brushes or brush Free brushed, Replace , if
lead adrift. necessary.
(iii) Dirty slip ring Clean the slip ring.
(iv) Rotor open circuit. Check that the ends of the rotor
(v) Yellow lead connecting winding are soldered properly to
rectifier to regulator open. slip ring terminals. Resolder the
windings, if open, or replace the
rotor.
(c) If the bulb does not light
even after grounding WL
Terminal, the causes are :
(vi) Fused warning lamp bulb. Check for short circuit, if any, in
the wiring harness. After
rectifying the short replace bulb.
(vii) Short circuited warning Replace Holder.

lamp holder.
(d) If still WL does not appear Replace regulator.
when Ignition switch is on,
the cause is faulty Regulator.
2. Warning lamp glows dim (i) High resistance in warning Check and correct.
lamp
(ii) Regulator defective. Replace Regulator.
(iii) Rotor defective. Replace Rotor.
3. Warning lamp 'on'. Ammeter (i) Loose belt. Tighten the belt to the limits as
shows no charge while indicated in routine
engine is running. maintenance.
(ii) Aux. diode lead 'A' open. Check diode connection and
trace short. Rectify if possible or
replace rectifier assembly.
(iii) Shorted rotor Replace rotor.
(iv) Stator open/shorted Replace stator assembly.
4. Warning lamp 'on' or dim but (i) Faulty bridge. Replace defective heat sink assy.
ammeter shows charges (low
output)
5. Warning lamp goes off. (i) Faulty rectifier bridge. Replace defective heat sink assy.
Ammeter shows low output
(ii) Stator winding short. Rectify or replace stator assembly
6. Warning lamp (Ammeter) (i) High resistance in the Check connections and ensure ELECTRICAL
flickers considerably. Negative line. use of recommended wire.
(ii) Slip ring dirty. Clean the slip ring and recheck.
7. Overcharging (battery gases) (i) Faulty regulator. Replace regulator.
(ii) Rotor shorted to earth on Rectify or replace rotor assembly
negative side.
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28. SERVICE DETAILS FOR STARTER MOTOR :

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.
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2) PRECAUTIONS :
SOLENOID CHECK :
The following points must be adhered to when
starting the engine :- To check the solenoid switch connect a bulb in
series with the main terminal contact, energise
• Ensure that all electrical connections the winding if the bulb glows solenoid switch is
to the Starter are in a good condition. OK.
• 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.
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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3) SPECIFICATION :
NOMINAL OUTPUT 0.8 K.W MIN.

ENGAGING SYSTEM PRE-ENGAGED DRIVE
VOLTAGE CURRENT TORQUE SPEED

CONDITION
(VOLTS) (AMPS) (Nm) (R.P.M)
PERFOMANCE SPECI- NO LOAD 11 50 MAX -------- 6000 MIN

FICATION
AT + 25O C LOAD 9.7 ± 0.2 230 MAX 4.5 MIN 2300 MIN
± 0.2
LOCKED 7.0 550 MAX 13.0 MIN ------------
OPERATION OF 1) PULL IN VOLTAGE 8V MAX.

SOLENOID SWITCH WHEN PINION TRAVEL RESTRICTED AT 2 MM
2) DROP OFF VOLTAGE 4V MAX.
WEIGHT 4.1 Kg (APPROX)
CONNECTION DIAGRAM :
12
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EXPLODED VIEW
ELECTRICAL
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106
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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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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
Fig. 5
6) 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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7) Disassemble the insul brushes from the

brush plate assembly.
Ref. Fig.7
Fig.7
Fig. 7
8) 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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10) Remove the plastic engaging lever assembly

and Armature assembly simultaneously.
Ref. Fig.10
Fig.10
Fig. 10
11) Remove the jump ring collar using a mild

steel tube of suitable bore. Remove the jump Jump ring
ring from its groove. Remove the thrust collar,
thrust washer and shim.
Ref. Fig.11 Thrust collar
Fig.11
SHIM
12) Remove the drive assembly. THRUST WASHER
JUMP RING
Ref. Fig.12
DRIVE ASSEMBLY
THRUST COLLAR
Fig.12
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13) Removal of pole screw from the yoke.

Ref. Fig.13
Fig.13
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)
Fig.15
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8) ARMATURE TEST :
• If growler equipment is available, check for short

circuited windings. -
EG
MM ON S
• Insulation Test - If the lamp glows renew the N CO
armature. R O W O ENT
A R M
Ref. Fig.16
FT
SHA
Fig.16
• Armature winding ground test :

Ref. Fig.17
Fig.17
Brush Plate Test 15W
• 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
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9) FIELD COIL TEST : 15W

WINDING
• Closely inspect field coils insulation.
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 Fig.19
special fixture while pole pieces are
held in position by suitable mandrel.
REASSEMBLY :
It is reverse order of dismantling proce-
dure. 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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10) Testing :
After reassembly, Check for no load, lock torque and
run torque as follows insert fig.
VOLTAGE CURRENT TORQUE SPEED

CONDITION (VOLTS) (AMPS) (Nm) (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
7.0 ± 0.2 550 MAX 13.0 MIN ------------ Fig.20
TORQUE
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.
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DEFECT CAUSE REMEDY
1) Pinion fails to engage. Discharged Battery. Substitute with a fully charged bat-
tery:
if the starter now cranks the engine,
then the battery must be attended to.
Defective solenoid switch. Remove starter for further inspection.

Check solenoid, plunger and spring
replace, if necessary.
2) Armature fails to rotate or Discharged / Defective battery. Substitute with a fully charged battery.
rotates slowly and the starter if the starter now cranks the engine,
does not crank the engine then the battery must be attended to.
though pinion has engaged
with ring gear
Loose or oxidised battery terminals / Clean the terminals and smear petro
Corroded or loose connections / leum jelly. Tighten all connections.
Defective earth connections.
Brushes wornout and not making Replace brushes, if found to be

proper contact with commutator. wornout.
Dirty, oily or badly burnt commutator. Remove dirt or oil. If commutator is

burnt, replace armature.
Starter terminal or brush box having Remove the starter for further
earth fault. Defective Solenoid investigations and replace parts as
Switch. Defective Armature / found to be necessary.
Field Coils.
Contd...
ELECTRICAL
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TROUBLE SHOOTING Contd...
DEFECT CAUSE REMEDY

3) Armature rotates but pinion Pinion sticky on shaft. Shaft splines and the pinion internal
fails to engage. splines to be cleaned and lu-
bricated
check solenoid switch.
Burrs on pinion or ring gear. Deburr by filing.
4) Armature rotates, pinion Clutch slip. Remove the starter from the vehicle
engages with the ring gear but and replace drive assy., test and refit
the engine is not cranked starter.
(A whining noise is heard).
5) Starter continues to run after Sticky starter switch or Disconnect starter cable immediately
the Ignition switch is released. Ignition switch 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 Clean throughly, deburring pinion and

damaged. ring gear by filing.Replace, if necessary.
6) Starting problem
before investigating any starting First ensure that the battery cables If the battery has been removed from
problem, it is essential to and connections are in good the vehicle it is essential that it is
ensure that the battery is in a conditions, clean and tight with the reconnected with the correct polarity.
satisfactory condition. earth connection secure. Ideally Reverse polarity connection will
A defective battery will result in check the battery condition using a seriously damage the Alternator &
cranking difficulties. battery tester. associated parts.
Identify your vehicle symptom, then follow in order the likely causes and checks.
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LAYOUT OF FRONT WIRING HARNESS (RHD)
INDEX
ELECTRICAL
GROUP INDEX
1 FR AND REAR WASH MOTORS 12 BRAKE FLUID SWITCH 23 EARTH - E11
2 FRONT FOGLAMP RH 13 EARTH 24 TO ENGINE W / H
3 EARTH 14 TO FLOOR W / H 25 TO SENSOR W / H
4 HORN 15 TO CABIN W / H 26 BONNET SWITCH
5 HEADLAMP RH 16 TO MAXIFUSE (ENGINE W / H) 27 FUSE AND RELAY BOX (ENGINE)
6 FRONT POSITION/PARKING LAMPS 17 FRONT WHEEL SPEED SENSOR LH 28 FRONT FOGLAMP LH
NEXT
7 FRONT BLINKERS RH 18 EARTH E13 29 HOOTER
8 HEADLAMP LEVELLING MOTOR RH 19 FRONT WIPER MOTOR 30 HEADLAMP LH
9 ABS ECU HU
PREVIOUS
20 TO CABIN W / H 31 POSITION / PARKING LAMPS LH
10 FRONT WHEEL SPEED SENSOR RH 21 TO FRONT WASHER 32 FRONT BLINKERS LH
11 AC COMPRESSOR CLUTCH 22 TO ENGINE COOLING W / H 33 HEADLAMP LEVELLING MOTOR LH
117
ELECTRICAL
118
LAYOUT OF CABIN WIRING HARNESSES (RHD)
INDEX
ELECTRICAL
GROUP INDEX
1 TO FRONT W / H 11 TO ROOF LAMP 21 TO CABIN HVAC W/H
2 TO FLOOR W / H 22 TO SRS / AIRBAG W/H
12 EARTH - ROOF
3 TO DRIVER DOOR W / H 23 TO FRONT W/H
13 SIDE INDICATOR LH
4 FACIA SWITCHES 24 TO ACCESSORY RELAY (12V 50A)
14 FRONT DOOR SWITCH LH
5 INST LIGHT DIMMER 15 EARTH 25 DIGITAL CLOCK
6 FUSE AND RELAY BOX - CABIN 26 STOP LIGHT SWITCH
16 DASH SPEAKERS LH
7 DASH SPEAKER RH 27 HEADLAMP LEVELLING SWITCH
17 TO CO-DRIVER DOOR LH
8 EARTH 28 STEERING LOCK / IGNITION SWITCH
18 HAZARD WARNING SWITCH
NEXT
9 SIDE INDICATOR RH 29 COMBINATION SWITCH (ON STEERING COLUMN)
19 RADIO / MUSIC SYSTEM
10 DRIVER DOOR SWITCH 30 INSTRUMENT CLUSTER
20 CIGARETTE LIGHTER
PREVIOUS
LAYOUT OF AIRBAG WIRING HARNESSES (RHD)
INDEX
ELECTRICAL
GROUP INDEX
1 DRIVER AIRBAG
2 PASSENGER AIRBAG
3 CABIN W/H
4 ECU SRS
NEXT
5 GROUND
6 INHIBIT SWITCH
7 PRETENSIONER LH
PREVIOUS
8 PRETENSIONER RH
119
ELECTRICAL
120
LAYOUT OF TAILGATE WIRING HARNESSES (RHD)
INDEX
ELECTRICAL
GROUP INDEX
1 REAR WIPER MOTOR
2 REAR GLASS HEATER
3 REAR GLASS WASH TUBE
4 TAILGATE SWITCH
5 HIGH MOUNTED STOP LAMP
6 TO FLOOR WIRING HARNESS
7 EARTH / GROUND FOR TAILGATE
NEXT
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ELECTRICAL
LAYOUT OF FLOOR WIRING HARNESSES (RHD)
ELECTRICAL
121
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ELECTRICAL
122
NEXT
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ELECTRICAL
ELECTRICAL
123
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PREVIOUS
ELECTRICAL
124
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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
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ELECTRICAL
CIRCUIT SCHEMATIC - EARTH GROUND POINT LOCATIONS
129
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC EMS ECU START/CHARGING HD INDICA/INDIGO MPFI EURO-II
130
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ELECTRICAL
131
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ELECTRICAL
CONNECTOR DETAILS FOR ECU EMS
132
INDEX NEXT
ELECTRICAL
CIRCUIT SCHEMATIC INSTRUMENT CLUSTER
133
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC HEADLAMP/PARKING/FOGLAMPS
134
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC INTERIOR LIGHTS, CHIME UNIT AND SWITCHES
135
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ELECTRICAL
CIRCUIT SCHEMATIC INTERIOR LIGHTS AND SWITCHES - INDICA/INDIGO
136
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ELECTRICAL
CIRCUIT SCHEMATIC WIPERS AND WASH
137
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ELECTRICAL
CIRCUIT SCHEMATIC ANTITHEFT IMMOBILISER SYSTEM
138
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ELECTRICAL
CIRCUIT SCHEMATIC WINDOW WINDING SYSTEM
139
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ELECTRICAL
CIRCUIT SCHEMATIC-HORN/CLOCK MUSIC SYSTEM/CIG LIGHTER
140
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC HAZARD WARNING AND SIDE INDICATOR
141
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC ANTILOCK BRAKING SYSTEM
142
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC - AIR BAG SYSTEM - DAB/PAB
143
INDEX PREVIOUS NEXT

ELECTRICAL
CIRCUIT SCHEMATIC AIR BAG SYSTEM - DAB
144
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DIAGNOSTICS
AIR BAG
ABS
EMS
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GROUP INDEX
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DIAGNOSTICS AIRBAG
CONTENTS :
1) General 2
A) Salient Features
2) Detailed Description 3
A) Electrical
3) Specification 3
A) Laptop/Desktop
B) Vehicle Interface Unit
4) Installation and Operating Procedure 5

A) Installation
B) Operating Procedure
5) Maintenance 11
A) Trouble shooting
6) Faultcode list and Repair Guidelines 12
DIAGNO-
STICS
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DIAGNOSTICS AIRBAG
1. GENERAL : 1) Read Central ECU data

2) Read Sensor Information
3) Read Manufacturing / Repair Date
Air Bag ECU is used for controlling firing of air-bags 4) Read ECU Status
for passenger safety on a vehicle in event of a crash. 5) Read DTCs i.e. Error Codes
6) Clear DTCs
This air bag module has a provision for sensing the 7) Read Vehicle Identification
front impacts. The system includes the possibilities 8) Write Vehicle Identification No
to handle front air bags (driver and passenger) and 9) Write Manufacturing / Repair Date
seat pretensioners for driver and passenger. 10) Write Ignition Data
11) Set Diagnostic mode
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.
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.
DIAGNO-
STICS
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DIAGNOSTICS AIRBAG
2. DETAILED DESCRIPTION :
A. Electrical
Required power supply : OBD Cable

PC/Laptop Serial cable Vehicle
(with Interface
Power supply for the Laptop/Desktop.The Vehicle software) Unit
Interface Unit does not require any external power RS232 COM
Port
supply . It works on vehicle battery, provided
through the OBD cable .
To vehicle wiring
Connect the RS232 cable to the Laptop/Desktop Harness
COM port
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)
The software works with the above features of a Fig 2.Diagnostic connector under co-driver seat
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
DIAGNO-
STICS
Fig 3.Diagnostic connector cap removed
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DIAGNOSTICS AIRBAG
Diagnostic Equipment Components :
Fig 4. Laptop
Fig 5. Interface Unit
DIAGNO-
STICS
Fig 6. OBD cable connected to diagnostic
connector
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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 -
support_ed@tatamotors.com
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 .
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DATA DISPLAY AREA STATUS DISPLAY
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
DIAGNO- h] READ VIN
STICS
i] WRITE DATE: MFG/REPAIR
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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 Fig 9.

this button.
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:- On clicking of this , user has to select either MFG.
Date or Repair Date of from popup menu.
ISOFIX A SENSOR / INHIBITION KEY:- INHIBIT MFG. Date displays date of manufacturing.
KEY CONFIGURED 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
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Fig 10.
d] READ ECU STATUS: 13) Instantaneous State for passenger Airbag

inhibition
This service allows the user to read following 14) AIRBAG inhibition
ECU parameters - 15) Configuration of Squib lines
1) No. of recorded Faults in ECU RAM 16) Squib Firing Status
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
DIAGNO-
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DIAGNOSTICS AIRBAG
e] READ DTCs : g] WRITE VIN:
This allows to read error codes recorded in the This service is used to write Vehicle
error buffer in ECU. ACU-3 can record up to 16 Identification Number (VIN) .
error codes. Reading the 16 error codes requires Enter the VIN number in the text window. This
to execute two commands. has to be entered as per the
On clicking of READ DTCs , user has to first Car Manufacturer.
select First 8 DTCs and then The maximum length of VIN number is 19.
Second 8 DTCs from the popup menu. If length of VIN number is less then 19 then
number will be stored with succeeding zeros.
After this Error codes will displayed in the list. If After clicking the button a small screen will
errors are not there then No Errors Present appear in the data display area , enter the VIN
message will be displayed. number and then Click ok .
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 automati-
cally pop-up .
e.g. The Errors will be displayed as
MAT6042213PR12345
0240:- ERR_WLAMP_LEAK_GND
1242:- ERR_BATTERY_VOLTAGE
0DCB:- ERR_CAP_NOT_CHARGED(1)
0DC1:- ERR_CHARGE_SEQUENCE
Fig 11.
After the VIN number is entered the data display

area displays:-
f] CLEAR DTCs :
VIN No. ENTERED IN THE ECU:-
This service is used to clear faults from the error MAT6042213PR12345
buffer in ACU-3.
If the errors are physically cleared then the tester Note : Do not enter special characters like # ,
will give the following message in the status ,, * etc.
display:- If VIN No is MAT6042213PR12345
Then stored number will be MAT6042213PR123450
ERRORS ARE CLEARED FROM THE ECU AND
THE ASSEMBLY h] READ VIN:
But error codes will be recorded again if they are This service is used to read the VIN number from
not physically cleared. 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

DIAGNO-
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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 todays 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.
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DIAGNOSTICS AIRBAG
5. Maintenance :
A. Troubleshooting
Problem Cause Remedy
ECU communication error 1) LEDs status On the - Check the OBD cable connection with
Silicon Engines interface Diagnostic Connector of wiring harness.
unit. - 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.
Software Not Working Corrupt version of software Reinstall the software.
For software support or assistance please visit the following website :

http://ed.tatamotors.com
DIAGNO-
STICS
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AIRBAG FAULTCODE & REPAIR GUIDELINE
6. FAULTCODE AND REPAIR GUIDELINES :
DESCRIPTION POSSIBLE CAUSE ACTION TO BE

FAULT CODES
TAKEN
ERR_LEAK_PLUS_ Co-driver pre tensioner line Co-driver Pretensioner line Check the wiring
SQUIB (1) shorted to +ve supply. Firing of shorted supply line harness for damage.
pre-tensioner inhibited. Replace if necessary.
ERR_LEAK_PLUS_ Driver Pretensioner line shorted Driver Pretensioner line Check the wiring
SQUIB (2) to +ve supply. Firing of shorted supply line. harness for damage.
Pretensioner inhibited. Replace if necessary.
ERR_LEAK_PLUS_ Driver airbag line shorted to +ve Driver airbag line shorted Check the wiring
SQUIB (3) supply. Firing of airbag inhibited. supply line. harness &
Clockspring for
damage. Replace if
necessary.
ERR_LEAK_PLUS_ Co-driver airbag line shorted to Passenger airbag line Check the wiring
SQUIB (4) +ve supply. Firing of airbag shorted supply line. harness for damage.
inhibited. Replace if necessary.
ERR_LEAK_PLUS_ RH side airbag line shorted to RH Side airbag line shorted Check the wiring
SQUIB (9) +ve supply. Firing of airbag supply line. harness for damage.
ERR_LEAK_PLUS_ LH side airbag line shorted to LH Side airbag line shorted Check the wiring
SQUIB (12) +ve supply. Firing of airbag supply line. harness for damage.
ERR_LEAK_GND_ Co-driver pre tensioner line Co-driver pre-tensioner line Check the wiring
SQUIB (1) shorted to GND supply. Firing shorted to Vehicle Ground. harness for damage.
of pre-tensioner inhibited. Replace if necessary.
ERR_LEAK_GND_ Driver pre tensioner line shorted Driver pre-tensioner line Check the wiring
SQUIB (2) to GND supply. Firing of shorted to Vehicle Ground. harness for damage.
pre-tensioner inhibited. Replace if necessary.
ERR_LEAK_GND_ Driver line shorted to GND. Driver airbag line shorted to Check the wiring
SQUIB (3) Firing of airbag inhibited. Vehicle Ground. harness &
Clockspring for
damage. Replace if
necessary.
ERR_LEAK_GND_ Co-driver line shorted to GND. Passenger airbag line Check the wiring
SQUIB (4) Firing of airbag inhibited. shorted to Vehicle Ground. harness for damage.
DIAGNO-
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FAULT CODES
TAKEN
ERR_LEAK_GND_ RH side airbag line shorted to RH Side airbag line shorted Check the wiring
SQUIB (9) GND. Firing of airbag inhibited. to Vehicle Ground. harness for damage.
ERR_LEAK_PLUS_ LH side airbag line shorted to LH Side airbag line shorted Check the wiring
SQUIB (12) GND. Firing of airbag inhibited. to Vehicle Ground. harness for damage.
ERR_HIGH_RES_ The resistance in the Co-driver Co-driver Pretensioner not Check connections
SQUIB (1) Pretensioner is higher than the connected or connection and wiring harness for
specified limit. loose or line open. damages. If problem
persists try replacing
wiring harness or
Pretensioner.
ERR_HIGH_RES_ The resistance in the Driver Driver Pretensioner not Check connections
SQUIB (2) Pretensioner is higher than the connected or connection and wiring harness for
wiring harness or
Pretensioner.
ERR_HIGH_RES_ The resistance in the Driver Driver airbag not connected Check connections
SQUIB (3) airbag line is higher than the or connection loose or line and wiring harness for
specified limit. open. damages. If problem
wiring harness or
airbag.
ERR_HIGH_RES_ The resistance in the co-driver Passenger airbag not Check connections
SQUIB (4) airbag line is higher than the connected or connection and wiring harness for
wiring harness or
airbag.
ERR_HIGH_RES_ The resistance in the RH side RH side airbag not Check connections
SQUIB (9) airbag line is higher than the connected or side airbag and wiring harness for
specified limit. pigtail not connected to the damages. If problem
airbag wiring harness or persists try replacing
connection loose the airbag or wiring
harness.
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FAULT CODES
TAKEN
ERR_HIGH_RES_ The resistance in the LH side LH side airbag not connected Check connections
SQUIB (12) airbag line is higher than the or side airbag pigtail not and wiring harness for
specified limit. LH side airbag connected to the airbag damages. If problem
not connected or side airbag wiring harness or connection persists try replacing
pigtail not connected to the loose. the airbag or wiring
airbag wiring harness or harness.
connection loose.
ERR_LOW_RES_ Low resistance in the Co-driver Shorting in the wiring Check the wiring
SQUIB (1) Pretensioner line. harness. Internal error in harness for shorting
Pretensioner. and replace if
necessay. If problem
persists, replace
wiring harness or
Pretensioner.
ERR_LOW_RES_ Low resistance in the driver Shorting in the wiring Check the wiring
SQUIB (2) Pretensioner line. harness. Internal error in harness for shorting
persists, replace
wiring harness or
Pretensioner.
ERR_LOW_RES_ Low resistance in the driver Shorting in the wiring Check the wiring
SQUIB (3) airbag line. harness. Internal error in harness for shorting
persists, replace
wiring harness or
airbag.
ERR_LOW_RES_ Low resistance in the co-driver Shorting in the wiring Check the wiring
airbag line. and replace if
persists, replace
wiring harness or
airbag.
ERR_LOW_RES_ Low resistance in the RH side Shorting in the wiring Check the wiring
side airbag line. and replace if
DIAGNO-
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FAULT CODES
TAKEN
persists, replace
wiring harness or
side airbag.
ERR_LOW_RES_ Low resistance in the LH side Shorting in the wiring Check the wiring
side airbag line. and replace if
persists, replace
wiring harness or
side airbag.
ERR_CAP_NOT_ ECU internal capacitor not Malfunction of the internal Check the battery
CHARGED (1) charged. ECU power circuit. voltage to the ECU. If
the problem persists
change the ECU.
ERR_CAPACIATANCE ECU internal capacitor error. Malfunction of the internal Check the battery
_CAP(1) ECU power circuit. voltage to the ECU. If
the problem persists
change the ECU.
ERR_BATTERY_ Vehicle battery voltage too high Battery overcharged or Check the vehicle
VOLTAGE or too low. undercharged. Leakage of battery voltage.
battery voltage. Acceptable voltage
range- 10.5 to 16
Volts.
ERR_CHILDSEAT_OC Error in resistance of PAB Passenger airbag inhibition Check the PAB
inhibition switch. switch not connected or inhibition connections.
resistance values not in Check resistance of
drawing limits. Inhibition switch as
per drawing. Replace
if necessary.
ERR_WLAMP_LEAK_ Warning lamp voltage not OK. Warning lamp not connected Check the warning
VBAT or the lamp has fused. lamp and its proper
connection. Replace
the lamp if necessary.
ERR_BLAMP_LEAK_ PAB inhibition LED voltage not LED not connected or the Check the PAB
VBAT OK. lamp has fused. inhibition LED and its
connection. Replace
the wiring harness or
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FAULT CODES
TAKEN
Inhibition switch if
necessary.
ERR_WLAMP_LEAK_ SRS lamp on instrument cluster Shorting in the wiring Check wiring harness
GND shorted to Vehicle Ground. harness or in the cluster. for shorting and
replace if necessary.
ERR_BLAMP_LEAK_ PAB inhibition LED shorted to Shorting in the wiring Check wiring harness
GND Vehicle Ground. harness or in the Inhibit for shorting and
switch. replace if necessary.
ERR_LOWER_ Fault in the Co-driver Internal fault in ECU. Replace the ECU
TRANSISTOR(1) Pretensioner firing circuit in the
ECU. Firing of the Pretensioner
inhibited.
ERR_LOWER_ Fault in the driver Pretensioner Internal fault in ECU. Replace the ECU
TRANSISTOR(2) firing circuit in the ECU. Firing
of the Pretensioner inhibited.
ERR_LOWER_ Fault in the driver airbag firing Internal fault in ECU. Replace the ECU
TRANSISTOR(3) circuit in the ECU. Firing of the
airbag inhibited.
ERR_LOWER_ Fault in the co-driver airbag Internal fault in ECU. Replace the ECU
of the airbag inhibited.
ERR_LOWER_ Fault in the LH side airbag Internal fault in ECU. Replace the ECU
of the side airbag inhibited.
ERR_LOWER_ Fault in the RH side airbag Internal fault in ECU. Replace the ECU
of the side airbag inhibited.
ERR_UPPER_ Fault in the Co-driver Internal fault in ECU. Replace the ECU
TRANSISTOR(1) Pretensioner firing circuit in the
ECU. Firing of the Pretensioner
inhibited.
ERR_UPPER_ Fault in the driver Pretensioner Internal fault in ECU. Replace the ECU
of the Pretensioner inhibited.
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FAULT CODES
TAKEN
ERR_UPPER_ Fault in the driver airbag firing Internal fault in ECU. Replace the ECU
TRANSISTOR(3) circuit in the ECU. Firing of
the airbag inhibited.
ERR_UPPER_ Fault in the co-driver airbag Internal fault in ECU. Replace the ECU
of the airbag inhibited.
ERR_UPPER_ Fault in the LH side airbag firing Internal fault in ECU. Replace the ECU
side airbag inhibited.
ERR_UPPER_ Fault in the RH side airbag firing Internal fault in ECU. Replace the ECU
side airbag inhibited.
ERR_RAM_ERROR ECU Malfunction Internal fault in ECU. Replace the ECU
ERR_CPU_ ECU Malfunction Internal fault in ECU. Replace the ECU

BEHAVIOUR
ERR_EEPROM_NOT_ ECU Malfunction Internal fault in ECU. Replace the ECU

PROG
ERR_EEPROM_OUT_ ECU Malfunction Internal fault in ECU. Replace the ECU

OF_ORDER
ERR_CALIBRATION_ ECU Malfunction Internal fault in ECU. Replace the ECU

EEPROM
ERR_COMPENSATION ECU Malfunction Internal fault in ECU. Replace the ECU

_OFFSET
ERR_EXTERNAL_ ECU Malfunction Internal fault in ECU. Replace the ECU

WATCHDOG
ERR_INTERNAL_ ECU Malfunction Internal fault in ECU. Replace the ECU

WATCHDOG
ERR_AD_ ECU Malfunction Internal fault in ECU. Replace the ECU

CONVERTER
ERR_ENABLE_LOW_ ECU Malfunction Internal fault in ECU. Replace the ECU

AT_STARTUP
DIAGNO-
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FAULT CODES
TAKEN
ERR_CRASH_ ECU Malfunction Internal fault in ECU. Replace the ECU

CONFIRMATION
ERR_CHARGE_ ECU Malfunction Internal fault in ECU. Replace the ECU

SEQUENCE
ERR_ACCEL_X_ ECU Malfunction Internal fault in ECU. Replace the ECU

ERROR
ERR_ACCEL_Y_ ECU Malfunction Internal fault in ECU. Replace the ECU

ERROR
ERR_SAFING_X_ ECU Malfunction Internal fault in ECU. Replace the ECU

ERROR
ERR_CRSH_SPY_ ECU Malfunction Internal fault in ECU. Replace the ECU

DATA
ERR_ACCELERO_ ECU Malfunction Internal fault in ECU. Replace the ECU

SATURATION
ERR_NO_COMM_ LH side Remote sensing unit Fault in wiring harness. Check the wiring
DRV_SAT connection open harness connections
for damage. Replace
the wiring harness if
problem persists.
ERR_NO_COMM_ RH side remote sensing unit Fault in wiring harness. Check the wiring
PSNG_SAT connection open. harness connections
for damage. Replace
the wiring harness if
problem persists.
ERR_DRV_SAT RH Remote sensing unit Internal Fault in Remote Replace the RSU
malfunction. sensing.
ERR_PSNG_SAT LH Remote sensing unit Internal Fault in Remote Replace the RSU
malfunction. sensing.
ERR_DRV_SAT_VOLT Insufficient supply to driver Internal Fault in Remote Check the battery
Remote sensing unit. sensing. supply. If problem
the ECU or RSU.
DIAGNO-
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FAULT CODES
TAKEN
ERR_PSNG_SAT_ Insufficient supply to Co-Driver Internal Fault in Remote Check the battery
VOLT Remote sensing unit. sensing. supply. If problem
the ECU or RSU
ERR_RSU_ Malfunction of the remote Internal Fault in Remote Replace the RSU
SATURATION control unit. sensing.
DIAGNO-
STICS
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DIAGNOSTICS ABS
CONTENTS :
1) General 2
A) Salient Features
A) Electrical
3) Specification 3
A) Laptop/Desktop
B) Vehicle Interface Unit
4) Installation and Operating Procedure 4

A) Installation
B) Operating Procedure
5) Maintenance 8
A) Trouble shooting
6) ABS Fault Code List 9
7) ABS Repair Guidelines 26
DIAGNO-
STICS
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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) 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 &
DIAGNO- Rear)
STICS
2
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DIAGNOSTICS ABS
2. DETAILED DESCRIPTION :
A. Electrical
Required power supply :
Serial cable OBD Cable
Power supply for the Laptop/Desktop.The PC/Laptop Vehicle
Vehicle Interface Unit does not require any (with Interface
software) Unit
external power supply . It works on vehicle RS232 COM
battery, provided through the OBD cable . Port
Connect the RS232 cable to the Laptop/

Desktop COM port
To vehicle wiring
The OBD cable is connected to the Harness
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
Fig 2. Diagnostic connector under co-driver seat
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.
B. Vehicle Interface Unit (Fig. 5)
Interface unit from M/s Silicon Engines, USA OBD

cable
RS232 cable
DIAGNO-
STICS
Fig 3. Diagnostic connector cap removed
3
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DIAGNOSTICS ABS
Diagnostic Equipment Components :
Fig 4. Laptop
Fig 5. Interface Unit
DIAGNO-
STICS
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 E-
mail on following
E-mail ID - support_ed@tatamotors.com
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 To start the communication between the
All the functions catering to the Diagnostic ECU and the Tester press the “START”
of the ECU can be performed through the button. This initialises the ECU
tester. To perform any function press the communication and enables the other
respective button.This also gives context commands.
sensitive help for the system. Just Press
‘F1’ on any button, the help for the
DIAGNO-
particular button will be displayed . STICS
5
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DIAGNOSTICS ABS
Fig 9.
The Following operations can be performed with the help • No Of DTC’s Gives the number of Diagnostic
of these commands trouble codes
a] Read ECU status • Relay status gives the relay status of the Relay
b] Actuate the components • Motor Status gives state of the Pump motor. In
default condition Pump Motor should be ‘OFF’ .
c] Read the Diagnostic Trouble Codes (DTC’s)
• Valve status give the condition of the valves,
d] Clear the Diagnostic Trouble Codes (DTC’s)
normally the Inlet valves are ‘ON’ and Outlet valves
a] On clicking the ‘Read ECU status’ the frame as are ‘ OFF’
shown in Fig. 9 is displayed.
• 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 .
DIAGNO- Fig 10.

STICS
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
Fig 11.
ACTUATED ’
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.
DIAGNO-
STICS
7
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DIAGNOSTICS ABS
5. Maintenance :
a. Troubleshooting
Problem Cause Remedy
ECU communication error 1) LEDs status On the - Check the OBD cable connection with
Silicon Engines interface Diagnostic Connector of wiring harness.
unit. - 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
DIAGNO-
STICS
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ABS FAULTCODE LIST
Faultcode
Table List
of Contents:
Fault- Fault path Repair- Fault detection by Remarks

code Guideline
List of Diagnostic Trouble No.
Code (DTC)
DTC 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
DIAGNO-
STICS
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1101 Battery vltg. 1 • Monitoring is activated after running of cut-in

Over volt test and when the vehicle has exceeded 6km/h.
(>16V) The battery voltage is measured continously
and cyclically assessed.
C1102 Low volt • If battery voltage is below 8.2V when ABS

(<8V) 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.
DIAGNO-
STICS
10
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1161 Brake light 2 • With ignition ON (after running of cut-in test)

Switch 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.
DIAGNO-
STICS
11
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1604 Hardware 3 • ABS module internal failure, e.g. RAM, ROM

(ECU) etc.
Effects:
• ABS and EBD are switched off.

• ABS and EBD warning lamps are switched
on.
DIAGNO-
STICS
12
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C2114 Disturbance 4 • A permanent or short term break, earth or

(Including open circuit between the solenoid valve of the
Valve affected brake circuit and the control unit is
failures) 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 warning lamps are switched
on.
Note:
EBD function immediately switches off on

failure of solenoid relay.
DIAGNO-
STICS
13
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C2402 Electrical 5 • Return pump motor still not running 80ms

(Pump after driving pump motor relay via control unit.
Motor)
• 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.

* EBD function at least after start of

journey and exceeding 12 km/h.
DIAGNO-
STICS
14
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1203 FR Wheel 6 • A direct current is injected in the wheel-speed

Sensor: sensor by a power source in the input amplifier
Line fault 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).
DIAGNO-
STICS
15
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1200 FL Wheel 7 • A direct current is injected in the wheel-speed

is detected.
Effects:

longer possible.
pressure is decreased (until switch off ).
DIAGNO-
STICS
16
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1209 RR Wheel 8 • A direct current is injected in the wheel-speed

is detected.
Effects:

longer possible.
pressure is decreased (until switch off).
DIAGNO-
STICS
17
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1206 RL Wheel 9 • A direct current is injected in the wheel-speed

is detected.
Effects:

longer possible.
pressure is decreased (until switch off ).
DIAGNO-
STICS
18
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1245 Wheel 10 • If the vehicle reference speed is above

Speed 12 km/h after initial movement of the vehicle,
frequency the speed of the affected wheel remains at
error 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.
DIAGNO-
STICS
19
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1204 FR Wheel 11 • If the vehicle reference speed is above

Sensor 12 km/h after initial movement of the vehicle,
Range/ the speed of the affected wheel remains at
Performance 2 km/h.
Plausibility
fault • If no speed is detected on the affected wheel
Effects:

Note:

regulation.
DIAGNO-
STICS
20
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1201 FL Wheel 12 • If the vehicle reference speed is above

Performance 2 km/h.
Plausibility
Effects:

Note:

regulation.
DIAGNO-
STICS
21
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1210 RR Wheel 13 • If the vehicle reference speed is above

Performance 2 km/h.
Plausibility
Effects:

Note:

regulation.
DIAGNO-
STICS
22
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1207 RL Wheel 14 • If the vehicle reference speed is above

Performance 2 km/h.
Plausibility
Effects:

Note:

regulation.
DIAGNO-
STICS
23
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C2112 Main Relay, 15 • Valve relay switches off due to detected

fuse 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.
DIAGNO-
STICS
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ABS FAULTCODE LIST
Faultcode List

code Guideline No.
C1274 G Sensor 16 Monitoring for open circuit

Signal • Monitoring includes line short to ground,
Signal line short to supply voltage and mutual line
failure short.
C1275 G Sensor Monitoring of lateral accelerator offset when

Plausibility standing
fault
• 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.
DIAGNO-
STICS
25
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ABS REPAIR GUIDELINES
TableRepair
of Contents:
Guideline
No. Tester-Display Work Instructions Set Value Fault Codes Connection

List of Diagnostic Trouble Code (DTC)
Guideline No. DTC 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
11 C1204 FR Wheel Sensor Range/Performance: Plausibility fault ......................................... 40

Troubleshooting : Set Value : Causation :
12 C1201 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
DIAGNO-
STICS
26
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Repair Guideline
1 Battery voltage Ignition on 9.4V - 16 V C1101 UBatt (+) 18 (17)

Over volt (>16V) Vehicle standing when C1102 UBatt(-) 19
Low volt (<8V) pump motor Term (Ignition) 15
running and against ground
valves actuated
(chassis)
Ignition on • Battery discharged; defective

Activate motor relay via diagnosis Pump motor running
tester and battery voltage • Voltage regulator (electric system)
minimum 9.4 V 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) as above as above
• Voltage measurement between pin 15
(ignition) and ground (chassis) or pi 16
DIAGNO-
STICS
27
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Repair Guideline
2 Brake light switch Ignition on C1161 BLS (pin14)

malfunction
Brake not actuated Switch inactive,0V
Brake actuated Switch active,12V
Ignition on
• Brake not actuated • 0V
• Brake lights must
not illuminate • Positive short with line BLS 14 or with
line switch “NC side”, or line to rear lights.
• Brake actuated • 12V (UBatt)

• Brake lights, left,
middle and
right illuminate • 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
DIAGNO-
STICS
28
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Repair Guideline
3 ECU is defective Ignition ON, ECU w/o failure C1604 -

Vehicle standing.
• ABS-/EBD and brake • ECU damage; ECU exchange.

warning lamp
illuminate
• 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.
• All warning lamps
illuminate and switch
off after a short time
DIAGNO-
STICS
29
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Repair Guideline
4 Disturbance Ignition on, All valves C2114 Refer to

(Including Valve Vehicle standing inactive “Note”
failures)
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.
• Ignition OFF • ABS,- /EBD and • Inlet-,outlet- solenoid valve’s damage.

• Disconnect 26-pin plug from ABS unit Brake warning lamp • ABS unit exchange.
and remove assembly from vehicle. illuminate
• Install new ABS unit.
• Connect 26-pin plug to ABS unit.
• Ignition ON
• Check the ABS version and control
the warning lamps. • All warning lamps
off after a short time
DIAGNO-
STICS
30
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Repair Guideline
5 Electrical pump Ignition on Only running C2402 Ground pin 16

motor circuit failure during a
regulation
Positive pin 17
• Initiation fault First, not during a Motor relay,
regulation Inside ECU
• Running-on Second, actuated pump Pump motor
fault motor with diagnostic- pin 2
tester.
• Ignition on
• Is pump-motor running? • Pump motor is not • Pump motor is defect

actuated
• Start pump motor with diagnostic • Pump motor is • ECU defect
tester. running
• End of running • Pump motor runs
out with discharge-
speed (not stopped
directly) • Elimination: Replace ABS unit completed
DIAGNO-
STICS
31
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Repair Guideline
6 FR Wheel Sensor: Ignition on no interrupted the C1203 FR sensor (pin5)

Line fault With vehicle jacked up, speed wheel Ground FR(pin4)
slowly turn FR wheel by sensor
hand
OR
Drive vehicle (test bench) 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.
• Ignition on • ABS,EBD and brake • Short circuit Speed Wheel Sensor control
warning lamps Unit
illuminate • Line rupture
• Ignition off • Sensor fault
• Disconnect the 26pin connector of the
control-unit and the connector of the
speed wheel sensor
• Connect ohmmeter between plug K1 • Correct correlation • Exchange sensor lines
and terminals pin 5 and 4 lines WSS(FR) and
Wire lines(FR)
• Check internal resistance from ECU • Internal-resistance • Repair and exchange the wiring harness
(FR) to wheel speed connector (FR). (1,00KOhm to and connectors when possible
1,90Kohm)
• Move cable around by hand • Line no interrupt • Exchange wheel speed sensor FR
especially in area of wheelarch.
Observe continous display of reading.
• Connect ohmmeter between plug K1 • Greater 100 Kohms • Repair and exchange the wiring harness.
wheel speed sensor terminals FR &
to ground or positive.
DIAGNO-
STICS
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Repair Guideline
6 FR wheel sensor: C1203

Line fault
Troubleshooting : (Continue) Set Value : Causation :
• Set voltmeter to AC voltage.

• Connect voltmeter to control unit plug
(connection: FR sensor wheel)
• Turn FR wheel by hand at approx. • exceeding 120mV • Open circuit in line betwwen control unit
1 revolution per second. (AC voltage) plug and wheel speed sensor FR
• Air gap between sensor and impulse

wheel too large.
DIAGNO-
STICS
33
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Repair Guideline
7 FL Wheel Sensor: Ignition on no interrupted the C1200 FL sensor (pin7)

slowly turn FL wheel by sensor lines (FL)
hand
OR
Important Notes :
warning lamps Unit
• Disconnect the 26pin connector of
the control-unit and the connector of
the speed wheel sensor
and terminals pin 7 and 6 lines WSS(FL) and
Wire lines(FL)
(FL) to wheel speed connector (FL) (1,00KOhm to and connectors when possible
1,90Kohm)
• Move cable around by hand • Line no interrupt • Exchange wheel speed sensor FL
wheel speed sensor terminals FL &
DIAGNO-
STICS
34
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Repair Guideline
7 FL wheel sensor: C1200

Line fault

(connection: FL sensor wheel)
• Turn FL wheel by hand at approx. • exceeding 120mV • Open circuit in line betwwen control unit
1 revolution per second. (AC voltage) plug and wheel speed sensor FL

wheel too large.
DIAGNO-
STICS
35
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Repair Guideline
8 RR Wheel Sensor: Ignition on no interrupted the C1209 RR sensor (pin3)

slowly turn RR wheel by sensor lines (RR)
hand
OR
Important Notes :
warning lamps Unit
speed wheel sensor
and terminals pin 3 and 1. lines WSS(RR) and
Wire lines(RR)
(RR) to wheel speed connector (RR). (1,00KOhm to and connectors when possible
1,90Kohm)
• Move cable around by hand • Line no interrupt • Exchange wheel speed sensor RR
wheel speed sensor terminals RR &
DIAGNO-
STICS
36
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Repair Guideline
8 RR wheel sensor: C1209

Line fault

(connection: RR sensor wheel)
• Turn RR wheel by hand at approx. • exceeding 120mV • Open circuit in line betwwen control unit
1 revolution per second. (AC voltage) plug and wheel speed sensor RR

wheel too large.
DIAGNO-
STICS
37
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Repair Guideline
9 RL Wheel Sensor: Ignition on no interrupted the C1206 RL sensor (pin9)

slowly turn RL wheel by sensor lines (RL)
hand
OR
Important Notes :
warning lamps Unit
speed wheel sensor
and terminals pin 7 and 6. lines WSS(RL) and
Wire lines(RL)
(RL) to wheel speed connector (RL). (1,00KOhm to and connectors when possible
1,90Kohm)
• Move cable around by hand • Line no interrupt • Exchange wheel speed sensor RL
wheel speed sensor terminals RL &
DIAGNO-
STICS
38
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Repair Guideline
9 RL wheel sensor: C1206

Line fault

(connection: RL sensor wheel)
• Turn RL wheel by hand at approx. • exceeding 120mV • Open circuit in line betwwen control unit
1 revolution per second. (AC voltage) plug and wheel speed sensor RL

wheel too large.
DIAGNO-
STICS
39
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Repair Guideline
10 Wheel speed Ignition on Impulse wheel C1245 refer to test-

frequency error with 47 teeth step 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.
Refer to rapir guideline, test step 6 to 9

and 11 to 14.
DIAGNO-
STICS
40
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Repair Guideline
11 FR Speed Sensor Ignition on more than C1203 FR sensor(pin5)

Range/Performan- With vehicle jacked up, 40 km/h (26 m/h) Ground FR(pin4)
ce Plausibility fault slowly turn FR wheel by
hand OR
OR diagnostic-tester
drive vehicle display approach-
ing speedometer
display
Important Notes:
• Ignition OFF before the plug connector will divided from the wheel- speed sensor.
• Couple the diagnostic tester,

Ignition on • ABS and brake • Speed Wheel Sensor or lines interrupted
warning lamp (temporary or static)
illuminate
• Read the DTC. • Impulse Wheel fault
• Check the wheel-speed and • Wheel- speed by • Intermittent contact between wheel-
correlation of the wheel to the sensors wheel FR speed sensor to cable harness(connector)
• Check wheel-speed signal of the • Wheel- speed must • Air gap between sensor and impulse
correct min value be always existent. wheel.
• Wheel speed more
than 2 km/h(under
test-bench wheel
speed the same as
the rollers)
DIAGNO-
STICS
41
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Repair Guideline
12 FL Speed Sensor Ignition on more than C1201 FL sensor(pin7)

Range/Performan- With vehicle jacked up, 40 km/h (26 m/h) Ground FL(pin6)
ce Plausibility fault slowly turn FL wheel by
hand OR
ing speedometer
display
Important Notes:

illuminate
correlation of the wheel to the sensors wheel FL speed sensor to cable harness(connector)
than 2 km/h(under
test-bench wheel
speed the same as
the rollers)
DIAGNO-
STICS
42
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Repair Guideline
13 RR Speed Sensor Ignition on more than C1210 RR sensor(pin3)

Range/Performan- With vehicle jacked up, 40 km/h (26 m/h) Ground RR(pin1)
ce Plausibility fault slowly turn RR wheel by
hand OR
ing speedometer
display
Important Notes:

illuminate
correlation of the wheel to the sensors wheel RR speed sensor to cable harness(connector)
than 2 km/h(under
test-bench wheel
speed the same as
the rollers)
DIAGNO-
STICS
43
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Repair Guideline
14 RL Speed Sensor Ignition on more than C1201 RL sensor(pin9)

Range/Performan- With vehicle jacked up, 40 km/h (26 m/h) Ground RL(pin8)
ce Plausibility fault slowly turn RL wheel by
hand OR
ing speedometer
display
Important Notes:

illuminate
correlation of the wheel to the wheel RL speed sensor to cable harness(connector)
sensors
than 2 km/h(under
test-bench wheel
speed the same as
the rollers)
DIAGNO-
STICS
44
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Repair Guideline
15 Main relay, fuse Ignition on The valve- power C2112 positive

relay is energised (pin17,18)
when system has
not shut- down
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.
Ignition off
• Replace ABS Unit
Ignition on • ABS and brake • Control unit(valve relay circuit)

warning lamp must
off
DIAGNO-
STICS
45
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Repair Guideline
16 G Sensor Signal Ignition On a= C1274 GND 30

Signal fault Vehicle standing, - 0.11 to 0.11 g C1275 AY 10
positioned on even
surface
Plausibility fault Lift vehicle at one side or a exceeding U5V sensor 28
drive onto ramp -0.11 to 0.11 g
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.
Ignition Off • Open circuit in line between cables

• Disconnect 3-pin cable harness plug from wiring harness and plug’s,terminal
from acceleration sensor. 30,10,28
Ignition On • Excessive line and contact resistance
• Using mult imeter, measure voltage at plug contact.
at cable harness plug terminal 28
(positive) against terminal 30(ground)
Ignition Off Ustab = 5V + 0.1V • Sensor defective; relace.
• 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.
DIAGNO-
STICS
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DIAGNOSTICS EMS
CONTENTS :
1) General 2
A) Salient Features 2
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
DIAGNO-
STICS
1
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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.
DIAGNO-
STICS
2
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2. DETAILED DESCRIPTIONS
Power Display
Screen Rubber
A. ELECTRICAL (Required Power Supply) Monitor Jacket
Lamp
The diagnostic tester does not require any external Key
power supply. It works on the vehicle battery, Pad Power
Switch
provided through the intermediate cable.
B. DIAGNOSTIC EQUIPMENT DETAILS
1. HITACHI DIAGNOSTIC MONITOR ( HDM 2000 )

should be loaded with the cartridge TATA Indica Cartridge Wrist
Version 1.2. Fig. 1. Strap
LED
Display
2. Intermediate cable. Strap
Hook
Connecting the Diagnostic Equipment :
Fig. 1
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. 2.
Fig. 2 Female socket below co-driver seat
DIAGNO-
STICS
3
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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.
DIAGNO-
STICS
Fig. 3
4
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3. TROUBLE SHOOTING OF SENSORS B. HITACHI DIAGNOSTIC MONITOR DATA :

USED IN MPFI TYPICAL DATA DURING NORMAL IDLING :
A. 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 SR. NO. PARAMETER VALUE
analysis and efficient trouble shooting.
1. Battery Voltage 14.0 V
Stores ‘No Good’ conditions of Sensors/Actuators as listed
2. Vehicle Speed 0.0 kmph
in Read Memory Switch’s diagnostic mode. That is in E C
U’s memory. 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 6. Throttle Position Sensor Volt 0.50 V
faults.
7. Fuel Injection # 1 Pulse 2.30ms
NOTE :
8. ISC Valve Step 23.5 Step
At the end of each diagnosis and rectification of the
9. Engine Load 34.4%
fault,‘HISTO RY CODES’isto be erased by opting
‘CLEAR MEMORY’ option in the menu and check for 10. Front O2 Sensor 0.24 to 0.68V
normal functioning of Engine/Vehicle 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
DIAGNO-
STICS
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
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 :
‘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) :
Fig. 5 Read memory switch mode white connector in
Read memory switch mode method (Blink code method) shorted condition.
is a manual diagnostic method used to check the
malfunctioning of the following parts. DIAGNOSTIC TESTER
1. Water temperature sensor

2. Air temperature sensor
3. Manifold air pressure sensor READ TEST
4. Idle speed control valve MEMORY SWITCH
5. Throttle position sensor

6. Lambada sensor
7. Vehicle speed sensor WHITE BLACK
CONNECTOR CONNECTOR
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
DIAGNO-
Code checks the functioning of the Sensors/Actuators as
STICS indicated in the Blink code table. Fig. 6
6
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DIAGNOSTICS EMS

1. Short the terminals of the connector using suitable
connector and OBSERVE the following :
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:
‘HISTORY CODE’ is to be erased by opting‘CLEAR MEMORY’
option in HDM 2000 or by removing the battery supply for
atleast 3 minutes.
DIAGNO-
STICS
7
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DIAGNOSTICS EMS
4. ECU HANDLING CARE : l Do not use an ECU which has been dropped once.
Earth (Ground) Connection l Do not try to repair the ECU.

l Connect GND - P, GND - I, GND - C each to the engine l Use standard harness for circuit connections.
block. l Ensure that Do not try to insert any thing into the ECU
l The above mentioned GND should be connected case.
firmly using screws. l The installation should be done in such a way as to
l Ensure that the ignition coil GND and ECU GND - C keep the connector side down and the wiring done
are connected firmly together to the engine block accordingly (to avoid water penetration into the ECU
by screws; and ensure that even if these are through the wiring).
detached from the engine block, they are not l Take care to avoid any bending of the connector pins
detached from each other. while inserting the connector.
Power Supply l Ensure that the connector is inserted in the end after
l The power for the ECU should be taken through the all the installation is complete.
Main Relay. Do not take out the connector from the l To carry out welding job on the car the ECU should
ECU for at least 5 sec after IGNITION OFF. Never take be disconnected.
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.
DIAGNO-
STICS
8
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WORKSHOP MANUAL

INTRODUCTION: This manual brings to you the technical know-how on the

WHEELS AND TYRES

This manual provides the information on good workshop

It also provides information on fuel, lubricants and coolants

All lubrication & maintenance work should be carried out

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

7. Tightening Torques of Standard Bolts & Nuts 17

9. Fuel, Lubricants & Coolants (Details) 19

10. Branded Lubricants and Coolants / Recommended Oils, Lubricants 20

Precaution for Catalytic Converter (MPFI Petrol

l Be sure to turn the ignition switch off before

l Make sure the connector halves are mating properly

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

Rear Tow Hook :

Rear tow hook

USING THE HOIST

Front Jacking Point

Chassis Sales Designation Description

MAT XXXXXX X X X XXXXX

Chassis type No. Serial No. to start every

Year of Production Drive Type - R - For RHD

Year Code Plant location

Example 475 SI 45 FWZ P 00451

TRANSAXLE : NUMBERING (for location see fig. 16)

VEHICLE LEi & LSi LX & LXi

10. BODY : Semi-mono Volume, Semi-mono Volume,

11. ELECTRICAL SYSTEMS : 12 Volts -ve earth 12 Volts -ve earth

14. WEIGHTS (kg) (TOLERANCES AS PER EEC 92/21)

15. LUGGAGE SPACE

16. PASSENGER CAPACITY : 2 Front + 3 Rear 2 Front + 3 Rear

18. EXCLUSIVE ELECTRICAL ITEMS

19. EXCLUSIVE BODY FITMENTS

Integral Head Rest for : Standard Standard

M8 1.25 21 - 25 2.1 - 2.5

1.5 41 - 51 4.1 - 5.1

ENGINE OIL UPTO DIPSTICK MAX.MARK @ 4.0 Litres

WINDSHIELD WASHER RESERVOIR

BRAKE FLUID @ 0.270 Litres

TRANSAXLE OIL @ 3.3 Litres TYRE (TUBELESS) PRESSURE

RECOMMENDED OILS, LUBRICANTS AND FILLING CAPACITIES

Engine (-200 to 400C) 10W40 API SL (ACEA A2/B2) 4.0 Litres

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

INTRODUCTION : Tata Indica (Petrol) is available in 4 versions namely LEi,

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

Max. engine output

Compression ratio : 9.5 : 1

Firing order : 1-3-4-2

Ignition system : Grouped Ignition supported by Hitachi EMS

Emission compliance : EURO II

ECU 2 Coil A STEPPING MOTOR

2 P1 3 P1 Supply (+) TYPE ISC VALVE